MATERIAL INVESTIGATION

METALS
 About Metals
A vast range of metals exist and they fit in two categories,
‘ferrous’ and ‘non-ferrous’ metals. These metals can be
used to build/manufacture an equally large range of items.

Non Ferrous Ferrous

These are metals that do not contain
any iron at all. These metals therefore
do not rust in the same way when
exposed to moisture and are not
attracted to a magnet.
Typical examples are: copper,
aluminium, tin and zinc
These are metals that consist mostly of
iron and small quantities of other
elements and metals. Ferrous metals
are prone to rusting if exposed to
moisture and can be picked up by using
a magnet. Both properties are due to
the iron.
Typical examples are: steel, cast iron
and stainless steel
 Alloys
Alloys are substances that contain two or more
metals. And sometimes other elements, to improve
their properties.
These metals are carefully chosen and mixed to
achieve specific properties which may include
reducing the melting point.

ZINC + COPPER = BRASS

+ =
 Ferrous Metals
NAME ALLOY OF PROPERTIES USES
Mild Steel Carbon 0.1 - 0.3% Tough. High tensile Most common metal
Iron 99.9 - 99.7% strength. Can be case used in school
hardened. Rusts very workshops. Used in
easily. general metal
products and
engineering.
Carbon Steel Carbon 0.6 - 1.4% Tough. Can be hardened Cutting tools such as
Iron 99.4 - 98.6% and tempered. drills.
Stainless steel Iron, nickel and Tough, resistant to rust Cutlery, medical
chromium. and stains. instruments.
Cast iron Carbon 2 - 6% Strong but brittle. Castings, manhole
Iron 98 - 94% Compressive strength covers, engines.
very high.
Wrought iron Almost 100% iron Fibrous, tough, ductile, Ornamental gates
resistant to rusting. and railings. Not in
much use today.
 Non Ferrous Metals
NAME COLOUR ALLOY OF; PROPERTIES USES
Aluminium Light grey Aluminium 95% Ductile, soft, Window
Copper 4% malleable, machines frames,
Manganese 1% well. Very light. aircraft,
kitchen ware.
Copper Reddish Not an alloy Ductile, can be beaten Electrical
brown into shape. Conducts wiring, tubing,
electricity and heat. kettles, bowls,
pipes.
Brass Yellow Mixture of copper Hard. Casts and Parts for
and zinc 65% - machines well. electrical
35% most Surface tarnishes. fittings,
common ratio. Conducts electricity. ornaments.
Silver Whitish Mainly silver but Ductile, Malleable, Jewellery,
grey alloyed with solders, resists solder,
copper to give corrosion. ornaments.
sterling silver.
 Die Casting
Die casting is the process of forcing molten metal under high pressure
into mould

http://uk.youtube.com/watch?v=azsNpqW4J1s&feature=related
 Press Forming

the moulds are controlled by hydraulic rams which create massive pressures.
Sheet metal is fed into the mould to be pressed. They are stamped and pressed while
still cold.
This method of manufacture is often used to make panels for cars

http://www.youtube.com/watch?v=Oka7Tc5ceZc&feature=related