You will need...

Planner, Pencil, Apron, Folder, Stool

Lesson Objectives:

• To learn about metals & why they are so widely used

• To understand how metal products are made

• To understand how to create a range of designs

restricted by the tools and processes

• To safely & accurately use the Pillar Drill

• Where do materials come from?
• In what stock sizes and forms are they found?
• What properties do different materials have?

Open the textbook

to page: 34 & 35
The library has copies of this textbook
 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

+ =
 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
 Die Casting

Good Points Bad Points

• Complex shapes • Set up costs are
can be produced high
• High numbers • creating the
can be produced moulds are
quickly expensive
 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
 Press Forming

Good Points Bad Points

• A range of shapes • Set up costs are
can be made high
• High numbers can • creating the
be produced quickly moulds are
expensive