1. Metals and Processes Theory. Knowledge and Understanding.

2. Metal Theory. Metals can be divided into THREE main categories FERROUS, NON FERROUS AND ALLOYS. Ferrous metals contain iron this means they are magnetic and they rust. Fe is the chemical symbol for iron. Examples: Cast iron, Mild steel, Medium carbon steel, Stainless steel, and High speed steel. Non-ferrous metals do not contain iron, they do not rust and they are not magnetic. Examples : Aluminium, Duralumin, Copper, Zinc, Brass, Gold, Silver and Tin. Ferrous metals Facts. Non Ferrous metals Facts.

3.  An alloy is a mixture of two or more elements, at least one of which is a metal.elementsmetal  Alloying one metal with others often enhances its properties  Steel is the most common alloy (iron and carbon) Metal Theory. Alloy Facts.

4. Aluminium – Good strength, light, soft, easy to bend, doesn’t rust, good conductor of heat and electricity. Generally used in Kitchen equipment, window frames, general cast components. conductor Stainless Steel - Hard and tough, resists wear, heavier than aluminium and it does not rust. There are different grades and surface finishes of stainless steel to suit the environment to which the material will be subjected in its lifetime. Common uses of stainless steel are cutlery and watch straps, and outdoor furniture.cutlerywatch Metal Theory.

5. 1. Metal is divided into two groups, they are: Fe rrous Non - Fe rrous 2. Briefly describe the difference between them: Ferrous metals contain iron this means they are magnetic and they rust. Fe is the chemical symbol for iron. Non-ferrous metals do not contain iron, they do not rust and they are not magnetic. 3. What is an alloy?: Metals mixed together to make new metals with different properties, are called alloys.

6. Metal Theory. 4. Name and briefly describe two methods of shaping metal: Casting is a metal-forming process. Molten metal is poured into a mould, when cooled it solidifies and takes on the characteristic shape of the mould. Casting Casting is used to produce intricate shapes in metal and is used for mass production. Such as car engines and workshop vices. What is it? Products made Where are they used.

7. Metal Theory. Extrusion The principle of this process is very similar to squeezing toothpaste from a tube. Extrusion is a manufacturing process used to create long objects of a fixed cross-sectional profile. What is it? A material, often in the form of a billet, is pushed through a die of the desired profile shape. Extrusion may be continuous (producing indefinitely long material) or semi-continuous (producing many short pieces). How is it done?