GCSE RESISTANT MATERIALS & PRODUCT DESIGN

METALS

 Recognise the classifications of metals and their properties.

Understand the lifecycle of metal products.
Gain understanding of the manufacturing processes involved
in making products from metal.
Be able to suggest specific metals for certain products.

Outcomes
MUST tackle a previous exam question on woods and their
uses.

SHOULD use the materials quiz to assess their learning needs,

and judge the progress they have made.
COULD go on to read over revision guides to consolidate
their learning.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

Lesson Objectives

METALS

THERE ARE 3 CLASSIFICATIONS

REGARDING METALS, THESE ARE:

1.Ferrous metals

2.Non Ferrous metals

3.Alloys

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

Objective: Understand the lifecycle

of metal products.

The word ferrous comes from the Latin

word for iron.
Ferrous metals are metals made from
iron.
They tend to rust unless they have a
protective coating
Cast iron, mild steel, high carbon steel
etc. Are all examples of ferrous metals.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

FERROUS

Objective: Recognise the

classifications of metals and their
properties.

The word ferrous comes from the Latin

word for iron.
Non ferrous metals do not contain iron.
Aluminium, copper, lead and tin are
all examples of non - ferrous metals.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

N0N -FERROUS

Objective: Recognise the

classifications of metals and their
properties.

The word ferrous comes from the Latin

word for iron.
Alloys are a combination of
Two or more metals.
Pewter, bronze and brass are all
examples of alloys.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

ALLOYS

Objective: Recognise the

classifications of metals and their
properties.

LIFECYCLE OF METALS:
EXTRACTION
PROCESSING

MANUFACTURE
USE
RECYCLED

SCRAP
METAL

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

Objective: Understand the

lifecycle of metal products.

IRON = BLAST
FURNACE
http://www.youtube.com/watch?v=w
AcnOpOHeCU&feature=related

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

PROCESSING OF THE
RAW MATERIAL

Objective: Understand the lifecycle

of metal products.

COPPER =
MINING

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

PROCESSING OF THE
RAW MATERIAL

Objective: Understand the lifecycle

of metal products.

FERROUS
METALS

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

Objective: Understand the lifecycle

of metal products.

 HARD SKIN.
STRONG UNDER
COMPRESSION.
CANNOT BE BENT OR
FORGED.
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

CAST IRON

Objective: Recognise the

classifications of metals and their
properties.

Write notes in your

revision book.

WROUGHT IRON is no longer commercially produced, it was

made OBSOLETE by mild steel made it as it cost twice to make.
It is used in HERITAGE projects but only in the recycling of
metals, not from scratch.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

WROUGHT IRON

Objective: Recognise the

classifications of metals and their
properties.

 Tough, ductile and

malleable.
Easily joined.

Poor resistance to
corrosion
Cant be hardened
or tempered
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

MILD STEEL.

Objective: Recognise the

classifications of metals and their
properties.

 Very hard
Can be hardened
or tempered.

But less ductile and

malleable.
Difficult to cut

Write notes in your

revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

HIGH CARBON STEEL

Objective: Recognise the

classifications of metals and their
properties.

 HARD AND TOUGH.

RESISTS WEAR AND
CORROSION.
DIFFICULT TO CUT
OR FILE
TECHNICALLY AN
ALLOY
(CHORMIUM &
NICKEL MAKE IT
STAINLESS)
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

STAINLESS STEEL

Objective: Recognise the

classifications of metals and their
properties.

 Very hard.
Can be used as a cutting
tool even when red hot.
Can only be shaped by
grinding.
Technically an alloy
(Cobalt added)

Write notes in your

revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

HIGH SPEED STEEL

Objective: Recognise the

classifications of metals and their
properties.

NON
FERROUS METALS

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

Objective: Understand the lifecycle

of metal products.

 Platinum
Gold
Silver
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

PRECIOUS METALS

Objective: Recognise the

classifications of metals and
their properties.

 Soft, malleable, and ductile.

Corrosion resistant.
Low melting point.
Difficult to work.
Expensive.
Poisonous if ingested, gives off
toxic fumes!!
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

LEAD

Objective: Recognise the

classifications of metals and their
properties.

 HIGH STRENGTH TO WEIGHT

RATIO - LIGHT WHILST STRONG
GOOD CONDUCTOR OF HEAT &
ELECTRICITY
POLISHES WELL
DIFFICULT TO JOIN
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

ALUMINIUM

Objective: Recognise the

classifications of metals and their
properties.

 Malleable and
ductile.
Good conductor of
heat and electricity
Easily joined
Polishes well.
Expensive.
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

COPPER

Objective: Recognise the

classifications of metals and their
properties.

Malleable.
Cut easily.
Corrosion resistant.

Soft and weak

Write notes in your

revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

TIN

Objective: Recognise the

classifications of metals and their
properties.

ALLOYS

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

Objective: Understand the lifecycle

of metal products.

ALLOYS - BRONZE
An alloy of copper and tin

Strong and tough

Corrosion resistant
Resistant to wear (metal
fatigue)
Metal on metal it doesnt
create sparks so is often use in
explosive/flammable
atmospheres.
Expensive thanks to its copper
content.
Can get bronze disease
where the bronze disintegrates.
The sculpture here has a
patina a green oxidation layer
that protects the bronze from
bronze disease

Write notes in your

revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

Objective: Recognise the

classifications of metals and
their properties.

 An alloy of
Copper & zinc.
Corrosion resistant.
Good conductor of heat and
electricity.
Polishes well.
Cheaper than copper.
Doesnt spark so used in
explosive environments.
Low tensile strength.

Write notes in your

revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

BRASS

Objective: Recognise the

classifications of metals and
their properties.

 An alloy of tin
Copper & lead.
Easily cut
Cheap metal
Has a low melting point
and can be polished to
look like silver
MUST BE LEAD FREE FOR
HEALTH REASONS.
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

PEWTER - ALLOY

Objective: Recognise the

classifications of metals and their
properties.

In the exam you need to have knowledge and

understanding of the following:
Sand Casting
Die casting

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

Manufacturing
Techniques.

1.
2.
3.
4.
5.
6.

Place a pattern in sand

to create a mold.
Incorporate the pattern
and sand in a gating
system.
Remove the pattern.
Fill the mold cavity with
molten metal.
Allow the metal to cool.
Break away the sand
mold and remove the
casting.
Write notes in your
revision book.

LOOK FOR THE SAND GRAIN EFFECT IN THE METAL.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

MANUFACTURE
SAND CASTING

Objective: Recognise the

classifications of metals and their
properties.

Advantages
This process can be used
for a large range of sizes
and for small or large
production runs. It is the
cheapest casting process
available for small
production runs and can
sometimes be economical
for large production runs.

Disadvantages
The surface finish and
tolerances of the finished
casting are poor. This form of
casting can significantly alter
the mechanical properties of
the material being cast. The
time required to cast a
components can be excessive
due to the need to allow the
casting to cool before
removing it from the mould.

This involves packing a moulding material

(traditionally a mixture of sand and clay) around a
pattern of the casting. This is usually made of a
hardwood and will be larger than the requirements
of the finished casting to allow for shrinkage. The
mould is then split so that the pattern can be
removed.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

MANUFACTURE - SAND CASTING

Objective: Recognise the classifications

of metals and their properties.

Die casting is a metal casting process

that is characterized by forcing molten
metal under high pressure into a mould
cavity, which is machined into two
hardened steel dies.

Depending on the type of metal being

cast, a hot- or cold-chamber machine is
used.
Look for the split line
Write notes in your
revision book.

GCSE RESISTANT MATERIALS & PRODUCT DESIGN

MANUFACTURE
DIE CASTING

Objective: Recognise the

classifications of metals and their
properties.