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Engineering Materials
Resource 4
Manufacturing Techniques
Edexcel Principles of Learning in EngineeringResource 4
Aims & Objectives
• Identify engineering materials & uses• Differentiate metallic & non-metallic materials• Understand the hardening & tempering processes
Edexcel Principles of Learning in EngineeringResource 4
• Select appropriate materials for manufacturing activities• Identify materials properties & uses• Manufacturing processes for a range of materials• Harden & temper materials
Aims & Objectives
Edexcel Principles of Learning in EngineeringResource 4
Materials
Edexcel Principles of Learning in EngineeringResource 4
Ferrous Metals
• Mild steel• Cast iron• Wrought iron• High carbon steel• Stainless steel
Edexcel Principles of Learning in EngineeringResource 4
Uses
• Mild steel – Structures, Bridges, Steel products, Nuts & bolts
• Cast Iron – Castings, Engines, Machine vices
• Wrought Iron – Gates, railings
• High Carbon Steel – Tools, drills, centre punch, chisels, files
• Stainless Steel – Cutlery, Kitchen & bathroom appliances, medical instruments
Edexcel Principles of Learning in EngineeringResource 4
Non Ferrous Metals
• Copper • Brass• Lead• Aluminium• Silver• Gold• Zinc
Edexcel Principles of Learning in EngineeringResource 4
Uses
• Copper – Pipes, electrical wiring, kitchen ware
• Brass – musical instruments, tableware, ornaments
• Lead – Batteries, soldering, roofing & cladding
• Aluminium – Aircraft, Window frames, Kitchen ware, cans
• Silver – Jewellery, coins, cutlery
• Gold – Jewellery, coins, cutlery, dentistry
• Zinc – Galvanising steel products
Edexcel Principles of Learning in EngineeringResource 4
Alloys
Some metals can be used in their pure form or combined with other metals to produce an Alloy metal. An alloy is a combination of two or more metals to improve the mechanical properties of the materials. A few materials are listed below: -
• Brass• Bronze• Stainless steel• High carbon steel
Edexcel Principles of Learning in EngineeringResource 4
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Forms of supply
Materials can be cut in various shapes & sizes.
Round Flat Square Hexagonal Octagonal Sheet Channel Angle Square Tube Round Tube
Edexcel Principles of Learning in EngineeringResource 4
Grain Structures
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Crystalline & Amorphous
Edexcel Principles of Learning in EngineeringResource 4
Crystalline
During the solidification process, crystals begin to form, multiply and grow until the material is completely solidified. These crystal contain atoms that are packed tightly together forming patterns.
Edexcel Principles of Learning in EngineeringResource 4
Amorphous
Rapidly increasing the cooling rate during the solidification process can produce minuscule micro crystals or in some cases amorphous that
is, non-crystalline solid liquid metals. The non-crystalline liquid structure is retained since the opportunity
for crystallisation is avoided due to the extreme temperature change.
Edexcel Principles of Learning in EngineeringResource 4
Heat treatment processes
HardeningHardening is accomplished by heating the material (metal) to a required temperature between 800°C & 1500°C (depending on the properties required) then quenching in either oil or water.
TemperingTempering consists of re-heating the material between 200°C & 600°C (depending on the properties required) then quenching in either oil or water.
Edexcel Principles of Learning in EngineeringResource 4
Case Hardening
Case hardening produces a hard, wear resistant surface on low carbon steels.
The process is accomplished by heating the material between 800°C & 1500°C and infusing carbon elements onto the materials surface.
Re-heat material between 800°C & 1500°C (depending on the properties required) then quenching in either oil or water.