1. ENGINEERING THE TOUGH STUFF!

2. 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.

3. 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!

5. 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.

6. Is Copper an alloy?

7. What about brass?

8. 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.

9. 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…

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

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

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

14. 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.

15. 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.

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

17. 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

18. ANSWER
5. List 3 engineered products made from ceramics.

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

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

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

22. BIOMEDICAL USES!

23. BIOMEDICAL USES!

24. 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.

25. 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.

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

27. 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!

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

29. 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

30. Shape Memory Alloys

31. Shape Memory Alloys

32. Shape Memory Alloys

33. Shape Memory Alloys

34. 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.

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

36. 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

37. 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.

38. 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.

39. ANSWER
10. Electrochromic materials change COLOUR SHAPE SIZE .

40. Electrochromic Materials

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

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

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

44. Electrochromic Materials

45. 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.

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

47. ANSWER
13. Piezoelectric changes movement into SOUND PRESSURE ELECTRICITY

48. Piezoelectric Piezoelectric Generate electricity when pressed.
Smart Materials

49. ANSWER
14. Describe what a piezoelectric ACTUATOR does

50. Piezoelectric Actuators
Generate movement from electricity.

51. ANSWER
14. Describe what a piezoelectric TRANSDUCER does

52. Piezoelectric Transducer
Converts mechanical movement to electricity.

53. Piezoelectric Transducer
Converts mechanical movement to electricity.

54. 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

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

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

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

59. 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.

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

61. 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?

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

63. Hydrogen Fuel Cells + =
WATER
HYDROGEN +
OXYGEN =

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

65. 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!

66. 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!

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

68. Hydrogen Fuel Cells
Where are they used?

69. 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?

70. Surface Nano Technologies
Changing materials at an atomic level!

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

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

73. Uses for surface technology
ANTI FOG WINDOW COATINGS

74. Uses for surface technology
DIRT / RAIN RESISTANT PAINTWORK

75. Uses for surface technology
ANTI RAIN WINDOW COATINGS

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

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

78. 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.

79. 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.

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

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

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

83. Telematics
You are always being watched!

84. 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.

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

86. ANSWER
25. Blended wing bodies reduces SPEED DRAG LIFT

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

89. ANSWER
26. Name 2 other advantages of blended wing bodies

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

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

92. 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.

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

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

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

96. 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.

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

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

99. 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.

100. 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.

101. Method 2: KAIZEN

102. 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!

103. 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.

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

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

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

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

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

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