1. EdExcel Product Design: Graphics
Metals
EdExcel Product Design: Graphics

3. Metals Ferrous Non-ferrous Alloys Aesthetic
Steel
Non-ferrous
Aluminium
Tin
Alloys
Stainless steel
duralumin
Aesthetic
Functional & mechanical properties
Application
Advantages
Disadvantages
For graphic products & commercial packaging

4. Properties Ductility (being ductile) Malleability Hardness
is a solid material's ability to deform under tensile (pulling/tension) stress; this is often characterized by the material's ability to be stretched into a wire.
Malleability
is a material's ability to deform under compressive stress; this is often characterized by the material's ability to form a thin sheet by hammering or rolling.
Hardness
is a measure of how resistant solid matter is to various kinds of permanent shape change when a force is applied.
Corrosion resistance
Is the materials ability to not corrode (or rust). Some metals are more intrinsically resistant to corrosion than others.

5. Micro-structure of metals
Metals usually have one or two loose electrons in their outer electron shell and therefore they are likely to become easily detached, it is this movement of electrons which accounts for metals high electrical and thermal conductivity. This ability for movement also leads metals to have ductile and malleable properties.
All metals are solid at room temperature (with the exception of mercury).

6. Closed-packed hexagonal (CPH) Face-centred cubic (FCC)
When in a solid state the atoms energy is reduced and they arrange themselves in a regular lattice structure in the form of small seed crystals or grains, there are 3 possible lattice structures;
Closed-packed hexagonal (CPH)
Face-centred cubic (FCC)
Body-centred cubic (BCC)
BCC
CPH
FCC

7. Micro-structure of iron:
Properties
Examples
CPH
Weak, poor strength to weight ratio.
Zinc, magnesium
FCC
Ductile, good electrical conductor.
Gold, copper, silver, aluminium, tin
BCC
Hard, tough.
Chromium, steel.
Micro-structure of iron:
Iron changes from BCC lattice to FCC lattice at 9100C and above 14000C it changes back again. In the FCC form it absorbs carbon which essential for steel making.

8. Steel Dull grey in colour (brown with corrosion)
Steel is an alloy of iron and other elements, including carbon.
Alloys with a higher than 2.1% carbon are known as cast iron. Because they are not malleable even when hot, they can be worked only by casting (pouring metal into a mould)
Magnetic
Melting point for steel degrees C.
Usually the least expensive metal
Corodes easily
Hardening & tempering can be used
Key metals: HSS, mild steel, cast iron, carbon steel

9. Aluminium Appearance ranging from silvery to dull gray
Aluminium is the most abundant metal, in the Earth's crust.
Relatively soft, durable, lightweight, ductile and malleable metal.
Does not corrode
It is non-magnetic.
Melting point: 660°C
Comes from bauxite in its raw form.
Once extracted electrolysis is used for processing

10. Bauxite is difficult to break down and therefore electrolysis is needed rather than melting so that it can be processed (this process requires a great deal of electrical expenditure).
The bauxite (red-brown solid) - aluminium oxide mixed with impurities - is extracted from the earth.
It is the most used non-ferrous metal:
Automobiles, aircraft, trucks, railway cars, marine vessels, bicycles, packaging (cans, foil, etc.), cooking utensils, watches, street lighting poles, sailing ship masts, walking poles, outer shells of consumer electronics, also cases for equipment e.g. photographic equipment.

11. Tin Is malleable & ductile Silvery-white metal.
Tin melts at a low temperature of about 232 °C
Tin resists corrosion from water but can be attacked by acids and alkalis. Tin can be highly polished and is used as a protective coat for other metals.[4] In this case the formation of a protective oxide layer is used to prevent further oxidation.
Mainly mined in china
About half of tin produced is used in solder. The rest is divided between tin plating, tin chemicals, brass and bronze, and niche uses

12. Stainless Steel
Stainless steel does not readily corrode, rust or stain with water as ordinary steel does.
Magnetic
Poor conductor of electricity
Melting point: 1510°C
Stainless steels are iron alloys with a minimum of 10.5% chromium. Other alloying elements are added to enhance their structure and properties such as formability, strength and cryogenic toughness. These include metals such as:
Nickel
Titanium
Copper

13. Duralumin
Aluminium Alloy - The main alloying constituents are copper, manganese, and magnesium.
Strong, hard, lightweight alloy of aluminum, widely used in aircraft construction,
After heat treatment and aging, these alloys are comparable to soft steel in strength.
Duralumin alloys are relatively soft, ductile, and workable in the normal state; they may be rolled, forged, extruded, or drawn into a variety of shapes and products. Their light weight and consequent high strength per unit weight compared with steel suit them for aircraft construction.
Melting point 650°C

14. Questions Explain what is meant by the term alloy?
Explain in detail the difference between ferrous and non-ferrous metals.
Define the terms ductile, malleable and corrosion resistant.
Suggest a use for:
Mild Steel, stainless steel, Aluminium, Copper, Brass & Lead

15. Functional & mechanical properties
Task
Log onto the computers
Create a table:
Wood
Aesthetics
Functional & mechanical properties
Advantages
Disadvantages
Steel
Aluminium
Tin
Stainless steel
Duralumin
For aesthetics get an image of the metal and write a brief descrition.
For properties add things like lightweight or malleable etc
Then put some advantages and disadvantages for each
Print off