1. AS Engineering Composite materials Name: Date: 1. Definition of a Composite (1 mark) 2. What is the main advantage of Composite materials? (1 mark) 3. What are the three main groups of composite materials? Give a little description (3 marks) 4. What are the general characteristics of particle-based composite materials (4 marks) Concrete Concretes are made up of materials known as ____________(gravel and stone), as well as sand and cement. The properties of concrete are determined by ____________________________________. Concrete is thoroughly mixed while its is ____. Water is then added and continually mixed until every particle of aggregate is coated with the cement paste. The concrete is then ____________ whether it is used for garden ornaments, foundations of a building or other structural means. A “lean” mixture of _____ would not be as strong as a “rich” mix of _____. During hardening, the temperature of the mix will _______ due to the _______________ that takes place. Different pigments can also be added either as a liquid or powder form. Additives are also available to combat _______________ __________________________________________.

2. Name: Date: 1. Give an example where concrete is used and give and explanation why it is used (3 marks) 2. List the advantages and disadvantages of concrete (6 marks) Advantages: Disadvantages: 3. This image shows a cavity wall, supported by concrete foundations. Complete the diagram by adding notes and arrows indicating the forces acting on the foundations (4 marks) Reinforced Concrete Concrete is very good when in ________________ (e.g foundations for a building) but very poor in __________ (e.g. beams that span for a distance). It can be made ___________ under tension by adding ____________________________________________ to the composite. The concrete is _________________________ the bars combat the possibility of failure under tension. As there is still some potential for ______________, the reinforcing bars need to be ______________________ while the concrete is casting. Once set the tension is removed from the bars. Using reinforcing bars in this way allows it to withstand ______________________________________. 4. Why might steel rods be used to reinforce the concrete? (2 marks) AS Engineering Composite materials

3. Name: Date: Particle-based composites Cermets - Tungsten Carbide 1. Cermets are a mixture of what? 2. What are the advantages of Cermets? 3. What are the disadvantages of cermets, and what effect do these have on processing the material? 4. Tungsten carbide is a combination of what? (2 marks) 5. What is it commonly used for and why? (2 marks) 6. Another Cermet used in the manufacture of components for jet engines, name the two components of this mixture. (2 marks) 7. Name the process by which tungsten carbide can be formed. Give examples of possible applications. Sintering Why is the Sintering process used? (1 mark) Explain and Describe the process of Sintering (5 marks) How can Sintering help to self-oil some products, lasting a lifetime (give an example product) (2 marks) What advantages and disadvantages does tungsten carbide have over stainless steel, when used for kitchen knives? (4 marks) AS Engineering Composite materials

4. Name: Date: Fibre-Reinforced Composites What are the general characteristics of fibre- reinforced composite materials (4 marks) Glass-Reinforced Plastic (GRP) 2. Describe the structure of a typical piece of glass- reinforced fibre. Include a sketch of a ‘weave’ of Glass-Fibre fabric. (3 marks) 1. Describe the stages of create a GRP product, include sketches where appropriate (4 marks) 2. GRP matting is laid up with each layer lying across the one below, rather than all the fibres running in the same direction. Explain what the likely outcome would be if all the fibres did all face the same way? (2 marks) 3. Describe the properties of GRP (3 marks) 4. Describe 2 possible applications of GRP. (4 marks) AS Engineering Composite materials

5. Name: Date: Carbon Fibre Reinforced Plastic (CFRP) 1. Describe two advantages Carbon Fibre Reinforced Polymers has over materials such as GRP? (3 marks) 2. Describe a disadvantage of CFRP to GRP. (1 mark) 3. Initially why was carbon fibre expensive? And why has it reduced in price? (2 marks) 4. List applications of CFRP. (2 marks) 1. Describe a practical application of CFRP. Include an explanation of why CFRP has been used. (4 marks) 2. Describe the stages of create a CFRP product, include sketches where appropriate (4 marks) AS Engineering Composite materials

6. Name: Date: Kevlar 1. Write a brief summary of what Kevlar is made from and how it works. (3 marks) 2. List the properties of Kevlar. (3 marks) 3. Describe two different products which Kevlar is used and explain why it is used. (6 marks) 1. Kevlar is used in the manufacture of arm protectors for use by people in the glass industry. State the reasons why Kevlar is an appropriate material for this application. (5 marks) 2. Fill in the missing composite name (5 marks) CompositeCommon uses A mixture of glass fibres and polyester resins, used in: the manufacture of some vehicles bodies; the from sections of some locomotives engines and sports equipment, e.g. canoes and boat hulls A mixture of carbon fibres and resin, used in: the manufacture of sports equipment, e.g tennis racquets, bicycle frames, etc; the manufacture of artificial limbs. A mixture of aramid and aromatic fibres interwoven into a cloth, used in body armour and sport equipment. Cotton/resin composites, used in the manufacture of gears and cams giving quieter operation than metal components and greater wear resistance. Mixture of resin and paper, used to produce worktops for kitchens AS Engineering Composite materials

7. 1. State the meaning of GRP (1 mark) 2. Give two properties of GRP that make it suitable for the yacht hull (2 marks) 3. Name the two base material used in the manufacture of GRP. (2 marks) 4. Explain why a finish is not applied to the hull of the yacht. (2 marks) The picture shows a yacht made from GRP The picture shows a F1 racing car. Many of the components are made from carbon fibre 5. The rear spoiler is made from carbon fibre. Give two properties of carbon fibre that make it suitable for the race car spoiler. For each property justify your answer. (4 marks) Property 1 Justification. Property 2 Justification 6. Name a suitable adhesive for attaching different components of the car (1 mark) 7. The spoiler could have been made from GRP. Explain one advantage of making the frame from carbon fibre and not GRP. (1 mark) Spoiler Hull Name: Date: AS Engineering Composite materials