Metals Lesson Year 10

Metals Lesson Year 10

Learning Objectives:

Learn how Welding works

Learn how Forging works

Learn how Casting works

Learn how to join metal

Recap on Metal Properties

Answer the following questions

Multiple Choice

What is the definition of Ductile?

• A metal easily hammered into shape

• A metal easily stretched into shape

• A metal with good conductivity

Multiple Choice

What is the definition of Malleable?

• A metal easily hammered into shape

• A metal easily stretched into shape

• A metal that is resistant to scratching

Multiple Choice

What is the definition of Hardness?

• How difficult it is to scratch the surface

• How difficult it is to shatter the metal

• How easily the metals surface corrodes

Multiple Choice

What is the definition of Toughness

• How difficult it is to scratch the surface

• How difficult it is to shatter the metal

• How easily the metals surface corrodes

Open Ended

What are some products which need a high tensile strength?

TIG Welding

TIG—i.e., tungsten inert gas—welding is highly versatile, enabling industry professionals to join a wide range of small and thin materials. It uses a non-consumable tungsten electrode to heat the metal and can be used with or without a filler.

MIG Welding

MIG—i.e., metal inert gas—welding is generally used for large and thick materials. It employs a consumable wire that acts as both the electrode and the filler material.

Difference between TIG and MIG

• TIG welding is much slower, often resulting in longer lead times and greater production costs. Additionally, welders require highly specialized training to ensure they achieve proper precision and accuracy. However, it also offers greater control during the welding operation and produces strong, precise, and aesthetically pleasing welds.

• As such, MIG is quicker and therefore cheaper, easier to use but less precise and strong joints.

Open Ended

List 3 items of PPE you will need to wear when welding

When welding you need to

• Wear PPE - Heat proof gloves, Heat proof apron, Welding Mask

• Hold the metal being welded together with magnets

• Make sure to change the settings of the welder so they are correct for beginning welding - E.g. setting the amount of gas being released

• Make sure to hold the electrode a centimetre away from the metal so it doesn't get attached to the metal

Forging

•Iron and steel can be heated until it softens. By applying a force the metal can be reformed. This is called FORGING.

•Shaping by forging rather than cutting ensures the grain of the metal is not interrupted. Forged components are therefore much stronger

Hand Forging

• Hand forging is completed without the use of machinery, and instead uses hand tools

• Most forging utilises an Anvil as a bed to shape the metal into place on

Drop Forging

• Drop forging instead uses machinery to forge metal

• A hot metal workpiece is placed into a Die, and the Punch is then hammered into place using machinery