Engineering materials (ceramics and composites)
Ceramics are inorganic, non-metallic solids comprising metal, non-metal or metalloid atoms primarily held in ionic and covalent bonds. The crystallinity of ceramic materials range from highly oriented to semi-crystalline, and often completely amorphous (e.g. glasses). Varying crystallinity and electron consumption in the ionic and covalent bonds cause most ceramic materials to be good thermal and electrical insulators and extensively researched in ceramic engineering.
Composites are made by physically combining two or more materials to achieve a more desirable set of properties. The use of composites is not new, but composites are being developed to meet demands. The vast majority of composites were developed to provide strength and rigidity while being relatively light. This makes them ideal to be used for furniture, buildings, sports equipment, boats, cars, and planes. Composite materials are also being developed for their ability to provide a specific combination of properties and functions, not simply for their mechanical properties.
This list suggests some activities that can be used with students to demonstrate the properties and applications of some common ceramics and composties. There are links to other resources that can be used to illustrate their engineering applications.
Whilst this list provides a source of information and ideas for experimental work, it is important to note that recommendations can date very quickly. Do NOT follow suggestions which conflict with current advice from CLEAPSS, SSERC or other recent safety guides. eLibrary users are responsible for ensuring that any activity, including practical work, which they carry out is consistent with current regulations related to health and safety and that they carry an appropriate risk assessment. Further information is provided in our health and safety guidance
Composites: Designing Materials for the Future
This booklet provides a source of ideas and information about the properties and range of uses of composite materials, as well as suggesting classroom activities and materials that can be used to demonstrate the properties of composites. The practical activities are intended for KS4 students but can be extended to use with Post-16 students.
The following activities are particularly useful in the engineering context:
A1 How much filler (pages 40-41) – this activity can be used to illustrate the effect of differing amounts of filler on the composite strength. It also considers overall cost implications and workability of the mix.
A2 Particle and Fibre size (pages 42 – 43) – this activity can be used to model how longer fibres improve the strength and workability of a composite.
A3 Changing filler material (page 44) – this activity can be used to model the effects of using filler of varying sizes on the strength of composites.
A4 Making and testing plywood (page 45) – this activity can be used to demonstrate how the orientation of grain in the layers of plywood affects its strength.
Smart Materials: the Next Generation
This video clip can be used to introduce the use of carbon fibre in the manufacture of cars.
The film clip looks at the use of different materials in a formula one car. With a carbon fibre material, the car can be designed with the correct balance of strength and stiffness so that if the car crashes it will collapse and not crush the driver. It can be used to prompt discussion with students about the desired properties of the materials used in the manufacture of cars.
QTC - Making the Most of a Novel Material
This Catalyst article can be used to introduce Quantum Tunnelling as a composite designed by accident.
Its resistance decreases dramatically under pressure. In this article, David Bloor of Durham University describes how QTC was discovered and how his team set about exploring this strange new material.
This artcicle can be given to students as background information at the start or end of the topic or as part of a research project into smart materials.
Net Composites
NetComposites is a global research, consultancy and online media company. They use new technologies to create innovative composites products and processes to advance the composites industry.
This website is the industry's leading online portal for composites. It contains the world's largest stores for composites information, including over 1000 books, videos, journals, CDs, software and market reports.
This can be used to highlight to challenges of managing composite materials at the end of their life. Data sheets can be downloaded to show how Carbon Fibre can be recycled.
Thermoplastic composites can be illustrated using data sheets that are available for download on this website. These are a particular type of composite where a thermoplastic matrix is reinforced with a high tenacity fibre from the same polymer family (e.g. polypropylene reinforced polypropylene). The reinforcing effect results in a material with a stiffness and strength that is 3-5 times higher than the base polymer. This allows less material to be used for the same performance, and gives easy recycling compared to conventional multi-material fibre reinforced composites. SRPs can also provide excellent impact performance.
Morgan Technicial Ceramics
The Technical Ceramics business of Morgan Advanced Materials designs and manufactures advanced ceramic components from a portfolio of cutting edge materials.
The website provides links to downloadable materials on latest technology and case studies. The animations can be used to illustrate the processes involved in the manufacture of ceramics. Data sheets are available for the range of ceramics they manufacture. It can be used to highlight the type of industries in which ceramics are used.
Tungsten Carbide
This publication is a reference guide for designers, engineers, fabricators and end users of tungsten carbide material. Specifically, it is a compilation of recommendations derived from practical experience, theoretical stress analysis, proven application engineering practices and modern manufacturing techniques. It provides an insight in to best practices for using one of the most unique engineering materials available today.
Additional information on tungsten: sources, properties and uses can be found at: INTERNATIONAL TUNGSTEN INDUSTRY ASSOCIATION
Resistant Materials
This 'Technology Student' website has a wide range of information, worksheets and revision cards that can be used by teachers and students.
The following are particularly useful for this resource list are:
Carbon Fibre Reinforced plastic (CFRP)
Glass reinforced plastic /Fibre glass
Kevlar:
Advantages and disadvantages of using Kevlar
Kevlar and Modern cars
Royal Academy of Engineering
The Royal Academy of Engineering has produced contextualised curriculum resources. These are appropriate for use at post-16 education at Levels 1 and 2 and can easily be extended for Level 3+ learners. Two of them have a sports theme and the other has a disaster relief theme. They can be found in the curriculum resources section of this website.