AS DT Product Design/Resistant Materials (Edexcel) Processes List

List, and detailed explanations/diagrams/uses of ALL the processes you need to know for the Edexcel AS Product design/resistant materials exam.

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Process Explanation Pr Materials Appliances Diagram
op Used
ert
ie
s
Sand Molten metal is poured/forced into a sand P Ferrous Machinery
mould with a cavity where the metal fills r metals component
casting Firstly, a mould is produced by green sand
(or Petrabond) with a pattern inside to create o Aluminium Engine parts
the cavity for the metal (usually in two parts, to d Magnesium Mechanical
create a complex shape) (usually made from u Brass pieces
MDF) that is slightly oversized to allow for
c Bronze 70% of all
contraction.
The pattern is covered with parting powder (to e metal
stop it sticking) and then compact facing s components
sand and the drag is filled with backing sand. are made
The cope and drag are placed on top of one
another, the sprue pins are locked in place e from sand
this is where the metal will enter the cavity, x casting.
(runner) and how the air is released (riser). t Caterpillar
Gates are cut and a hollow is cut where the
r tracks
metal will flow into the sprue pins.
The mould is clamped and enclosed, the e
metal is heated in a crucible in a furnace until m
it is molten, then it is fluxed and degassed e
(removing impurities and bubbles) before
being poured. The metal is then poured l
slowly into the mould until the riser becomes y
occupied with metal. The metal is then left to
cool and solidify, when ready, the mould is
h
opened and the component removed and
fettled (runner/risers/waste cut off with i
hacksaw). g
Green sand must be thoroughly dried before h
the metal is poured to prevent an explosion.
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