Unit A622: Engineering Processes

Engineering Revision

Engineering Sectors

Sector

Products

Aerospace

Wing

Rotors

Passenger aircraft doors

Automotive

Wheels

Glass (privacy, quick-clear, laminated)

Airbag

Chemical and Process

Coatings (paint, plastics)

Cement

Shampoo

Computers, Communication and IT

Portable data storage

Webcams

Radio

Electrical and Electronics

Electric toothbrush

Smoke alarm

Radio-controlled car

Medical and Pharmaceutical

Blister packs

Wheelchairs

Monitors (heart, blood pressure)

Rail and Marine

Passenger information systems

Power sources (wind, electricity, fossil fuels, human, solar)

Life jacket

Structural and Civil

Tunnels

Artificial environment domes (e.g. eco-domes, arboretum, leisure, winter sports domes)

Wind power generators

 

Engineering materials and their properties

Ferrous metals

·         Metals that contain iron

·         Cast steel, mild steel, grey cast iron

Non-ferrous metals

·         Metal NOT containing iron

·         Copper, aluminium, zinc

Alloys

·         A mixture of two or more metals or elements to form a new material

·         Solder, brass, bronze

Polymers

·         The scientific term for plastics, they are formed when monomers bond together

·         Phenolic, polythene, acrylic, rubber

Ceramics

·         Inorganic, non-metallic materials made from compounds of a metal and non-metal, commonly associated with the Egyptians and the ancient Greek

·         Alumina, silicon carbonate and zirconia

Composites

·         Combinations of different types of reinforced materials mixed together with a bonding agent

·         Glass fibre, carbon fibre, MDF and concrete

Smart materials

·         Materials that respond to a stimulus or change in the environment

·         Thermochromic materials respond to changes in heat and change colours

Modern materials

·         Materials made by humans for a purpose

·         ABS plastic

 

Function of components

Mechanical components

·         Wide variety of mechanical devices known as fasteners

·         Threaded fasteners such as bolts require nuts, or the component that they go into must be threaded

·         Unthreaded fasteners are known as rivets and are squashed over at the end to form a joint

·         A bolt will need a nut which makes the component easy to take apart although they are strong and reversible as well. Component could have a screw thread formed into it

·         Bolts have a screw thread which fits into a threaded hole or hexagonal nut, and are normally used to join two or more pieces of metal or plastic. A bolt is only threaded for a part of its length and normally have hexagonal heads

·         Nails are used where appearance is not important or where a quick job is needed, they are made of mild steel

·         Panel pins and veneer pins are used to fix backs onto cupboards and bottoms onto boxes. Veneer pins are finer, they are made of mild steel

·         Wood screws are used to join metal or plastic components to wood, or to join two pieces of wood to make a strong joint

·         Machine screws have a screw thread to fit into a threaded hole or hexagonal nut. They can be used to join two or more…