Modern Materials

Composites A composite is a combination of 2 or more materials to form a new material. They combine the strengths of the different materials to create an even better material.

Glass Reinforced Polyester (GRP) COMPOSITES

Glass Reinforced Polyester (GRP) COMPOSITES

Glass Reinforced Polyester (GRP) COMPOSITES Glass fibre covered in a polyester resin and left to harden. Light weight Strong Used for cheap shell products

Carbon Fibre COMPOSITES

Carbon Fibre COMPOSITES Carbon fibre is a woven fabric of carbon that when combined with a resin can be baked to become hard. Light weight Strong Expensive to use in manufacture.

Kevlar COMPOSITES

Kevlar COMPOSITES Kevlar is a fabric that when combined with a resin creates a very strong material. Light weight 5 times stronger than steel Expensive to use.

High Performance Materials These are materials that have been created to perform jobs where strength, speed and weight are very important!

Tungsten High Performance Materials Tungsten is a metal that was discovered in Hard Dense Expensive to use in manufacture.

Titanium High Performance Materials Titanium is a metal that contains no iron. Light weight Strong Resistant to wear

Super Alloys High Performance Materials A super alloy is 2 or more metals that have been combined to produce an alloy with improved properties. Strong at high temperatures and will not crack or change shape when changing temperature.

Ceramics High Performance Materials Cubic boron nitride Boron Carbide Zirconia Ceramics are made by the process of heating a solution of materials, then leaving them to cool and become hard. Heat / scratch resistant Good under compression Poor under tension

Metal Foams Metal foam is made by adding air to cast aluminium and steel. Advantages: Light weight Strong Can be cast into shapes Rigid Will absorb energy well Thermal conductor Disadvantages: Expensive to produce Once crushed, they do not spring back into shape.

Metal Foams

Where are they Used?

Engine Disc Brakes Exhaust System Body Frame

Exhaust System The exhaust is made from titanium so it is light and can with stand the heat generated by the engine.

Body Frame The frame is made from aluminium with a carbon fibre shell.

Engine The engine needs to be light weight and withstand high impact. It is made from titanium.

The disc brakes are made from a carbon ceramic composite. They can withstand the high temperature created by friction. Disc Brakes

These are REAL exam questions that have been used… Get some scrap paper to write your answers!

Match the product to the most appropriate material. 1

Give 2 properties of carbon fibre that make it an ideal material for prosthetic limbs. 2

3

Explain why car companies do not use carbon fibre to make family cars. 4

Answers!

Match the product to the most appropriate material. 1

Give 2 properties of carbon fibre that make it an ideal material for prosthetic limbs. 2 Elastic (springy!) Good strength to weight ratio Very strong for a light material Can be shaped easily

3

Explain why car companies do not use carbon fibre to make family cars. 4 Expensive Factories would need more expensive equipment Anything else?!