1. Year 7 Metal Definitions Extracting Metal
Automation is the use of machines to do a task automatically without much, or any, human input.
Computer Aided Design (CAD) is the process of designing using a computer
Computer Aided Manufacture (CAM) is the process of making a product using a computer and machinery
Flexible Manufacturing Systems (FMS) is the process of different machines being set up to carry out different stages of the production process
Lean Manufacturing is about reducing the amount if waste produced during manufacturing. It can be done through a number of different ways such as only making products when they are needed
Just in time (JIT) is about only producing the products when they have been ordered. This reduces the cost of storage but relies on materials being delivered as and when they are needed
Extracting Metal
Metal bearing rocks are called Ores.
Rocks removed from the ground that contain enough metal are extracted from the ore though either heating the ore or through electrolysis
Extraction through a furnace:
Metals are obtained from raw ores. Raw ore is mixed with charcoal and other chemicals, and air is blown into a furnace. The molten metal trickles from the bottom of the furnace and this can be cast or extruded into shapes.
Extraction through electrolysis:
The more the reactive the metal the higher the temperature needed to extract it from its ore.
A metal like aluminum cannot be extracted by a furnace. It is dissolved in a ‘cryolite solution’ and electrolysed (electricity is passed through) at a temperature of around 650°C.
What is Refining?
When metals have be extracted from their ore there is still small amounts of other substances present. These impurities need to be removed before the metal is used.
This process is called Refining.
Some methods of refining:
Adding limestone to a furnace will remove sand during extraction.
During electrolysis gases are pumped through to push the impurities to the surface.
Some substances when heated and cooled separate the impurities due to different boiling points.

2. DUCTILE DULL SONOROUS MALLEABLE BRITTLE / WEAK CONDUCTOR NOT MAGNETIC
CAN BE MADE INTO WIRES
DULL
CANNOT BE POLISHED
Working Property
Example
Strength
Climbing rope, Cycle helmet
Hardness
Tools, Files, Drill bits
Toughness
Bulletproof vests
Elasticity
Spring, Elastic band
Malleability
Metals can be hammered into thin sheets without breaking
Ductility
Copper wire
LOW MELTING POINTS
MELT EASILY OR BURN
SONOROUS
RINGS WHEN STRUCK
MALLEABLE
CAN BE MOULDED
BRITTLE / WEAK
NOT STRONG
Physical Property
Example
Electrical Conductivity
Metals
Thermal Conductivity
Saucepans
Fusibility
Solder
Density
Wood is heavier than plastic
Absorbency
Paper towel
HIGH MELTING POINTS
DIFFICULT TO MELT AND BOIL
CONDUCTOR
WILL ALLOW HEAT AND ELECTRICITY TO PASS
SOME ARE MAGNETIC
IRON, NICKEL OR COBALT
NOT MAGNETIC
NO MAGNETS HERE!
Metals can be classified into two groups:
DENSITY
HEAVY FOR ITS SIZE
LIGHT FOR THEIR SIZE
INSULATORS
DO NOT ALLOW HEAT OR ELECTIRICTY TO PASS
SHINY
REFLECT LIGHT WHEN CUT OR POLISHED
STRONG
CAN SUPPORT A LOAD
Types of metal:
Ferrous- These metals contain iron (Most ferrous metals can be identified by using a magnet).
Non-ferrous- These metals do not contain iron.
Alloys- (mixture of metals or a metal mixed with elements): They are developed to have a specific set of properties.