Chapter 8

Manufacture
d Substances
in Industry
8.1 Alloy & Its Importance

8.2 Composition of Glass & Its Uses

8.3 Composition of Ceramics & Its

Uses

8.4 Composite Materials & Its

Importance
8.1 Alloy & Its Importance
Definition
• Mixture of 2 or more elements

• where the main element is a pure metal

• by certain percentage

Examples:
a) Steel 钢 d) Brass 黄铜

b) Pewter 锡 e) Duralumin 硬铝

c) Bronze 青铜 f) Stainless steel 不锈钢

8.1 Alloy & Its Importance
Composition, Properties and Uses of Alloys

STEEL BRONZE DURALUMIN

PEWTER BRASS
STAINLESS STEEL

相框
8.1 Alloy & Its Importance • Main element
Composition, Properties and Uses of Alloys

Alloy Composition Properties Uses

• Iron, carbon
3 types :
• Harder, stronger, more • Buildings, bridges,
Steel Low carbon steel resistant to rust than iron railways, body of cars
Average carbon steel
High carbon steel

Stainless • Iron, carbon, chromium, • Harder, stronger, shinny, • Medals, statue, coins
steel nickel resistant to rust
• Cutlery, kitchenware,
Bronze • Copper, tin • Harder surgical instruments
• Stronger
• Musical instruments, keys,
Brass • Copper, zinc • Shinny
• bullet
Resistant to corrosion
Pewter • Tin, copper, antimony • Souvenir, cup, photo frame

• Aluminium, copper, • Light & strong • Body of aircraft & bullet train,
Duralumin magnesium, manganese • Resistant to corrosion racing bicycle
8.1 Alloy & Its Importance
Composition, Properties and Uses of Alloys
STEEL BRONZE PEWTER
• Iron & carbon • Copper & tin • Tin, copper, antimony

BRASS STAINLESS STEEL

• Copper & zinc • Iron, carbon, nickel chromium
8.1 Alloy & Its Importance
How to
Process of making alloy : ALLOYING make
ALLOY?

Why Purpose of Alloying

alloying ? a) Increase the hardness of metal
b) Increase the resistant to corrosion of metal
c) Improve the appearance of metal (more shinny)
Alloy is harder, stronger and more resistant to corrosion than pure metal. Why?

In alloy, In pure metal,

Pure metal
atom

• Atoms (ID) in alloy have different sizes • Atoms (ID) in pure metal are same size

• Foreign atoms (ID) disrupts the orderly • Atoms (ID) are orderly arranged in layers
arrangement of pure metal atoms (ID)

• Layers of atoms in alloy are difficult to slide • Layers of atoms in pure metal are easy to slide
over each other when a force is act on it. over each other when a force is act on it.
 Experiment :
To compare the resistance to corrosion between alloy and pure metal
Procedure
1. Clean the iron nail and steel nail with sandpaper.
2. Add 2 cm3 of distilled water into a test tube.
3. Put the iron nail into the test tube.
4. Repeat steps 1 to 3 with steel nail.
5. Leave both test tubes aside for 1 week.
6. Record the observation.
Variables
a) MV : Type of nail
b) RV : Rusting of nail
c) CV : Volume of distilled water

Hypothesis
Steel nail is more resistance to corrosion than iron nail.
Iron nail Steel nail
 Experiment :
To compare the resistance to corrosion between alloy and pure metal

Type of Observation
Nail Observation
Before After
Type of nail Observation
Iron nail Brown solid formed on iron nail
Iron Steel nail No changes
nail

Discussion
1. Iron nail rust whereas steel nail does not rust.
Steel 2. Steel nail more resistance than iron nail.
nail (Note: Steel nail will rust)
 Experiment :
To investigate the hardness between alloy and pure metal
Procedure
1. Fix a steel ball bearing on the bronze.
2. Hang a 1 kg weight at 50 cm above the bronze.
3. Release the weight onto the steel ball bearing.
4. Record the diameter of dent formed.
5. Repeat steps 1 to 4 to get an average diameter of dent.
6. Repeat steps 1 to 5 with copper block.
Variables
a) MV : Type of block
b) RV : Hardness of block
c) CV : Weight, steel ball bearing

Hypothesis
Bronze block is harder than copper block.
 Experiment :
To investigate the hardness between alloy and pure metal

Bronze block Copper block

Observation
Diameter of dent / cm
Type of Block 1 2 3 Average
0.3 0.3 0.4 0.3
Bronze block
0.5 0.6 0.5 0.5
Copper block
Discussion
1. Diameter of dent on bronze block is smaller than copper block.
2. Bronze block is harder than copper block.
HOTS Question (TP4)
Compare and contrast alloy and pure metal by using a suitable I-Think Map
(Double Bubble Map) based on the following properties.

• Hardness

• Strength

• Physical appearance

• Malleability and ductility

• Resistance to corrosion

• Electrical conductivity

• Heat conductivity
HOTS Question (TP5)
Compare the hardness of bronze and pure copper based on the arrangement of atoms. [6m]
8.2 COMPOSITION OF GLASS & ITS USES
Glass
Definition
High thermal
• Inorganic substance made of silica /
expansion coefficient
Quartz Transparent (High TEC)
which is found in fine white sand.

Hard but Basic Chemically

Main component in silica
brittle properties inert
• Silicon dioxide of Glass

Heat & High

Element in silica electrical compressive
insulator Can be strength
• Silicon, Oxygen recycled
repeatedly
 Types of Glass and Its Components
4 Types of Glass
Glass Component
Fused silica glass Silica
(Simplest glass)
Soda-lime glass • Silica
(Most common glass) • Sodium carbonate (Soda)
• Calcium carbonate (Lime)
• Silica
Borosilicate glass • Boron oxide
• Sodium oxide
• Calcium oxide
• Aluminium oxide
Lead crystal glass • Silica
• Lead(II) oxide
• Sodium oxide
 Properties and Uses of Glass
Glass Properties Uses
• Very high MP, 1800⁰C • Laboratory glassware
Fused glass
• Zero TEC • Optical lenses
(Simplest glass) • High purity & clarity • Optical fibres
• Glass containers
Soda-lime glass • Do not withstand heat (Low MP) • Light bulbs
(Most common • Easily moulded when melted • Mirrors
glass)
• Window panes
• Highly heat resistant (Very high MP) • Glass cookware
Borosilicate glass • Low TEC • Laboratory glassware

• Soft and easily melt (MP: 600⁰C) • Art objects

Lead crystal glass • High refractive index • Glass prism
• High density, easily scratched • Glasses
HOTS Question (TP5)
Lead crystal glass can be used to make food containers.

Justify this statement.

8.3 Composition of Ceramics and Its Uses

Definition
⚫ Solid of inorganic and non-metallic which
heated at very high temperature
High Thermal
Type of bonds in ceramics Resistant (High MP)
⚫ Covalent bonds
⚫ Ionic bonds
Basic
Brittle Hard &
Properties
Strong
of
Ceramics
Electrical
Chemically
& heat
Inert
Insulator
 Types of Ceramics and Its Components
2 Types of Ceramics

Traditional Ceramics Advanced Ceramics

Main component Main component

• Hydrated aluminium silicate / Kaolin (clay)
(Al2O3.2SiO2.2H2O) – brown (Fe3+ ion)
Preparation method
• Heated at a very high temperature in a
furnace
Products
⚫ Pottery, plates, bowls, bricks
• Mixture of oxides, carbides and nitrides
into ceramics
Preparation method
• Modern high-technology involving high
heat treatment
Products with superior characteristics
⚫ Medicals, telecommunication,
transportation, ICT and energy fields
Properties and Uses of Traditional Ceramics

Properties Uses

Strong and hard Building materials

• Bricks, cement, roof, toilet bowl

• Resistance to heat Kitchenware

• Non-corrosive • Cooking pots, plates, bowls

Electrical insulator Electrical appliances

• Plugs, ovens
Easily moulded and Decorative and household items
coloured • Tiles, vases, potteries, basins
Properties and Uses of Advanced Ceramics
Properties Uses

Superconductivity Semiconductor (Al2O3 & SiO2)

• Microchip
Silicon carbide, titanium carbide
• Hard and strong • Cutting tools
• Withstand thermal • Brake discs
shocks
• Hard Tungsten carbide
• Resistance to abrasion • Rings
Zirconium oxide (Zirconia)
• Highly chemical inert • Dentures
• Non-compressible • Orthopedic joint replacement
Lithium silicon oxide carbide
• Good heat insulator • Engine parts,
• Heat shield rocket

Aluminium oxides (Alumina)

• Good electric insulator • High voltage electric cables
HOTS Question (TP5)
Sodium carbide is an example of advanced ceramic which has a diamond like
properties. Can it be used to make drinking glass ? Explain.
8.4 Composite Materials & Its Importance
Definition
⚫ Materials made from combining 2 or more non-homogenous substances
(metal, alloy, glass, ceramic and polymer)
⚫ which are matrix substance and strengthening substance

Characteristic
⚫ Composite material has better properties than the original components
Composite Materials and Its Components
Composite
Components
Material
Reinforced Concrete
concrete Steel bars / rods / mesh, polymer fibres
Fibre glass Plastic
Glass fibres

Plastic coating (outermost layer for protection)

Fibre optic
Glass or plastic cladding (sheath layer)
Glass fibres (core)

Photochromic Glass
glass Silver chloride / Silver bromide
Copper(I) chloride
Superconductor
YBCO Yttrium carbonate, Barium carbonate,
(Perovskite) Copper(II) carbonate

• Matrix
• Strengthening substance
Difference in Properties of Composite Materials and Their Original Components
Concrete (Matrix)
• High compression strength
• Low stretching strength
• Hard but brittle
Steel bars / wire mesh
(Strengthening substance )
• High stretching strength
• Rust easily
Reinforced Concrete
• High compression strength
Uses
• • High rise building
High stretching strength
• • Bridges
Resistance to corrosion
• Easily moulded
• Dams
Difference in Properties of Composite Materials and Their Original Components
Plastic (Matrix)
• High compression strength
• Flexible, does not refract light
Glass fibre
(Strengthening substance )
• High light refractive index
• Low compression strength
• Brittle
Optical Fibre
• High compression & stretching
strength
• High light refractive index
causes :
a) High transmission capacity
& speed than copper wire
(Data is transmitted in the
form of light refraction)
b) Less susceptible to
interference
Uses
• Telecommunication cables
• Endoscope tube
• Surgical headlight
• Tube for inspecting the
interior of manufactured
structural products
Difference in Properties of Composite Materials and Their Original Components
Plastic (Matrix)
• High compression strength
• Light and elastic
Glass fibre
(Strengthening substance )
• Transparent
• Hard to be moulded
• Brittle
Fibre Glass Uses
• High compression & • Helmet
stretching strength • Storage tanks
• Light • Surfing board
• Thin but strong • Printed circuit board
• Easily moulded • Boat
• Chemically inert • Car bumper
Difference in Properties of Composite Materials and Their Original Components

Photochromic glass
Glass (Matrix) • Filter UV rays when exposed to
• Transparent Uses
high intensity of light (become
• Can not filter UV rays • Optical lenses
darker)
Ag+ ion 🡪 Ag atom • Car windshields
AgCl // AgBr & CuCl • Transparent when indoors • Smart energy
(Low light intensity) efficiency building
(Strengthening substance )
• Filter UV rays • CuCl catalyzes the reverse window
• Sensitive to intensity of visible light process
• Opaque Ag atom 🡪 Ag+ ion
Difference in Properties of Composite Materials and Their Original Components

Original Components Uses

• Yttrium carbonate • Maglev
• Barium carbonate Superconductor YBCO • Magnetic Resonance
• Copper(II) carbonate • Conduct electricity at very
Imaging
low temperature with zero • Particle accelerator
Properties
resistance • Nuclear Magnetic
• Does not conduct electricity at room
temperature (solid state) Resonance
 HOTS Question (TP5)
Based on the graph,
(Ω)

a) which material is a better electrical

conductor when temperature is higher than
Tc K ? Explain your answer.

b) State the range of the temperature at which

superconductor conducts electricity with 0
Ω.

c) Name a liquid that is able to provide an

extremely cold condition.
HOTS Question (TP5)
Photochromic glass and dark glass are 2 different type of glass.
Condominium is prone to intense sunlight. Which of type of glass is more suitable to be
used to make the window of condominium. Justify your answer.