AVCE - Engineering Medium Term Plan: Module 3: - Compulsory Unit 3, Engineering Materials
Module 3: Engineering materials
Unit 3 |
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Sequence of Lessons |
Theme/Aims |
Key Activities |
Resources |
Student Outcomes |
Assessment Opportunities |
Key Vocabulary |
1 |
Introduction
to the unit to understand the range of materials and the development of
modern materials. |
Discussion/introduction
to the unit. The history of materials,
natural materials, processing and refining to produce metals, polymers and
ceramics. Explanation
of the main classes and identifying examples. Product
analysis of workshop and household artefacts to identify the materials used
and why. |
Past exam
papers dealing with product analysis. Range of
materials found in the workshop and the environment |
Students
will have a a basic
knowledge of the main materials used in engineering and begin to understand
why. |
Tests and
completion of exam type questions. |
Names of
materials and classes metals, polymers, composites, ceramics. Ferrous
non ferrous alloys common plastics. Thermoplastic and thermosetting. |
2 |
Measuring
properties of engineering materials qualitatively. |
Students
will test a range of samples for simple properties. Materials in the room can
also be non -destructively included. Answering
exam type questions about materials suitability based on properties. |
Range of
samples mostly metals and polymers. |
Completion
of table displaying results and general conclusions drawn. Able to
identify the most suitable materials for a purpose. |
Website www.the-warren.org is used to support
the course. Relevant quizzes for self assessment are to be used. Response
to questions. |
Conductivity,
resistivity, density, tensile strength. |
3 |
Testing
materials quantitavely. |
Demonstrate
tensile strength testing machine. Take measurements using metal specimens. Impact
test demonstration. Hardness
testing by simple experiment and by reference to website. Looking
at stress strain graphs notes on web. |
Materials
testing machine and laptop. Specimens. Impact
testing machine. |
Understanding
of how materials behave when they have various forces applied. How materials
fail. Standardisation
of tests and the preparation of specimens for testing. |
Test/quiz
on materials testing. Write up testing procedures and results. Completion of
exam questions on testing machines and stress strain graphs |
Stress,
strain, Names of tests. |
4 |
Other
properties. |
Discussion
and notes on the other general properties of materials. Thermal
properties such as insulation, expansivity Electrical/magnetic properties such
as conductivity, permittivity, permeability. Durability properties such as
stability and resistance to environmental degradation, corrosion,
chemical solubility, absorption. |
Samples
including some that have suffered damage. Web. |
Understanding
that there are many factors to be considered when choosing suitable materials
for applications. |
Exam
questions and web quizzes. |
Range of
names of material properties. |
5 |
Structure
of materials. Grain
structure. |
Discussion
and notes on the structure of materials. Modifying
a materials properties. - Hardening and tempering. Alloying. Work
hardening, annealing. |
Silver
steel, copper sheet, polythene sheet. Brazing
hearth. Files. Weights. |
Understanding
of how materials can have their properties modified, and how the internal
molecular structure in polymers and the grain structure in metals can be
modified to enhance the properties. |
Tests/quizzes
and exam questions. |
Hardening
and tempering. Alloying. Work
hardening, annealing. |
6 |
Manufacturing
Processes. |
List and
describe the manufacturing processes which have been experienced already. Demonstrate
processes which have not been experienced. E.g. vacuum forming, injection
moulding. Pewter casting, Production of a GRP product. Casting in concrete. Laser cutting. Milling
horizontal and vertical. Joining
using rivets. |
Horizontal
mill. Laser cutter. Pewter. Ready-mix
and wooden mould. GRP resin and glass fibre. Pop
rivets and snap set. Self
tapping screws. Machine screws. |
Expanded
view of how to manufacture. Understanding
of the relative costs of processes. |
Tests/quizzes
and exam questions. |
Range of
processes. |
7 |
Project. |
Students
are to design a hovercraft or vehicle to travel over a set course carrying a
load. The design must be drawn in Prodesktop and manufactured using
engineering processes using materials from the main classes i.e. no paper,
card or wood. |
Paper and
drawing equipment. Prodesktop and PCs. |
Designs
for vehicle. |
Quality
of design work. (Drawings to be carried over into the CAD module) |
CAD. Process
names. Material names. |
8 |
Manufacture
of project. |
Students
manufacture their design in the engineering workshop. |
Workshop
facilities. Range of engineering materials, fixings and machines such as the
Vacuum former. |
The
vehicle manufactured work in teams. |
Workshop
organisation and quality of workmanship. |
Process
names. Material names |
9 |
Testing
and evaluation of project and processes. |
Students
complete their design and make work, then test competitively. |
Workshop
facilities. Range of engineering materials, fixings and machines such as the
Vacuum former. Test
track/ area. Load. |
Understanding
about the suitability of the materials and manufacturing processes chosen. |
Testing
evaluation and overall performance on project. |
|
10 |
Exam
preparation. |
Students
to answer complete exam papers under exam conditions. |
Past
papers. |
Ability
to complete answers to highest grade. |
Exam
papers. |
General
materials vocabulary. |