Year 11 Mock Revision

Plastics:
Many plastics are manufactured. Crude oil is heated in a fractioning tower. As the gases rise, they are passed through various liquids causing them to separate. Hydrocarbon Naphtha is the main product used in the production of plastics. Synthetic plastics are made by polymerisation, the joining of many monomers to make polymers. Thermoplastics: Thermo plastics soften when they are heated and can be shaped when hot. The plastic will remain stiff once cool but can be re-heated in order to be re-shaped. O-O-O-O-O O-O-O-O-O O-O-O-O-O Heated Soften- Cooled- Stiffen - Heated

Thermosetting Plastics: These are heated and moulded into shape. They cant be softened on the other hand as the polymer chains become interlinked during the moulding process. O-O-O-O-O I I I I I O-O-O-O-O Heated Soften Cooled Permanently rigid

Acrylic: - Baths and Bathroom furniture, Car indicator covers/reflectors - Thermoplastic - Durable - Stiff -Easily scratched -Self-finishing High Density Polythene: - Buckets, bowls, milk crates -Thermoplastic - Stiffer than LDPE Low Density Polythene: - Carrier bags, toys, packaging, squeezy detergent bottles - Weaker than HDPE - Soft and flexible - Resistant to chemicals

ABS: - Telephones, kitchenware, toys Thermoplastic - Strong - Lightweight and durable - Resistant to chemicals HIPS Used for Vacuum forming, Packaging - Softens at 95 degrees - Light and strong Epoxy Resin: Hardener and Resin are mixed together at a 1:1 ratio through a double plunger syringe. Used as an adhesive. High strength when used for bonding as it is a thermosetting plastic. Use to bond any clean and dry materials. Forming/Deforming Processes: Deforming processes are those that allow a material to change shape without changing its state. Laminating: This involves building up thin layers around a former produce the desired shape or curve. The thin veneers are cut to the correct shape and are glued together in the direction of the curve. Vacuum Forming: -The plastic is heated and the mould moves close to it. The air is sucked out forming a vacuum. -This causes the plastic to move towards the mould causing a rigid impression of it as the plastic cools. - The vacuum pump is turned on allowing the air to re-enter separating it from the final product. Line Bending: Acrylic sheets are often using a line bender or strip heater. The plastic is heated along the line of intended fold. The softened area is bent to shape using a bending jig. Injection Moulding: Plastic powder or granules are fed from a hopper into a hollow steel barrel. It is here the plastics melts and is forced its way to the mould by the screw. Once, there is enough plastic, it is forced into the mould. Pressure on the mould is maintained until it is cool enough to be opened.

Plastic Coating Process: Heat the oven to 200 degrees. Place the item to be coated in the oven for ten minutes. Remove the object cautiously from the oven and place it in the fluidising unit containing the heated plastic granules. Place object back in the oven for ten minutes. Then remove it and allow it to cool.

Scales of Productions:
- A one-off production: When a product is made at one particular time. Productions usually take a long time to make and therefore are expensive. - Batch production: A series of identical products are made together in small or large quantities. - Mass production: The product goes through various stages on a production line where different workers are responsible for different stages. They are usually produced in large numbers. - Continuous production: This is where the product is continually produced over a series of hours, days or years. They are usually cheap. - Just-in-time production: This production of components made just in time to arrive at factories to save space in warehouses.

Finishing Techniques:
Polish: -Applied to wood to protect it from moisture -Protect it from insect attack - Enhance the colour of the grain - Make it easier to wipe the surface clean Wax Polish: This fills porous surface of the timber as well as creating a layer of polish. It can be applied by hand or cloth. Polyurethane Varnish: -Tough -Heat and water proof Requires three coats and provides a gloss finish. French Polish/Sanding Sealer: Used to seal timber but causes the fibres of the timber to rise which then have to be rubbed down with abrasive paper.

Composites:
Carbon Fibre is a composite. It consists of a matrix, in the form of plastic resin which sets hard by carbon fibres, the matting. The matting is chopped-up stands woven together. They are woven in a unique pattern and are very strong. Uses: -Structural components in Aircrafts -Squash and tennis rackets -Body armour for the police force.

Computer Technology:
Computer Aided Design & Computer Numerical Control: CAD is where computer software allows you to draw directly onto a computer creating virtual 3-D images. It also creates CNC to drive a range of machinery. Advantages: - Accurate drawings can be produced - The size or shape of a design can quickly be edited - Information easily stored - The designs can be prototyped quickly using CNC machines - Information can be sent via email Computer Aided Manufacture: This uses CNC to make a product designed via CAD packages. Three sets of data control the three axis of any CNC machine: X axis To make side to side movements Y axis To make back and forth movements Z axis To make up and down movements Advantages: - High speed production - Multiple items can be identical (mass production) - Very accurate details cut - Changes to the programme can be made easily. E.g. Lathes vinyl cutters, engraving machines, milling machines and routers.

Environmental Issues & Sustainability:

The gases given off through the burning of fossil fuels can be harmful and tend to harm the natural environment. Companies that burn fossil fuels release carbon into the atmosphere. This is called their carbon footprint. Some raw materials like coal and electricity are finite. They cant easily be replenished and therefore to avoid using up all our finite resources, we should recycle and re-use materials. 6Rs: Reduce: the amount of material in manufacture Recycle: the materials already used by melting or re-processing Re-use: by designing disassembly and recover materials from end of life products Re-think: our attitude to the environmental impact Refuse: to accept unethical or wasteful designs Repair: products rather than replacing them Resources are finite so designers have to take account of sustainability. If we are careful, finite resources will last longer and alternatives may be found.

Properties of Materials:
Hardness: Resistance to scratching, cutting and wear. Toughness: Resistance to bending, breaking or deforming. Durability: The ability to withstand wear, tear and force for long periods of time. Ductility: The ability to be stretched without breaking. Elasticity: The ability to regain its original shape after being deformed. Malleability: The ability to be pressed, spread and hammered into shape. Work Hardness: When the structure of a metal changes after repeated hammering. Brittleness: The ability to break easily without bending. Tensile Strength: Very strong when stretched. Compressive Strength: Very strong when under pressure.

Adhesives:
All joints that use adhesives are permanent. Polyvinyl Acetate: This is the most common word-working adhesive. It is a white water-based adhesive. The PVA soaks into the surface and sets once the water is absorbed in the fibres. It is easy to use and apply.

Hot Melt Glue: The use of hot glue guns is very common in schools. Epoxy Resin: Hardener and Resin are mixed together at a 1:1 ratio through a double plunger syringe. Used as an adhesive. High strength when used for bonding as it is a thermosetting plastic. Use to bond any clean and dry materials. The full strength of the adhesive is only achieved 2-3 days later. It is useful for gluing plastics together. They are expensive. Contact Adhesives: Contact adhesives stick on contact. They are extensively used for gluing large sheet materials such as thin laminates to kitchen worktops. Both surfaces must be coated with the adhesive. It can be used for gluing dissimilar materials. Tensol Cement: Tensol cement is only used for gluing acrylic. It is a clear liquid with a solvent base that evaporates easily. It must be applied to the joint once put together. It is not very strong.

Tools:
Squares: -Try Square Marking out 90 degree lines on timber and woods -Engineer Square - Marking out 90 degree lines on metals -Mitre Square - Marking 45 degree angles Scriber: They are used for lightly scratching the surface of metals and plastics. Punches: Where holes are to be drilled in metals, an indent can be made by hammering the roof of a centre punch to provide a staring point for the drill. Saws: Tenon Saw: Most common saw in workshop and is used for all general joints. Dovetail Saw: Used for more accurate and making dovetail joints. Coping Saw: Used for cutting curves in woods. Adjustable Hack Saw: The blade can be angled for cutting difficult joints. Files: These are made of high carbon steel with rows of teeth to smooth the surfaces of woods.

Woods:
Hardwoods: This is wood that has come from deciduous or broad-leafed trees. They are generally slow-growing which tends to make them harder. Softwoods: This is wood that has been grown from coniferous. They are usually faster growing than hardwoods and are softer to work with. Manufactured Boards: These are timber sheets made from gluing wood layers or wood fibres together. They can be mass produced easily in consistent quality. E.g. MDF is made by gluing very thin fibres from hardwood and softwood residuals. Plywood is made by gluing layers of wood at 90 degrees to each other. Chipboard is made by gluing by gluing chips of wood together usually veneered. It often laminated in plastic. Joining Metals: Soft Soldering: This is method of joining metal parts together using heat and a suitable alloy (lead). The alloy melts at a much lower temperature and the join is not that strong as hard soldering. Flux is applied on the joint and heated with a gas torch. Hard Soldering/Brazing: Hard soldering is a permanent way of joining metals together using heat and a suitable alloy (brass). The alloy used melts at a much higher temperature than hard soldering. The metal is heated to red heat until the alloy which is a fluid sinks into microscopic spaces by capillary action filling them up and fusing them together. Knock Down Fittings: These are modern joining techniques and allow strong joints to be made quickly and easily. The can also be quickly taken apart and be flat-packed for transportation.

Metals:
Annealing: Annealing is the process of heating a metal such as copper with a gas torch. It is done because the metal is work harden after repeatedly being hammered. So it has to be heated to a cherry-red colour before the atoms are relaxed again.