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Design and Technology - In class assessment 3, Carbon Fibre, vs, Aluminium…

- - - - The fibres of carbon are woven into a sheet, different weave patterns can be created to have different strengths
      - The carbon fibre sheets are then layered into a mould of the shape of the final product
      - The mould is then filled with resin such as epoxy resin.
      - It is then heated or air cured to harden
      - Leaves a corrosion resistant, stiff, strong component. Resin adds structural integrity and stiffness to the carbon fibre
  - - - Silicon
      - Manganese
      - Magnesium
      - Tin
      - Copper
      - Zinc
- - - - One item / product
      - Small scale specialist team / one person
      - Extremely skilled workforce
      - Made for specalist market or particular client
      - Very expensive products
      - Extremely high standard of quality control
    - - A set number of products which are manufactured
      - Medium price range of products
      - Unskilled / semi-skilled workers
      - Needs flexible workforce as machinery / workers can be moved around for making the next batch of a different product
      - Often makes use of standard components or components form other companies
    - - Runs 24h a day, every day of the year
      - Used for manufacturing products which always have demand, e.g. pencils, paper, bricks
      - Split into different tasks or operations
      - Quality control at every stage of the manufacture
      - High start up price
      - Inexpensive products
  - - - Investment / Lost wax casting
        
        For making complex components with high accuracy
        
        Wax pattern made of component being manufactured
        
        Wax pattern coated in slurry, dries, leaving a shell, forming the die
        
        Die placed in furnace, wax melts away, creating a mould
        
        Molten material fills the die, creating the component. Mould broken off after material solidifies
      - Sand casting
        
        An impression is made in sand of pattern for product, slightly oversized to account for shrinkage
        
        Used for machine components, engine block, turbines
      - Resin casting
        
        Mould filled with liquid resin then hardens
        
        Used for small scale production and prototypes
      - Low temperature casting
        
        Mould made in two parts, held together by wire or clamps
        
        Metal heated, then poured into the mould
        
        Mould split open, casting is removed
        
        Small scale process used at school / college workshop
    - - Multiple layers of wood and adhesive are layered in moulds / forms where pressure is applied
    - - Sheet of plastic is heated until malleable
      - Mould of desired shape placed at the bottom of the bed in the vacuum former
      - Air is removed, and the plastic sheet forms around the shape of the mould
- - - - Fluidized bed of polymer powder
      - Metal is cleaned and heated
      - The heat melts the polymer powder as it is dipped, bonding the plastic to the metal surface
    - - Dry powder sprayed onto the metal
      - Are attracted to the metal because of an electrostatic charge
      - The powder is cured with heat, creating an even finish
    - - Metal submerged in a electrolytic solution and goes under the process of electrolysis
      - This forms a metal oxide film on the aluminium in the solution
      - The metal now has a very porous top layers. Dyes are often used here as it can be easily absorbed by the metal
      - The porous surface then goes through the process of sealing to close off the pours and finish the metal
    - - Hot bath of zinc
      - Metal is dipped into the zinc to create a protective zinc layer
      - The zinc surface will also oxidise, creating another protective layer on top
      - (Usually for steel)
    - - Metal is degreased, cleaned and sanded
      - Paint sprayed onto the surface of the metal evenly to protect it