Subject Focus 1. Understand different engineering materials, their properties and manufacturing processes.
 
1. List different metals.

• Ferrous metals:
  • e.g. mild steel, carbon steel; wrought iron;
  
  

• Non-ferrous metals:
  • e.g. aluminium; copper; lead;
  
  


• Ferrous alloys:
  •  e.g. Nickel; cast iron; stainless steel;
  
  


• Nonferrous alloys:
  • e.g. Brass; duralumin; solder.
    
  
  

2. Link materials to their key properties.

• Properties: e.g. hardness, ductility, malleability, resistance to environmental degradation, strength, elasticity.

 
3. List different woods.

• Natural woods
  
  
  • Hard wood: e.g. mahogany, oak, balsa wood, beech, walnut, cherry;
  
  
  • Soft wood:  e.g. pine; juniper.
    
  
  
  
  


• Manufactured wood:
  • Material: e.g. veneered, chipboard, plywood, block board, medium density fibreboard, oriented strand board.
  
  

 
4. Describe the characteristics of different groups of woods

• Natural woods
  
  
  • Hard wood: loose leaves during the cold wood; broad leaves;
  
  
  • Soft wood: ever-green trees; needle leaves; cheaper in price than hard wood; faster growth rate.
    
  
  
  
  


• Manufactured wood: can be manufactured according to industry needs; made from recycled natural wood; cheaper in price than natural wood; does not have live characteristics as natural wood.

 
5. List different polymers.

• Thermosetting polymers:
  • Material: e.g. Bakelite, epoxy resin, melamine,
  
  

• Thermoplastic polymers:
  • Material: e.g. acrylic, PET, PVC.
  
  

 
6. Describe the characteristics of different groups of polymers.

• Thermosetting polymers: e.g. once set cannot be reset, during manufacturing these transform from liquid to solid, if exposed to heat these materials degrade rather than melt.

• Thermoplastic polymers: once heated to the ideal temperature can be reset, during manufacturing these transform from granules or powders to the actual object with the help of heat.

 
 
1. Justify the choice of a material needed for a particular application based on the material’s key caracteristic. 
 
2. Explain the different manufacturing processes of different materials.
Processes:

• Metal Processes: e.g. Annealing; hardening; galvanizing.


• Wood Processes: e.g. seasoning; wood joints; bending.


• Polymers:
  
  
  • Thermoplastic processes: e.g. vacuum forming, line bending, injection moulding,
  
  
  • Thermosetting processes: casting.
  
  
  
  

 
Subject Focus 2. Carry out marking out operation.
 
7. Identify different measuring and marking out tools.

• Marking out tools: e.g. scriber, centre punch, dividers/callipers, surface plate, blueing or paint, scribing block, mortise gauge.


• Measuring tools: e.g. ruler, measuring tape, gauges, veneer calliper, micrometre, sliding bevel, combination sets.

 
8. Describe the function of measuring and marking out tools.

• Marking out tools: e.g. scriber, centre punch, dividers/callipers, surface plate, blueing or paint, scribing block, mortise gauge.


• Measuring tools: e.g. ruler, measuring tape, gauges, veneer calliper, micrometre, sliding bevel, combination sets.

 
3. Justify the selected measuring tools to be used to check that an engineering component has been manufactured to the required standard.

• Engineering task: e.g. hole diameter; hole depth; shaft diameter; length; angle.

 
1. Trace, a number of given templates, making sure to minimize waste material. 
 
2. Use tools to carry out a measuring and marking out activity from given information. 
 
 
Subject Focus 3. Make use of different tools safely and appropriately to produce an engineering component. 
 
9. Identify different tools and machinery.

• Tools:
  
  
  • Power tools and machinery: e.g. corded/cordless drills; hot air blowers; angle grinder; cross cut; jigsaw/scroll saw; orbital sanding machine.
  
  
  • Hand tools: e.g. hammers/mallets; pincers; pliers; saws; screwdrivers; files; spanners and sockets; chisels; tin snips; taps and dies.
  
  
  
  


• Machinery: e.g. pillar drills; lathe; sanding machines; band saw; strip wire heater; vacuum former

 
10. Describe, the function of hand tools and power tools.

• Hand tools: e.g. hammers/mallets; pincers; pliers; saws; screwdrivers; files; spanners and sockets; chisels; planer; taps and dies.


• Power tools and machinery: e.g. corded/cordless drills; hot air blowers; angle grinder; cross cut; jigsaw/scroll saw; orbital sanding machine.

 
4. Explain, step by step, the procedure when performing a task on a machine from given documentation.

•  Procedure: measuring; marking out; setting up machine; clamping material.


•  Task: eg. Drilling; facing; polymer bending, vacuum forming

5. Justify the choice of tools to be used to manufacture a particular engineering component.
 
3. Use different tools appropriately to produce a 3D engineering component from given information.