Cambridge
TECHNICALS
CAMBRIDGE TECHNICALS
IN ENGINEERING
LEVEL 3 UNIT 11 – MATERIALS SCIENCE
DELIVERY GUIDE
Version 1
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
CONTENTS
Introduction3
Related Activities
4
Key Terms
5
Misconceptions8
Suggested Activities:
Learning Outcome (LO1)
9
Learning Outcome (LO2)
12
Learning Outcome (LO3)
14
Learning Outcome (LO4)
16
Learning Outcome (LO5)
18
MATERIALS SCIENCE
2
This Delivery Guide has been developed to provide practitioners with a variety of
creative and practical ideas to support the delivery of this qualification. The Guide
is a collection of lesson ideas with associated activities, which you may find helpful
as you plan your lessons.
OCR has collaborated with current practitioners to ensure that the ideas put forward in
this Delivery Guide are practical, realistic and dynamic. The Guide is structured by learning
outcome so you can see how each activity helps you cover the requirements of this unit.
We appreciate that practitioners are knowledgeable in relation to what works for them
and their learners. Therefore, the resources we have produced should not restrict or
impact on practitioners’ creativity to deliver excellent learning opportunities.
Unit 11 Materials Science
LO1
Understand material structure and classification
LO2
Understand properties, standard forms and failure modes of materials
LO3
Understand material processing techniques
LO4
Know the applications and benefits of modern and smart materials
LO5
Be able to test the suitability of materials for different applications
MATERIALS SCIENCE
INTRODUCTION
Whether you are an experienced practitioner or new to the sector, we hope you find
something in this guide which will help you to deliver excellent learning opportunities.
Unit aim
Awareness of materials science is needed by design engineers and all other types of
engineers in order that they can make informed decisions about the engineering materials
that they choose to use in design and manufacture.
The aim of this unit is for learners to understand material structure and classification, and
common properties, standard forms and failure modes of engineering materials.
They will develop an understanding of industrial material processing techniques, and how
this is affected by materials’ properties.
They will gain knowledge on the application and uses of modern and smart materials, and
develop the ability to be able to test the suitability of different engineering materials for
their intended application.
Opportunities for English and maths
skills development
We believe that being able to make good progress in English and maths is essential to
learners in both of these contexts and on a range of learning programmes. To help you
enable your learners to progress in these subjects, we have signposted opportunities
for English and maths skills practice within this resource. These suggestions are for
guidance only. They are not designed to replace your own subject knowledge and
expertise in deciding what is most appropriate for your learners.
EnglishMaths
Please note
The timings for the suggested activities in this Delivery Guide DO NOT relate
to the Guided Learning Hours (GLHs) for each unit.
Assessment guidance can be found within the Unit document available from
www.ocr.org.uk.
The latest version of this Delivery Guide can be downloaded from the OCR website.
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OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
If you have any feedback on this Delivery Guide or suggestions for other resources you
would like OCR to develop, please email [email protected].
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OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
RELATED ACTIVITIES
The Suggested Activities in this Delivery Guide listed below have also been related to other Cambridge Technicals in Engineering units/Learning Outcomes (LOs). This could help with
delivery planning and enable learners to cover multiple parts of units.
This unit (Unit 11)
LO1
LO2
LO3
LO5
Title of suggested activity
Other units/LOs
Atomic structures and bonding
Unit 2 Science for engineering
LO4 Understand properties of materials
Crystalline structures of metals and alloys
Unit 2 Science for engineering
LO4 Understand properties of materials
Materials properties – part 1
Unit 2 Science for engineering
LO4 Understand properties of materials
Materials properties – part 2
Unit 2 Science for engineering
LO4 Understand properties of materials
Materials properties – part 3
Unit 2 Science for engineering
LO4 Understand properties of materials
Thermal equilibrium
Unit 1 Mathematics for
engineering
LO1 Understand the application algebra relevant to engineering problems
Electrical conductivity and resistivity
Unit 1 Mathematics for
engineering
LO1 Understand the application algebra relevant to engineering problems
Thermal conductivity
Unit 1 Mathematics for
engineering
LO1 Understand the application algebra relevant to engineering problems
Toughness
Unit 1 Mathematics for
engineering
LO1 Understand the application algebra relevant to engineering problems
Thermal expansion
Unit 1 Mathematics for
engineering
LO1 Understand the application algebra relevant to engineering problems
MATERIALS SCIENCE
4
UNIT 11 – MATERIALS SCIENCE
MATERIALS SCIENCE
KEY TERMS
Key term
Explanation
Abrasion resistance
Abrasion resistance is the ability of a fabric or material to resist surface wear caused by flat rubbing contact with another material. Testing for abrasion resistance is
carried out by rapidly abrading the surface of the material through tests being carried out in accordance with international standards.
Alloy
An alloy is a metal made by combining one or more metallic elements (along with other agents), especially to give greater strength or resistance to corrosion.
Atomic structure
Atoms are made up of three types of particle – protons, neurons and electrons. The atomic composition is different for different types of material (i.e. the number of
electrons, protons and neurons).
Bonding
Bonding is how atoms are arranged (connected) within a material. Different forms of bonding include metallic, ionic and covalent bonding.
Carbon fibre
Carbon fibre is a material consisting of thin, strong crystalline filaments of carbon, used as a strengthening material. It is sometimes combined with polymers to
form carbon fibre reinforced polymer (CFRP). CFRP is a composite material.
Casting
Casting is a process of making an object by pouring molten metal or other material into a mould.
Ceramic
A ceramic is an inorganic, nonmetallic solid comprising metal, nonmetal or metalloid atoms primarily held in ionic and covalent bonds. Ceramics are used in many
engineering applications – including cutting tools and semiconductors.
Charpy test
The Charpy impact test, also known as the Charpy V-notch test, is a standardized high strain-rate test which determines the amount of energy absorbed by a
material during fracture. It is a type of toughness test.
Classification (of
materials)
Materials are often classified into groups of materials with like properties. These include metals, ceramics, composites and polymeric materials.
Composite material
Composite materials (composites) are materials made from two or more constituent materials with significantly different physical or chemical properties, that when
combined, produce a material with characteristics different from the individual components.
Corrosion resistance Corrosion resistance refers to how well a substance (especially a metal) can withstand damage caused by oxidization or other chemical reactions.
Crystalline structure Crystalline structure refers to the unique arrangement of atoms, ions and molecules in a solid. Primary metallic crystalline structures are body-centred cubic (BCC),
/ crystal lattice
face centred cubic (FCC) and hexagonal close packed (HCP).
5
Elastomer
An elastomer is a natural or synthetic polymer having elastic properties.
Electrical
conductivity and
resistivity
Electrical conductivity is the degree to which a specified material conducts electricity. Resistivity is a measure of the resisting power of a specified material to the
flow of an electric current. Different materials exhibit different conductivity and resistivity characteristics.
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Explanations of the key terms used within this unit, in the context of this unit
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Explanations of the key terms used within this unit, in the context of this unit
MATERIALS SCIENCE
Key term
Explanation
Extrusion
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or pulled through a die of the desired cross-section.
Failure Mode
Failure modes are the modes by which a material (or component) may fail. Failure modes include: work hardening, overstressing, fatigue, creep, sudden loads,
expansion, thermal cycling and degradation.
Failure Mode and
Effects Analysis
(FMEA)
Failure Mode and Effects Analysis (FMEA) is a recognised technique for identifying and analysing potential reliability problems, including methods to overcome
them. It is a systematic and recognised technique – with standard templates available for its completion.
Forging
Forging is a process to make or shape (a metal object) by heating it in a fire or furnace and hammering it.
Forming
Forming is the metalworking process of fashioning metal parts and objects through mechanical deformation; the work piece is reshaped without adding or
removing material.
Glass
Glass is an amorphous (non-crystalline) solid material. Glass is a form of ceramic. Engineering applications of glass include heat shields and fibre optics.
Glass Reinforced
Plastic (GRP)
GRP is a composite material comprising of strands of glass embedded in a resin. The glass strands are woven into patterns in order to change the characteristics of
the material. Fibreglass is a type of glass reinforced plastic.
Grain size (metals)
Most metals are crystalline in nature and contain internal boundaries, commonly known as “grain boundaries”. The grain size is determined by the material itself and
its manufacture and processing. Grain size affects the properties of the material.
Heat treatment
Heat treatment refers to a range of heat-related processes that are used to alter the properties of a material of component. These include annealing, normalising,
hardening, tempering and case hardening e.g. carburising, nitriding.
Izod test
The Izod test is a material strength test in which a notched specimen is broken by a blow from a pendulum, the energy absorbed being determined from the
decrease in the swing of the pendulum. It is a type of toughness test.
Machinability
Machinability refers to the ease with which a metal can be cut permitting the removal of the material with a satisfactory finish at low cost. Materials with good
machinability require little power to cut, obtain a good finish and retain their desired properties and characteristics.
Nanomaterials
Nanomaterials are materials having particles or constituents of nanoscale dimensions, or one that is produced by nanotechnology. They are often added to other
materials in order to change the characteristics of that material in some way.
Periodicity
In the context of chemistry/materials and the periodic table , periodicity refers to trends or recurring variations in element properties with increasing atomic
number . Periodicity is caused by regular and predictable variations in element atomic structure.
Physical properties
Physical properties of materials are wide ranging, and include: hardness, toughness, elasticity, plasticity, ductility, malleability, conductivity, resistivity, machinability,
fusibility and corrosion resistance. Materials also possess strength- related properties.
Polymer
A polymer is a very large, chain-like molecule made up of monomers, which are small molecules.
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Key term
Explanation
Press forming
Press forming is a metal-forming operation performed with a mechanical or hydraulic press.
Quantum
Tunnelling
Composite (QTC)
Quantum-tunnelling composite (QTC) is a flexible polymer which contains tiny metal particles. It is normally an insulator but if it is squeezed it becomes a
conductor. Applications include switches and sensors.
Shape memory
materials
Shape memory materials are materials that remember their original shape. Once deformed they return to their original state when heated. Shape memory
materials include alloys and polymers.
Smart polymers
Smart polymers include polymers that change according to some external stimulus (e.g. temperature, humidity, pH, light, electrical or magnetic fields ). They also
include polymers exhibiting self-repairing characteristics. Electrically conductive polymers and self-healing polymers are two types.
Solidification
(metals)
Solidification involves the transformation of the molten metal back into the solid state. The solidification process determines the grain size of the metal, and hence
its properties.
Standard forms of
supply
Standard forms of supply refer to how a material is supplied for manufacturing (and machining). This varies from material to material and includes: sheet, bar, flat
stock, ingot/billet granules and liquid.
Strength (of a
material)
Strength of material relates to how the material behaves when loaded. Strength of material may be compressive strength, tensile strength, sheer strength and
torsional strength.
Thermal
conductivity
Thermal conductivity is a measure of the ability of a material to allow the flow of heat from its warmer surface through the material to its colder surface.
MATERIALS SCIENCE
Explanations of the key terms used within this unit, in the context of this unit
7
Thermal expansion
Thermal expansion is the tendency of matter to change in volume in response to a change in temperature, through heat transfer. As a material is heated its length
(volume) will commonly increase.
Thermoplastic
A thermoplastic, or thermosoftening plastic, is a plastic material, typically a polymer, that becomes pliable or moldable above a specific temperature and solidifies
upon cooling.
Thermosetting
plastic
A thermosetting plastic, also known as a thermoset, is a plastic material that irreversibly cures.
Toughness
Toughness is the ability of a material to absorb energy and plastically deform without fracturing.
Wasting
Wasting is a process of cutting away material to leave the desired shape.
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Thermal Equilibrium Thermal equilibrium diagrams (TEDs) are diagrams that show the changes that take place in the alloying process depending on the quantities of each part of the
Diagram (TED)
alloy. It can be used to find the ratio of phases between the liquidus and solidus states.
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
MISCONCEPTIONS
Some common misconceptions and guidance on how they could be overcome
What is the misconception?
How can this be overcome?
Resources which could help
Understanding atomic structure
Learners often find the understanding of atomic structure difficult. Teachers could use examples of the
atomic structure of different materials or elements – showing the structure of protons, electrons and
neurons for each.
http://www.chemicalelements.com/
groups/transition.html
Understanding atomic bonding
Learners often find it difficult to understand how atoms are bound together, and the different types
of bonding (e.g. metallic, ionic and covalent bonding). Resources showing different examples may be
useful.
http://www.chem4kids.com/files/
atom_bonds.html
http://www.bbc.co.uk/schools/
gcsebitesize/science/add_ocr_
gateway/periodic_table/metalsrev2.
shtml
Understanding crystalline
structures
Different crystalline structures are sometimes difficult to understand, and vary within materials. Giving
examples of crystalline structure for different materials may be useful.
https://www.nde-ed.org/
EducationResources/
CommunityCollege/Materials/
Structure/metallic_structures.htm
Understanding grain structures
Metals form a grain structure on solidification. Teachers might use microscope images of metals, or may
be able to use practical examples to show learners using a microscope.
http://www.youtube.com/
watch?v=uG35D_euM-0
Understanding alloying and
thermal equilibrium diagrams
(TEDs)
Teachers might use practical examples of alloys and their associated TEDs in order to explain this
concept.
http://www.practicalstudent.com/
subjects/eng/teds.shtml
Learners could us a TED to find the ratio of phases between the liquidus and solidus states.
MATERIALS SCIENCE
8
MATERIALS SCIENCE
SUGGESTED ACTIVITIES
LO No:
1
LO Title:
Understand material structure and classification
Title of suggested
activity
Suggested activities
Suggested timings
Teachers could begin this unit by an introduction to materials science including materials
classification and microstructures, and how these influence material properties (e.g. metals, ceramics,
composites and polymeric materials).
1 hour
Materials classification
Also related to
The following explains classification – http://www.nde-ed.org/EducationResources/
CommunityCollege/Materials/Introduction/classifications.htm
A reference text covering materials science, such as Bolton and Higgins (2004) “Materials for
Engineering and Technicians” may prove useful throughout the whole of the unit.
Learners could undertake an initial investigation of the classification of materials.
Atomic structures and
bonding
Teachers could introduce learners to atomic structures and bonding (e.g. metallic, ionic and covalent
bonding).
2 hours
Unit 2 LO4
Web-based resources might prove useful in explaining atomic structures and bonding – such as
http://www.nde-ed.org/EducationResources/CommunityCollege/Materials/Structure/bonds.htm and
http://www.chem4kids.com/files/atom_bonds.html
Periodicity
Materials are commonly categorised by their periodicity using the periodic table. The periodic table
organises elements by their atomic number (i.e. number of protons, electron configuration and
chemical properties). The table also includes many common engineering materials.
Teachers could introduce learners to the periodic table – explaining periodicity. The atomic properties
of common engineering materials – such as iron, zinc, tin could be explained to learners.
The following web-based resources is an interactive periodic table (showing element name, weight,
melting and boiling points) including common engineering materials – http://www.engineersedge.
com/periodic_table_of_elements.htm
See Lesson Element
Periodicity
9
Teachers could develop an elements quiz based on the periodic table.
1 hour
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Learners could in investigate the atomic structure for different materials/elements and also the
different types of bonding (i.e. metallic, ionic and covalent bonding).
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Title of suggested activity
Suggested activities
Suggested timings
Also related to
Crystalline structures of
metals and alloys
Teachers could introduce learners to the crystalline (crystal lattice) structure of metals and alloys.
This could include the crystalline structure of ferrous and non-ferrous metals and alloys, space lattice
structures, grain sizes, crystal growth and solidification.
3 hours
Unit 2 LO4
Web-based resources may prove a useful starting point with the following explaining the crystal
lattice (http://www.substech.com/dokuwiki/doku.php?id=metals_crystal_structure) and grain
structure/solidification (http://www.chemguide.co.uk/atoms/structures/metals.html)
Teachers may be able to show grain structure images of metals to learners, or learners may be able to
use microscopes to undertake practical activities. The following video shows images of grain structure
– http://www.youtube.com/watch?v=uG35D_euM-0
Learners could investigate the crystalline and grain structures of a range of metals and alloys.
Polymers (Plastics)
Polymers (plastics) are a common form of material used in many applications. Teachers could
introduce learners to the structure and composition of plastics including: thermo-plastics, thermosetting plastics, long chain molecules, cross linking and co-polymerisation.
2 hours
The following teacher-resource website explains the process of polymerisation (http://bpes.bp.com/
secondary-resources/science/ages-14-to-16/chemical-and-material-behaviour/polymerisation/).
Learners may be able to perform simple experiments to explore the manufacture of polymers (see
http://www.nuffieldfoundation.org/practical-chemistry/polymers-and-polymerisation)
Ceramics and glasses
The properties of ceramics and glasses are specified by the type of atoms present, type of bonding
and the way atoms are arranged. Teachers might begin by explaining the crystalline structures of
ceramics and glasses.
2 hours
Web-based resources might prove useful e.g. http://ceramics.org/learn-about-ceramics/structureand-properties-of-ceramics (ceramics).
The following video shows the applications of glasses –
http://www.youtube.com/watch?v=12OSBJwogFc
MATERIALS SCIENCE
Learners could independently investigate the properties and composition of different forms of
ceramic and glass e.g. tungsten carbide.
10
Suggested activities
Suggested timings
Elastomers
Learners could investigate the composition and structure of elastomers i.e. natural rubber,
styrene-butadiene, polychloroprene, butyl and ethylene-propylene.
2 hours
Also related to
MATERIALS SCIENCE
Title of suggested activity
The following web-page explains the properties of elastomers, including the concept of entropy –
http://pslc.ws/macrog/elas.htm
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OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Learners could further investigate the applications of different forms of elastomer.
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
SUGGESTED ACTIVITIES
LO No:
2
LO Title:
Understand properties, standard forms and failure modes of materials
Title of suggested activity
Suggested activities
Suggested timings
Also related to
Materials properties – part 1
Learners could investigate the physical properties of materials including hardness, toughness,
elasticity/plasticity, ductility and malleability.
2 hours
Unit 2 LO4
2 hours
Unit 2 LO4
2 hours
Unit 2 LO4
Web-based resources might prove a useful reference source with the following explaining various
material properties – http://www.technologystudent.com/joints/matprop1.htm
Teachers might be able to illustrate some properties using practical experiments.
Materials properties – part 2
Learners could continue their investigation of materials properties by considering conductivity/
resistivity, machinability, fusibility and corrosion resistance.
The following web-based resources explain corrosion (http://www.youtube.com/
watch?v=T4pSuflO9fk) and machinability (http://americanmachinist.com/cutting-tools/chapter-3machinability-metals)
Materials properties – part 3
Learners could conclude their investigation of materials properties by investigating stiffness,
compressive strength, tensile strength, sheer strength and torsional strength.
The following explains loading of components in further detail – http://www.nde-ed.org/
EducationResources/CommunityCollege/Materials/Mechanical/Loading.htm
Learners could develop an overall summary of the key material property – comparing different types
of materials against one another under each property (e.g. metals, polymers, ceramics and glasses).
Standard forms of supply
Materials are supplied in standard forms, depending on the material type, composition and
application. This includes sheet, bar, flat stock, ingot/billet granules and liquid.
2 hours
Learners could investigate and compare standard forms of supply for a range of different materials.
MATERIALS SCIENCE
12
Suggested activities
Suggested timings
Safety factors and failure
modes
Materials can fail in a number of ways, and for this reason are often specified in designs to a given
safety factor.
2 hours
Also related to
MATERIALS SCIENCE
Title of suggested activity
Failure modes are often as a result of work hardening, overstressing, fatigue, creep, sudden loads,
expansion, thermal cycling and degradation.
The following video explains failure analysis and may prove a useful introduction –
http://www.youtube.com/watch?v=85HxmnLEkwM
Learners could independently investigate modes of failure and how safety factors are included.
The following shows the effects of work hardening, and similar resources might prove useful –
http://www.youtube.com/watch?v=QtuedAQ6lwE
Failure Mode and Effects
Analysis (FMEA)
Failure Mode and Effects Analysis (FMEA) is a recognised technique for identifying and analysing
potential reliability problems, including methods to overcome them. It is often used in engineering
design and includes the analysis of materials and their potential modes of failure.
3 hours
Teachers could introduce learners to the theory of FMEA. Web-based resources might prove useful http://www.npd-solutions.com/fmea.html
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OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Learners could undertake an FMEA for a given component or system – completing a standard FMEA
template (see http://www.fmea-fmeca.com/fmea-examples.html).
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
SUGGESTED ACTIVITIES
LO No:
3
LO Title:
Understand material processing techniques
Title of suggested activity
Suggested activities
Suggested timings
Casting
Materials can be processed using a wide range of different techniques. Techers might begin this
new topic area with an overview of materials processing – and that it may result in changes in the
properties of a material.
2 hours
Also related to
Techers could begin by showing learners how materials can be cast, and their effect on the crystal
forms/grain structures and properties of material. Different casting methods might be considered.
The following explains the effects of casting on material properties, and the different techniques by
which materials may be cast – http://www.doitpoms.ac.uk/tlplib/casting/microsegregation.php
See Lesson Element Casting
Press forming
Press forming (or press brake forming) is a process that changes the shape of a work piece by the
application of pressure. It causes a change in the properties of the material it is applied to.
1 hour
Learners could investigate the press forming of sheet metal, including the mechanisms by which this
process alters the properties of the material.
Forming, wasting and
forging
Forging is a process that is used to alter the properties of a material (see http://www.the-warren.org/
ALevelRevision/engineering/grainstructure.htm).
1 hour
Cold forging is often used to alter the strength of a material while hot forging alters the grain
structure.
Other processing techniques include forming (often rolling) and wasting (meaning cutting materials
away).
Learners could investigate cold and hot forged components making a comparison with cold formed
or wasted component manufacture.
Extrusion
Extrusion is a process used to create fixed cross-sectional profile by pulling or pushing a material
through a die. Extrusion affects the properties of the material being extruded.
1 hour
MATERIALS SCIENCE
Learners could investigate the process of extrusion for different types of material, considering how it
affects material properties.
14
Suggested activities
Suggested timings
Machinability properties
The machinability of a material is related to the composition, structure, properties and performance of 2 hours
the material itself. Materials with good machinability require little power to cut, easily obtain a good
finish, and exhibit no degradation in material properties.
Also related to
MATERIALS SCIENCE
Title of suggested activity
Learners could investigate the relationship between machinability and materials properties.
Heat treatment
Heat treatments are used to modify the properties of materials, and include annealing, normalising,
hardening, tempering and case hardening e.g. carburising, nitriding.
2 hours
Teachers could begin by explaining some of these heat treatment techniques to learners, leaving
them to investigate the remainder independently.
The following video explains how heat treatment alters the properties of steel –
http://www.youtube.com/watch?v=98lh5Q0M0cg
Alloying
Alloying is a process of combining one or more metals with other agents to produce a metal
alloy whose properties are superior to a pure metal. Examples of alloys are steel, brass, duralumin,
phosphor bronze and solder. The effect of alloying is on the melting point and strength of materials.
2 hours
Teachers could begin by explaining the process of alloying. The following video explains how alloying
can modify the properties of metals (stainless steel) –
http://www.youtube.com/watch?v=jGW9orpZqak
Learners might investigate the composition of different types of alloys.
Thermal equilibrium diagrams (TEDs) show the changes that take place in the alloying process
depending on the quantities of each part of the alloy.
2 Hours
Teachers could show learners how to interpret TEDs including their application in alloy manufacture.
The following web-page explains TEDs with examples –
http://www.practicalstudent.com/subjects/eng/teds.shtml
Learners might develop and explain TEDs themselves.
Plastics
Plastics may be categorised into two types – thermosetting plastics and thermoplastics. Teachers
might begin by recalling the difference between both types,
Learners could investigate the applications of different types of thermosetting plastics and
thermoplastics, including how they are processed and how processing affects material properties.
The following web resource may prove a useful starting point –
http://www.mr-dt.com/materials/thermosetting.htm
15
2 hours
Unit 1 LO1
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Thermal equilibrium
diagrams
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
SUGGESTED ACTIVITIES
LO No:
4
LO Title:
Know the applications and benefits of modern and smart materials
Title of suggested activity
Suggested activities
Suggested timings
Modern materials – GRP
Modern and smart materials (i.e. materials that exhibit enhanced characteristics or that react to some
stimulus) are finding an increasing number of applications.
1 hour
Also related to
Throughout this Learning Outcome learners could independently investigate a range of modern and
smart materials.
Glass Reinforced Plastic (GRP) is a composite material consisting of strands of glass embedded into a
resin.
Learners could investigate the composition and applications of GRP. The following web-link might
prove a useful starting point – http://www.technologystudent.com/joints/fibre1.html
Teachers may be able to show learners practical examples of GRP manufactured items.
Modern materials – carbon
fibre
Carbon fibre is a material with crystalline filaments of carbon that is strong and lightweight – albeit it
1 hour
relatively expensive to manufacture. It is often combined with polymers to form a composite material.
Teachers could begin by explaining how carbon fibre is manufactured. This is shown in the following
video – http://www.youtube.com/watch?v=kaoq8Mc4xxw
See Lesson Element Modern
materials – carbon fibre
Modern materials – MDF and
composites
Learners could investigate the applications of carbon fibre – including summarising its properties.
Medium Density Fibreboard (MDF) is another form of composite material which is commonly found
in many applications including furniture and other engineered wood products. There are many other
similar forms of composite material.
1 hour
Learners could investigate the construction, characteristics and applications of a range of composite
materials.
The following website for the UK composites trade association may prove useful http://compositesuk.co.uk/composite-materials
MATERIALS SCIENCE
16
Suggested activities
Suggested timings
Smart materials – shape
memory alloys and plastics
Smart materials are materials that react (or change their properties) as a result of some external
stimulus e.g. heat, light, electricity.
1 hour
Also related to
MATERIALS SCIENCE
Title of suggested activity
Teachers could explain the key characteristics of shape memory materials (i.e. alloys and plastics) to
learners. As these materials are available relatively cheaply it may be possible to demonstrate material
properties practically.
The following explains shape memory alloy (http://www.technologystudent.com/equip1/
sma1.htm) and the following video shows shape memory polymer (http://www.youtube.com/
watch?v=1L8imyNvLJo)
Learners could independently investigate the application of shape memory materials.
Smart materials – QTC
Quantum Tunnelling Composite (QTC) is an electrically conductive material that exhibits properties
that make it suitable for use in sensing and switching systems.
1 hour
The following website explains QTC in detail, and includes a number of videos – http://www.peratech.
com/qtc-material.html
Due to its relatively low cost, teachers may be able to demonstrate QTC to learners with a simple
experiment.
Learners could explore further the properties and applications of QTC.
Nanomaterials are materials that are extremely small in size – and which are usually added to other
materials in order to provide enhanced properties of characteristics. Nanomaterials present a number
of challenges in their application – and also with some perceived health risks.
1 hour
Learners could investigate the development of nanomaterials and their applications.
The following website might prove a useful starting point – http://www.niehs.nih.gov/health/topics/
agents/sya-nano/
Smart materials – polymers
Smart polymers include conductive polymers and self-healing polymers.
Self-healing polymers are presented in the following BBC article – http://www.bbc.co.uk/news/
science-environment-27296365
Learners could investigate in further detail the properties and applications of smart polymers.
Practical experiments may be possible due to the relatively low cost of these types of material.
17
1 hour
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
Smart materials –
nanomaterials
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
LO No:
5
LO Title:
Be able to test the suitability of materials for different applications
Title of suggested activity
Suggested activities
Suggested timings
Abrasion resistance
Throughout this Learning Outcome learners may be able to perform a number of practical materials
testing activities and experiments.
2 hours
Also related to
Abrasion resistance testing is a form of accelerated wear testing of a material. It is usually performed
by machine to rapidly abrade the surface of the material to a set of international standards.
The following video shows commercial abrasion testing taking place –
http://www.youtube.com/watch?v=idJGrLcaDlQ
Learners may be able to access resources to perform abrasion resistance testing themselves – or could
devise a simplified experiment to test the abrasion resistance of a range of different materials.
Corrosion resistance
Corrosion causes damage to different types of material. Materials are often selected or protected to
be corrosion resistant.
2 hours
Learners could undertake simple experiments to determine the resistance to corrosion of a range of
different materials.
The following Nuffield website presents a number of simple corrosion experiments –
http://www.nuffieldfoundation.org/practical-chemistry/causes-rusting
Electrical conductivity and
resistivity
Different materials allow the passage of an electric current at different rates. This is the conductivity or 2 hours
resistivity of a material.
Unit 1 LO1
Learners could perform simple experiments to determine the resistivity of different materials.
The following explains a simple experiment along with appropriate theory to determine the resistivity
of copper wire – http://www.education.com/science-fair/article/resistivity-iron-conduct-electricitycopper/
Learners could test other materials.
MATERIALS SCIENCE
18
Suggested activities
Suggested timings
Also related to
Thermal conductivity
Thermal conductivity differs from material to material. Testing of thermal conductivity can be
performed using Ingenhousz’s apparatus.
2 hours
Unit 1 LO1
2 hours
Unit 1 LO1
2 hours
Unit 1 LO1
MATERIALS SCIENCE
Title of suggested activity
The following explains a simple experiment to determine thermal conductivity of different materials
– http://www.nuffieldfoundation.org/practical-physics/comparing-thermal-conductivities-differentmaterials
Learners may be able to perform suitable experiments.
Toughness
Toughness is the ability of a material to absorb energy and plastically deform without fracturing.
Toughness testing is often performed with calibrated equipment – and includes the Izod and Charpy
tests.
The following is an explanation of the Izod test – http://www-materials.eng.cam.ac.uk/mpsite/
properties/non-IE/toughness.html
Teachers may be able access suitable equipment for learners to perform a Izod or Charpy test
themselves for different materials.
Thermal expansion
Most materials expand as they are heated. This is termed thermal expansion.
Learners could perform simple experiments to determine the thermal expansion of different materials.
Learners could test a range of different materials using the same technique.
19
OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
The following Institute of Physics experiment explains how this might be done – http://www.
nuffieldfoundation.org/practical-physics/expansion-solid-rod
MATERIALS SCIENCE
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OCR LEVEL 3 CAMBRIDGE TECHNICALS IN ENGINEERING
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