Material Types

There are four classes of materials studied in this course:Metals

There are many metals which you are familiar with - copper pipes
and wire, aluminium saucepans and cast iron stoves. Metals may
be mixed with other elements especially other metals to produce
alloys which will have improved properties. Heat treatment can
also be used to change the properties of alloys e.g. hardening and
tempering of high carbon steel.
All metals are good conductors of heat and electricity. Copper is a
particularly good conductor but is not very strong, it is also fairly
dense. Aluminium is a good conductor has a low density and when
alloyed has a high tensile strength. Some alloys such as pewter and
zinc alloys have a low melting point and can be easily formed by
casting or moulding but they have a low tensile strength.
Metals in common use are corrosion resistant except iron and steel
which rust quickly. Corrosion resistance is achieved by
electroplating to add a layer of corrosion resistant material such as
chromium or zinc, painting, plastic coating, and coating with an oil
or grease. The alloy stainless steel is very rust resistant.
When choosing a metal for a particular job the properties must be
carefully considered. For example aluminium could be used for
overhead power lines as its lower density and good tensile strength
offset its slightly lower electrical conductivity.
Types of metal available in school - link to GCSE engineering
materials page

Polymers
Polymers are made from long chain molecules which may have
cross linking bonds affecting flexibility/stiffness.
There are three groups of polymer:Thermoplastics which may be reformed with heat. e.g. PVC, HIPS,
nylon, polycarbonate, PET, acrylic.
Thermosetting plastics which once moulded or formed cannot be
reformed by heat. e.g. Melamine(MF), epoxy resin, Urea

formaldehyde (UF).
Elastomers - rubbers long chain elastic molecules. e.g. neoprene,
natural rubber. Used for car tyres and elastic bands.
Applications
Nylon is used for bearings and the cases for power tools also used
for fishing line and ropes. Nylon is very strong and wear resistant it
is also slippery without the need for lubrication. Originally used as
a silk substitute - stockings and climbing ropes.
PVC is used for casings for electical consumer items and is also
used in its flexible form as the insulating sheath on electrical cable
and flex.
Melamine is used as the protective layer on worksurfaces and
laminated flooring.
UF is used to make electrical components when a good insulator is
needed such as plug tops and switch buttons.
Acrylic is used for safety shields but is not as tough as
polycarbonate. Polycarbonate is used for the lenses in safety eye
protection e.g. goggles.

Ceramics
This class of material includes plates and cups, bricks, earthenware
pots, engineering ceramics, glasses [glasses are non-crystalline and
not normally classed as ceramics], and refractory (furnace)
materials. Ceramics are made by heating together materials such as
silica, chalk and clays. Other chemicals may be included to act as
flux and to change colour etc.
Engineering Ceramics Include
Silicon carbide
Zirconia
Silicon nitride
Diamond
Cubic boron nitride
Tungsten Carbide

Properties
Engineering ceramics are ideally suited for high performance
applications where a combination of properties such as wear
resistance, hardness, stiffness and corrosion resistance are
important. In addition to these properties, engineering ceramics
have relatively high mechanical strength at high temperatures.
They are good electrical insulators, They often have a close
thermal expansion coefficient to metals (they can be bonded to
metals - e.g. carbide tipped tools).
Ceramics have been regarded as hard but brittle, however modern
ceramics have been developed which are viable alternatives to
metals and their alloys in many applications - engineering ceramic
parts and components are more durable and have longer life-spans
under given operational conditions. Ceramic cutting tools, for
instance, require less sharpening or replacement due to wear, and
will last at least 60 to 100 times longer than steel blades.
Engineering ceramics are chemically resistant to most acids, alkalis
and organic solvents and can withstand high temperatures. Metals
weaken rapidly at temperatures above 816 degrees C while
engineering ceramics retain a good degree of their mechanical
properties at much higher temperatures.
Applications
Mechanical components include wear plates and thermal barriers,
bearings for high speed and high stiffness spindles, bushes, gears.
Process components include pump shafts, seats, bearing surfaces,
gears and even complete pump bodies, valve guides and seats.
Ceramics are used for cutting tools including razor blades for film
and tape cutting to 300mm diameter circular slitters for the paper
industry.
Ceramic turbine blades are used in most turbochargers providing
lighter units than the steel alternatives allowing improved
performance at higher temperatures.

Composites
Are mixtures of materials which give improved properties. One of
the materials is the matrix or binding chemical and the other is the
reinforcer. A good example is GRP - glass reinforced
polyester(plastic) resin. where the glass fibres increase the strength
of the polyester resin. Carbon fibre reinforced epoxy resin is

stronger and lighter than steel.

Concrete is a composite (the cement is the matrix and the gravel
and steel rods are the reinforcer) as are bricks made from clay
reinforced with straw.
Natural composites include wood, shell and bone.
Applications
Car bodies - especially sports cars, F1 racing cars, boat hulls,
lightweight struts and supports in bridge building and the
construction industry. Aerospace - use of carbon fibre composites
as well as high tech ceramic parts has revolutionised this industry.