ENGINEERING THE TOUGH STUFF!

QUESTION A metal that contains iron will rust. TRUE? FALSE? 2. Explain the difference between a pure metal and an alloy. 3. Describe the difference between an alloy and a super alloy.

ANSWER A metal that contains iron will rust. TRUE? FALSE? IF A METAL HAS IRON IN IT, IT WILL RUST – TRUE! METALS THAT RUST ARE FERROUS!

ANSWER 2. Explain the difference between a pure metal and an alloy. ALLOY = 2 or more metals combined to improve the properties of a material. PURE = A metal from the periodic table.

Is Copper an alloy?

What about brass?

Alloys BRASS = COPPER + ZINC (BOTH PURE METALS) Copper is expensive…. add zinc to it to make it cheaper to manufacture. Brass is weather resistant and looks attractive! Not as good at conducting electricity.

ANSWER 3. Describe the difference between an alloy and a super alloy. SUPER ALLOYS are high performance metals made from combining other metals. They can be stronger, harder, more resistant to heat damage… BUT… for the full mark you would need to…

Super Alloys The key to Super Alloys are the metals they are made from.

Super Alloys Superalloys are usually made from COBALT OR NICKEL then combined with other metals

Super Alloys – E.g. Hastelloy CHROMIUM MOLYBDENUM TUNGSTEN IRON SILICON MAGNESIUM

HOW DID YOU DO? A metal that contains iron will rust. TRUE? FALSE? 2. Explain the difference between a pure metal and an alloy. 3. Describe the difference between an alloy and a super alloy.

QUESTION 4. Name 2 advantages of using ceramic. 5. List 3 engineered products made from ceramics. 6. Explain how ceramics are used in biomedical engineering.

ANSWER Heat / scratch resistant Good under compression 4. Name 2 advantages of using ceramic. Heat / scratch resistant Good under compression Poor under tension

High Performance Materials Ceramics 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 Zirconia Cubic boron nitride Boron Carbide High Performance Materials

ANSWER 5. List 3 engineered products made from ceramics.

High Performance Materials Ceramics Boron Carbide Cubic boron nitride High Performance Materials

High Performance Materials Ceramics Boron Carbide VERY HARD! High Performance Materials

High Performance Materials Ceramics Cubic boron nitride Boron Carbide Zirconia High Performance Materials

BIOMEDICAL USES!

BIOMEDICAL USES!

HOW DID YOU DO? 4. Name 2 advantages of using ceramic. 5. List 3 engineered products made from ceramics. 6. Explain how ceramics are used in biomedical engineering.

QUESTION 7. What activates a shape memory alloy to change its shape? HEAT LIGHT SOUND 8. Give an example of how shape memory alloys are used in biomedical engineering. 9. Give an example of how shape memory polymers are used in biomedical engineering.

ANSWER 7. What activates a shape memory alloy to change its shape? HEAT LIGHT SOUND

Shape Memory Alloys Alloys that remember the shape they should be in. They have a HOT SHAPE and a COLD SHAPE They can be bent and moulded!

ANSWER 8. Give an example of how shape memory alloys are used in biomedical engineering.

Shape Memory Alloys Reinforcement for Arteries and Veins For clogged blood vessels, an alloy tube is crushed and inserted into the clogged veins. The memory metal has a memory transfer temperature close to body heat, so the memory metal expands to open the clogged arteries. Frames for Glasses The glasses can be bent, but will return to their shape at room temperature. Smart Materials

Shape Memory Alloys

Shape Memory Alloys

Shape Memory Alloys

Shape Memory Alloys

Shape Memory Alloys The fins only bend when the engine exhaust gases are hot enough. They return to normal position when the engine is not running.

ANSWER 9. Give an example of how shape memory polymers are used in biomedical engineering.

Shape Memory Polymers Polymers that can be heated and bent into a shape. When they are heated again they will return to their original form. Smart Materials

HOW DID YOU DO? 7. What activates a shape memory alloy to change its shape? HEAT LIGHT SOUND 8. Give an example of how shape memory alloys are used in biomedical engineering. 9. Give an example of how shape memory polymers are used in biomedical engineering.

QUESTION 10. Electrochromic materials change COLOUR SHAPE SIZE 11. What passes through electrochromic materials to make them to change? 12. Give a use for electrochromic glass in the automotive industry.

ANSWER 10. Electrochromic materials change COLOUR SHAPE SIZE .

Electrochromic Materials

ANSWER 11. What passes through electrochromic materials to make them to change? .

Electrochromic Electrochromic materials change colour when electricity is passed through them. Smart Materials

ANSWER 12. Give a use for electrochromic glass in the automotive industry.

Electrochromic Materials

HOW DID YOU DO? 10. Electrochromic materials change COLOUR SHAPE SIZE 11. What passes through electrochromic materials to make them to change? 12. Give a use for electrochromic glass in the automotive industry.

QUESTION 13. Piezoelectric changes movement into SOUND PRESSURE ELECTRICITY 14. Describe what a piezoelectric ACTUATOR does 15. Describe what a piezoelectric TRANSDUCER does

ANSWER 13. Piezoelectric changes movement into SOUND PRESSURE ELECTRICITY

Piezoelectric Piezoelectric Generate electricity when pressed. Smart Materials

ANSWER 14. Describe what a piezoelectric ACTUATOR does

Piezoelectric Actuators Generate movement from electricity.

ANSWER 14. Describe what a piezoelectric TRANSDUCER does

Piezoelectric Transducer Converts mechanical movement to electricity.

Piezoelectric Transducer Converts mechanical movement to electricity.

HOW DID YOU DO? 13. Piezoelectric changes movement into SOUND PRESSURE ELECTRICITY 14. Describe what a piezoelectric ACTUATOR does 15. Describe what a piezoelectric TRANSDUCER does

QUESTION 16. Put these powder metallurgy process into the correct order. SINTERING SECONDARY MACHINING COMPACTING BLENDING/MIXING

ANSWER 16. Put these powder metallurgy process into the correct order. BLENDING/MIXING COMPACTING SINTERING SECONDARY MACHINING

QUESTION 17. Optic fibres transmit data by SOUND LIGHT VIBRATION 18. List 2 advantages of using optic fibre to transmit data.

Optical Fibres Transmit data through glass fibres. The information travels AT THE SPEED OF LIGHT!!! Advantages over wire: Transmit data at higher speeds. Transmit data digitally, with less errors.

HOW DID YOU DO? 17. Optic fibres transmit data by SOUND LIGHT VIBRATION 18. List 2 advantages of using optic fibre to transmit data.

QUESTION 19. Hydrogen fuel cells combine Hydrogen and what gas to make water? NITROGEN OXYGEN AIR 20. What is the bi-product of these gases combining? 21. Where are hydrogen fuel cells used in the automotive industry?

ANSWER 19. Hydrogen fuel cells combine Hydrogen and what gas to make water? NITROGEN OXYGEN AIR + =

Hydrogen Fuel Cells + = WATER HYDROGEN + OXYGEN =

ANSWER 20. What is the bi-product of these gases combining?

Hydrogen Fuel Cells W A T E R + + + + + - - - - - - - - How does it work? W A T E R + + Hydrogen Oxygen + + + - - - - - - - - The flow of electrons is………….. ELECTRICITY!

Hydrogen Fuel Cells They convert the oxygen and hydrogen to into electricity. They are quiet and efficient. Simple to produce as not many moving parts. Cheap to mass produce. Water is only waste product. Expensive materials!

ANSWER 21. Where are hydrogen fuel cells used in the automotive industry?

Hydrogen Fuel Cells Where are they used?

HOW DID YOU DO? 19. Hydrogen fuel cells combine Hydrogen and what gas to make water? NITROGEN OXYGEN AIR 20. What is the bi-product of these gases combining? 21. Where are hydrogen fuel cells used in the automotive industry?

Surface Nano Technologies Changing materials at an atomic level!

QUESTION 20. List 2 uses for surface nanotechnologies in the automotive industry. 21. List 1 use for surface nanotechnologies in the biomedical industry.

ANSWER 20. List 2 uses for surface nanotechnologies in the automotive industry.

Uses for surface technology ANTI FOG WINDOW COATINGS

Uses for surface technology DIRT / RAIN RESISTANT PAINTWORK

Uses for surface technology ANTI RAIN WINDOW COATINGS

ANSWER 21. List 1 use for surface nanotechnologies in the biomedical industry.

Surface Nano Technologies Ceramics – Hygienic surfaces that germs cannot attach to.

HOW DID YOU DO? 20. List 2 uses for surface nanotechnologies in the automotive industry. 21. List 1 use for surface nanotechnologies in the biomedical industry.

QUESTION 22. Telematics uses what to track locations across the world SATELLITES PYLONS SATELLITE DISHES 23. Give 1 use for telematics in the automotive industry. 24. Give 1 use for telematics in the logistics industry.

ANSWER 22. Telematics uses what to track locations across the world SATELLITES PYLONS SATELLITE DISHES

ANSWER 23. Give 1 use for telematics in the automotive industry.

ANSWER 24. Give 1 use for telematics in the logistics industry.

Telematics You are always being watched!

HOW DID YOU DO? 22. Telematics uses what to track locations across the world SATELLITES PYLONS SATELLITE DISHES 23. Give 1 use for telematics in the automotive industry. 24. Give 1 use for telematics in the logistics industry.

QUESTION 25. Blended wing bodies reduces SPEED DRAG LIFT 26. Name 2 other advantages of blended wing bodies

ANSWER 25. Blended wing bodies reduces SPEED DRAG LIFT

Blended Wing Bodies By joining the body and the wings, you can reduce drag, making it more efficient to travel through the air.

ANSWER 26. Name 2 other advantages of blended wing bodies

Blended Wing Bodies Improves fuel efficiency Combined with composites to produce very light and smooth vehicle body shapes.

HOW DID YOU DO? 25. Blended wing bodies reduces SPEED DRAG LIFT 26. Name 2 other advantages of blended wing bodies

QUESTION 27. Give 1 use for bionics assist in the movement of limbs. 28. Give 1 use of bionics for the heart. 29. Give 1 use of bionics for the senses.

ANSWER 27. Give 1 use for bionics assist in the movement of limbs.

ANSWER 28. Give 1 use of bionics for the heart.

ANSWER 29. Give 1 use of bionics for the senses. Cochlear implant

HOW DID YOU DO? 27. Give 1 use for bionics assist in the movement of limbs. 28. Give 1 use of bionics for the heart. 29. Give 1 use of bionics for the senses.

Life Cycle Assessment Raw materials extraction Material production Production of parts Assembly Use Disposal/recycling.

Life Cycle Assessment - Raw materials extraction - Material production - Production of parts - Assembly - Use - Disposal/recycling.

Rethink Reduce Recover Reuse Recycle Is there another way of doing it? Reduce size, materials Recover Can we make electricity from the waste? Reuse Reuse instead of throw away. Recycle Melt down materials to form new materials.

Method 1: JUST IN TIME The production process is organised in a way that makes sure: Parts are available when you need them. Equipment is available when you need it. Workers only move when they need to. Products are build to customer demand. There is no stock waiting to be sold. Production time is the least time possible. Automation is used to speed up manufacturing.

Method 2: KAIZEN

Method 2: KAIZEN Improvements are small changes. The workers have the ideas so they should be easier to make happen in the factory. Small changes don’t cost a lot of money. It is a cheaper way to improve your factory. Using the workers encourages them to take more ownership in their work – this improves MOTIVATION!

Method 3: POKA - YOKE Poka-Yoke aims to mistake proof the factory. It looks at simple process in the factory and comes up with ways of stopping them from going wrong. Improves quality by removing errors. Speeds up production by having a higher quality of product. (less mistakes!) Increases safety. Less injuries through mistakes. Reduces costs by improving efficiency and the skill needed by the workers.

Method 3: POKA - YOKE This is a good example of Poka-Yoke.

Less area to walk around What else is Lean? Less area to walk around

No time wasted finding tools. What else is Lean? No time wasted finding tools.

Easy to read ways of tracking jobs. What else is Lean? Easy to read ways of tracking jobs.

Quick ways to quality check work. What else is Lean? Quick ways to quality check work.

Clear description of who should be doing what. What else is Lean? Clear description of who should be doing what.