DT A-Level (AQA)

0.0(0)
studied byStudied by 1 person
learnLearn
examPractice Test
spaced repetitionSpaced Repetition
heart puzzleMatch
flashcardsFlashcards
Get a hint
Hint

What are the physical properties

Get a hint
Hint

-electrical conduction and insulation

-thermal conduction and insulation

-optical properties

-density

-fusibility

-magnetism

-degradation resistance

Get a hint
Hint

What are the mechanical properties a material may have

Get a hint
Hint

-compressive strength

-tensile strength

-shear strength

-torsional strength

-toughness (how much energy can be absorbed before fracture)

-plasticity

-ductility (being drawn out without plastic deform.)

-malleability (easily changed into a new shape

-elasticity

Card Sorting

1/238

encourage image

There's no tags or description

Looks like no tags are added yet.

Study Analytics
Name
Mastery
Learn
Test
Matching
Spaced

No study sessions yet.

239 Terms

1
New cards

What are the physical properties

-electrical conduction and insulation

-thermal conduction and insulation

-optical properties

-density

-fusibility

-magnetism

-degradation resistance

2
New cards

What are the mechanical properties a material may have

-compressive strength

-tensile strength

-shear strength

-torsional strength

-toughness (how much energy can be absorbed before fracture)

-plasticity

-ductility (being drawn out without plastic deform.)

-malleability (easily changed into a new shape

-elasticity

3
New cards

What are the categories for classification of metal

Ferrous

Non-ferrous

Alloy

4
New cards

What are the categories for classification of wood

Hardwood (deciduous)

Softwood (carnivorous)

Manufactured

5
New cards

What are the categories for classification of polymers

Thermoplastic

Thermosetting plastic

Elastomer (deformable at room temp)

6
New cards

What are the other classifications of materials

Smart material (changes with environment)

Modern material (made using modern materials)

Composite (2 or more materials)

7
New cards

How would you test for tensile strength

A high tensile strength material will resist stretching or pulling therefore it should be suspended and masses hung from it

8
New cards

How do you test for toughness

Hit a sample of the material with a hammer of a dot punch

9
New cards

How do you test for malleability and ductility

Band the test piece to 90 degrees if it cracks on the outside it is a lack of ductility if it cracks on the inside it is a lack of malleability

10
New cards

What are the 2 main ways to dry wood

Air drying (leaving wood in a dry space)

Kiln drying (wood is placed in a warm, moist and ventilated are until dry)

11
New cards

What effect does drying/seasoning wood have

Gives greater immunity to decay and rot increasing strength and stability and makes wood less corrosive to metals

12
New cards

Name some hardwoods

oak, mahogany, beech, balsa, ash

13
New cards

Name some softwoods

pine, larch, spruce, cedar

14
New cards

Name some manufactured boards.

MDF, plywood, chipboard

15
New cards

What forms do woods usually come in

Wood usually come in stock forms that are rough sawn but can also be planes square edge or plained all round however this usually takes about 3mm off the dimensions

16
New cards

Where do metals come from?

ores in the ground are smelted down to separate them from slag until a near pure metal is reached

17
New cards

Name some non ferrous metals and their properties

Aluminium- light

Copper- good thermal and electrical conductor and corrosion resistance

Silver and gold- malleable and ductile

Titanium- light and hard

Tin- ductile, malleable and low melting point

18
New cards

Name some ferrous metals and their properties

Low carbon steel- ductile, high tensile strength malleable, NOT corrosion resist.

Medium carbon steel- harder than low carbon but less ductile

Cast Iron- hard outer shell but brittle inside

19
New cards

Name some ferrous alloys and their properties

Stainless steel- Tough, Hard, corrosion resistance

High speed steel- hard tough and resistant to frictional heat

Die Steel (tool)- hard and tough

20
New cards

Name some non ferrous alloys and their properties

Copper- tough and corrosion resistance

Brass- corrosion resistance, good thermal and electrical conductor

21
New cards

What are the stock forms of metal

Sheet

Bar

Plate

Tube

Structural

22
New cards

How are polymers made

Polymers are distilled from crude oil by fractional distillation and cracking

23
New cards

Name some thermoplastics

LDPE

HDPE

PP

HIPS

PMMA

Nylon

UPVC

PVC

24
New cards

What are the properties and examples of LDPE

Tough, highly chemical resistant, and can be translucent not very rigid e.g. General packaging

25
New cards

What are the properties and examples of HDPE

Tough, weatherproof, chemical resistant can be translucent e.g. Jerry can

26
New cards

What are the properties and examples of PP

Fatigue and chemical resistant e.g. rope

27
New cards

What are the properties and examples of HIPS

Hard, rigid, tough e.g. yoghurt pot

28
New cards

What are the properties and examples of PMMA

Tough corrosion resistant and chemical resistance e.g. baths

29
New cards

What are the properties and examples of Nylon

Tough, corrosion resistant, low frict. coefficient, thermal resistance e.g. clothing

30
New cards

What are the properties and examples of UPVC

Rigid, Tough, hard, weather resistant, fire retardant e.g. window frames

31
New cards

What are the properties and examples of PVC

Tough, Flexible, weather resistance, chemical resistance e.g. hose pipe

32
New cards

Name some thermosets

Urea Formaldehyde

MF

Polyester resin

Epoxy resin

33
New cards

What are the properties of UF

Hard, heat resistant, electrical insulator, brittle e.g. electrical fittings

34
New cards

What are the properties of UF

Hard, Opaque, tough, chemical resistant e.g.laminated

35
New cards

What are the properties of polyester resin

Rigid, heat/chemical resistant e.g. GRP and boat hulls

36
New cards

Name the properties of epoxy resin

Rigid, clear, hard, tough, chemical resistant e.g. castings and surface coatings

37
New cards

Name some elastomers and their uses

Natural rubber- insulation

Butadiene rubber- tyres

Neoprene- wetsuits

Silicone- bakeware

38
New cards

Name some Biopolymers and their uses

Corn starch polymer- packaging

Potatopak- single use food items

Biobatch- packaging films

PLA- single use bottles

PHA- medical packaging

Lactide- slow release medicine

Glycolide- food film

39
New cards

What are the types of biodegradable polymers

Oxy-degradable

Photo-degradable

Hydro-degradable

40
New cards

Name some forming processes for papers and boards

Die cutting

Bending

Laser cutting

41
New cards

Name some forming processes for polymers

Vacuum forming

Line bending

Thermoforming

Calendaring

Lamination

Injection moulding

Blow moulding

Rotational moulding (mould rotated)

Extrusion moulding

Compression moulding

42
New cards

Name some forming processes of metals

Turning

Line bending

Press forming

Cupping

Drop forging (hydraulic ram)

Wrought iron forging (traditional)

Punch bending

Rolling

43
New cards

Name some redistribution processes of metal

Sand casting

Die casting (gravity/ pressure in metal moulding)

Investment (lost wax) casting

Low,temperature pewter casting

44
New cards

Describe the different types of welding

MIG welding- welds thin gauge metal using electrode and electric arc)

TIG welding- welds non ferrous metals and is like MIG welding except a separate filler rod is used instead of electrode welding

Oxyacetylene welding- welds low carbon steel when arc welding is not available O2 gas mix heats to 3500 degrees melting filler rod

Brazing (heavy soldering)- like OA but at 850 degrees

45
New cards

Name some metal addition processes

Pop riveting

Self tapping screws

Machine screws

Nut and bolt

46
New cards

State the metal wasting processes

Milling

Turning

Flame cutting

Plasma cutting (Uses ionising conductive gas)

Laser cutting

Punching and stamping

47
New cards

Name some fabrication processes of wood (joints)

Butt

Dowel

Mitre (45)

Dovetail

Mortise and tenon

Half lap

Housing

48
New cards

Name some addition processes of wood

Knock down fittings (flat pack)

Modesty blocks (polymers guiding screws)

Barrel nut and bolts (creates thread the other side of hole)

Cam lock connector (turns and locks screw like door chain)

Wood screws

49
New cards

Name some wasting and forming processes of wood

Turning

Routing

Milling

Laminating (ply)

Steam bending

50
New cards

Name some wood adhesives

PVA

Contact adhesive

Uv hardening adhesive

Solving cement (tensol 12 compound) can also join PVC and ABS

51
New cards

Describe the features of one off production

-created an individual product

-uses more skilled labour

-has a large manufacture time

-uses direct client consultation

-created a high quality individual production

52
New cards

Describe the features of batch production

-Jigs and fixtures used alongside CNC

-more accurate and faster than one off

-shorter production time than one off

-cheaper cost per unit than one off

53
New cards

Describe the features of mass production

-uses divisions of labour

-used line production

-very quick production time

-much cheaper per unit

54
New cards

What does quick response manufacture do

-greatly reduces the time between prototyping and production (concept to completion)

-meets client need quickly

-this can be done by reducing component arrival time ect...

55
New cards

What is a unit production system and where is it used

Overhead lines reducing transport time between labour stations, often used in textiles

56
New cards

What is vertical in house production

Where supply chains for a company ore owned by that company allowing for greater control and flexibility

57
New cards

How do we improve accuracy in design and manufacture

-CAD/CAM

-CNC

-six sigma (kaizen)

-JIT (making to order not stockpiling) requiring a good supply chain

58
New cards

What do most JIT systems rely on

EPOS, barcodes and RFID

59
New cards

What can a company do to make its production of a complex product more efficient and cheaper

Buy in standardised components and sub assembled parts

This can also be done by using a flexible manufacturing system (modular cell production)

60
New cards

State the specification criteria for fitness for purpose

Cost

Dimensions

Life span (Planned obsolescence)

Maintenance

Testing

Environmental impact

Safety

Ergonomics

Anthropometrics (95th 5th percentile)

Production

Performance (inclusive design)

Materials

Empathetic design (mirroring usage scenarios)

User centred design

61
New cards

By what methods can a product be developed

Concept modelling

Block modelling

Working prototypes

Rapid prototyping

62
New cards

Name the advantages of CAD/CAM

Easy to display ideas to client

Easy to collaborate

High accuracy

Speeds up the development process

Works together

63
New cards

State disadvantages of CAD/CAM

Expensive setup cost

Software has to be updated

Not very fast for quick sketches

64
New cards

How can CAD be used in product development

Can can be used for rapid prototyping and can be realistically rendered making it presentable to the client, these models can also be altered easily to keep up with development

for material and component behaviour- CFD and FEA can be used to test if a product may work before physical prototyping

65
New cards

Name some CAM processes

Laser cutting

Cnc routing

Milling

Turning

plotter cutting (mechanically cutting graphics)

3D printing

66
New cards

How can CAD CAM systems be used for automation and stock control

Computer systems can be used to control stocks and sales using EPOS data (capturing when consumers buy goods), JIT and a MPS can be used to control production rate

EPOS can be backed up by RFID and materials can be transported to stations by AGVs

67
New cards

State the 6 R's

Reduce

Repair

Reuse

Rethink

Refuse

Recycle

68
New cards

What is a primary carbon footprint

Measures direct emissions of CO2 from the burning of fossil fuels, including transport and domestic energy consumption

69
New cards

What is a secondary carbon footprint

measures indirect CO2 from the products we use

70
New cards

What can you do to reduce carbon footprint

Reduce product miles and use sustainable packaging (e.g. keepcup recyclable plastic cup) and materials

71
New cards

What three words describe a linear economy

Make

Take

Dispose

72
New cards

Describe a circular economy

Continues the cycle of use and recycling

preserving and optimising natural capital, optimising resource yield and fostering system effectiveness

73
New cards

Why is it important to maintain a circular economy

Works against a linear economy

Drives greater resource productivity

Reduces finite resource use

Reduces pollution

Drives a more competitive economy

Reduces overall environmental impact

74
New cards

what is the BSI and how is it represented on a product?

BSI (British Standards Organisation) represented by the kite-mark is a national organisation formed to ensure a net following of standard procedures when performing a widen range of materials, there are currently over 30,000 regulations including BS EN 62115 (electrical safety in toys)

75
New cards

What forms the ISO

Over 150 national bodies such as BSI

76
New cards

How is recycling aided in polymers

Codes on products describe a material and its recyclability in a form of categorisation

77
New cards

What is RoHS

This a directive aimed at preventing hazardous substances from entering the production process in order to prevent damage to human health and the environment.

78
New cards

What is the battery directive

An amendment of WEEE ensuring safe disposal of batteries

79
New cards

What is WEEE directive?

This is a mandatory European directive that covers the end of life of electric and electronic equipment.

80
New cards

What is the FSC Certification?

Ensures lumber comes from sustainable logging, this means that the wood was not from a clear cut or old growth forest

81
New cards

What is EC and eco labelling

Ensures/shows electrical efficiency and environmental impact of running an electrical product. EC labelling is recognised throughout Europe

82
New cards

What is the EU Energy star program?

This is was developed from an agreement between the EU and US to standardise how IT equipment was labelled to show the energy used

83
New cards

define material enhancement

The modification of a material to improve its properties relative to its final use/ function

84
New cards

Name the additives for polymers and what they do

-Lubricants- decrease the viscosity of the polymer making it easier to work with

-Thermal Antioxidants- prevent discolouration due to heat

-Fire Retardants (chlorine/bromine)- reduce chance of combustion

-Plasticisers- Make polymer more flexible

-Biobatch- Photo, Oxy and Hydrodegradable compounds added to reduce lifespan

-Antistatic- reduce build up of static by using a thin layer of moisture from the environment

-Antioxidants- reduce environmental degradation

-Fillers- reduce volume of polymer needed, mineral fillers also increase thermal conductivity

-Pigments- Give colour

-UV stabilisers- prevent polymers undergoing photolysis and altering colour and making product more brittle

-Biodegradable Antioxidants- Make product easier to break down

85
New cards

what are the disadvantages of natural wood

. Highly combustable

. Susceptible to Fungal/Insect attack and Rot

. Structural properties decrease when wet

. Anisotropic- different properties in different directions (grain)

86
New cards

What can be added to natural wood to better its properties

-Copper based preservatives can be injected, this is a naturally occurring Fungicide.

-Modified naturally occurring Polysaccharides can be added to increase hardness

-Pigments can be added to give colour.

-Resins May also be added to create manufactured boards

87
New cards

State the Manufactured boards/timbers and their enhanced properties due to the addition of UF resin

.MDF, Plywood, Chipboard, SCL (structural composite), LVL (laminated veneer)

-UF may also have additives promoting fire retardancy

-Boards May be clad with veneer to improve qualities

88
New cards

Describe how the Cold working of metal can lead to problems and how this can be corrected

Cold working can deform metal structure promoting easiness, lack of ductility. This can be fixed by Annealing

89
New cards

Describe the Annealing process in metal

Metal is heated ti above critical temperature and slowly cooled allowing the metal structure to form more bonds and become less ductile and brittle.

90
New cards

What is case hardening and how this done

Case hardening is the process of hardening the surface of steel with less than 4% carbon content this is a 2 stage process.

-Carburising- Metal is placed in ceramic box packed with carbon and heated to 930/950 degrees allowing carbon to diffuse in.

-Quenching- this is then cooled to 760 degrees and dipped in cold water

91
New cards

Describe the Hardening process and where is can be used. What process usually follows this to decrease hardness

Hardening is the process of heating medium/high carbon steel changing the crystalline structure and then quenching in cold water to improve hardness. Tempering may be used to make the metal a bit less hard where metal is heated to below critical temperature and left to slowly cool.

92
New cards

what are the different types of finishing process for papers and boards

. Lamination

-encapsulation (PET and EVA)

-Film Lamination (PP and Adhesive)

-Liquid Lamination (roller or spray

.Embossing and Debossing

.Foil Blocking

.Varnishing, UV Varnishing and Spot varnishing

93
New cards

what are the 4 types of printing processes that can be applied to papers and boards

.screen printing (like press printing)

.Digital Printing (like laser printing)

.Flexographic printing

.Offset Lithographic printing

94
New cards

Describe the Flexographic printing process including advantages and disadvantages

.4 Colour (magenta, cyan, black, yellow) system

.must be very precise to prevent blurry image so registration system is printed outside the printing area which can later be scanned

.cheap because uses water based UV curing inks

.uses flexible printing plates wrapped around rotating cylinders on web press

.Only efficient fir mass printing because of hight setup and running cost. Low maintenance and uses cheap ink.

95
New cards

Describe the offset Lithographic printing process

.Works on principle that oil and water don't mix so printing area is Oleophilic and non printing area is hydrophillic

1) printing substrate either sheet fed or web rolled into machinery

2)Printing plates are produced by a computer to plate process (CTP) via laser etching. these are attached to machine and dampened my a roller

3) ink applied to printing plate this rotates onto a blanket roller which becomes coated in ink, this is then rolled on to the substrate which is being fed in

.This gives a consistent high quality finish and produces long lasting printer plates however is expensive to set up and run

96
New cards

What are the methods of polymer finishing

.Adding pigment during moulding

.Acrylic spay paints (become water resistant after drying)

.Over-moulding (usually TPE Elastomer)

-this can be doe using two injection moulds or twin show moulding where mould rotates to reveal another shape

97
New cards

what are the methods of metal finishing with description

.Cellulose/ Acrylic paints (key and prime first)

.Electroplating (place in electrolyte solution and let charge attract metals out of solution)

.Dip coating (hot metal dipped in polymer moulding in fluoridation bath with air being blown thought it. this also works with metal being run under stream of other molten metal

.Powder coating (Statically (-) charged object attracts + charged thermoset polymer resin)

.baking

.Varnishing

.Sealants (polymer based)

.Anodising (similar to electroplating but sulphuric acid leaves built up oxidised layer on aluminium Anode

.Cathodic protection (next card)

98
New cards

Explain, including the two methods Cathodic Protection

-All metals have a natural voltage (proportional to reactivity)

-In the presence of water a current is induced in-between 2 metals creating an electrochemical cell.

-More active metals will oxidise (anode) and corrode to protect less reactive cathodes.

-This can be used via Impressed current or sacrificial anodes

.Impressed current:

-material to be protected is connected to pawer supply

-current flows through any liquid from inert electrode (anode) to material being protected causing the electrode to corrode

.Sacrificial Anodes:

more reactive metal is physically attached to less reactive metal and anode corrodes

99
New cards

Name the methods/types of wood finish

.Polyurethane/acrylic varnish (gives polymer properties)

.Stains

.Water based paint

.Varnishes

.Teak oil

.Danish oil

.Yacht Varnish

.pressure treating

.Wax

.colour washing

100
New cards

What should employers do to ensure Health and Safety in the workplace

-Ensure the workplace is safe and risk free

-Ensure Welfare facilities such as first aid are In place

-Ensure dangerous substances are stored and used safely

-Ensure Machinery is safe to use and well Maintained

-Ensure Training, Information and Supervision are provided where necessary

-Ensure Adequate safety signage is in place