Mdel Assignment Issued September 2008 OCR Level 3 Principal Learning in Engineering Unit F558: Selectin and applicatin f engineering materials Please nte: This OCR mdel assignment may be used t prvide evidence fr the unit abve. Alternatively, centres may tailr the assignment within permitted parameters (see Ntes fr Tutrs). It is the centre s respnsibility t ensure that any adaptatins made t this assignment allw learners t meet all the assessment bjectives and prvide sufficient pprtunity fr learners t demnstrate achievement acrss the full range f marks. The scheme cdes fr these qualificatins are: OCR Level 3 Principal Learning in Engineering 500/2400/0 The QCA Accreditatin Number fr this unit is: Unit F558: Selectin and applicatin f engineering materials M/501/1899 This OCR mdel assignment remains live fr the life f these qualificatins. ALL THESE MATERIALS MAY BE PHOTOCOPIED. Any phtcpying will be dne under the terms f the Cpyright Designs and Patents Act 1988 slely fr the purpses f assessment. OCR 2008 1
Cntents LEARNER INFORMATION Mdel Assignment This sectin cntains the assignment backgrund which learners will need t be familiar with in rder t cmplete the tasks. Page Number(s) 3 4 Tasks This sectin cntains all the tasks learners must cmplete befre submissin fr assessment. 5-8 TUTOR INFORMATION Guidance fr centres This sectin prvides general guidance t centre staff n the preparatin and cmpletin f the assignment. 9 10-11 Ntes fr tutrs This sectin prvides additinal guidance and supprt t centre staff fr each task. It is nt intended fr use by learners. 12-15 2 Mdel Assignment Issued September 2008 Unit F558: Selectin and applicatin f engineering materials
Mdel Assignment: Learner Infrmatin OCR Level 3 Principal Learning in Engineering Unit F558: Selectin and applicatin f engineering materials Mdel Assignment Issued September 2008 3 Unit F558: Selectin and applicatin f engineering materials
Mdel Assignment Descriptin f Mdel Assignment. In this unit yu will find ut abut the structure, prperties and classificatin f engineering materials. Yu will: understand the prperties f materials, their availability and cst implicatins, crrectly specify materials fr different engineering applicatins understand the key features and applicatins f new, mdern and smart materials investigate what causes materials t deterirate and understand hw this can be prevented use mathematical and scientific principles within engineering metallurgy Yu will wrk individually r in a team but yu will need t recrd yur wn results and cnclusins independently in the frm f a research reprt. A number f the tasks cntained within this unit will require yu t select and carry ut a detailed analysis f an engineered prduct. Care will need t be taken in the selectin f a suitable prduct. The prduct shuld cntain a wide range f materials t ensure there is sufficient scpe t address all the requirements f the unit. Read thrugh all f the fllwing tasks carefully, s that yu knw what yu will need t d t cmplete this assignment. 4 Mdel Assignment Issued September 2008 Unit F558: Selectin and applicatin f engineering materials
Tasks Task 1: Atmic structures, peridicity and classificatin f engineering materials Assessment Criterin 1.1 Yur task is t: plan and carry ut research int atmic structures, amunt f bnding, peridicity and classificatin f engineering materials analyse and evaluate infrmatin and judge its relevance and value apply yur knwledge t the cnsideratin f materials fr a particular applicatin Yu will need t investigate: the crystalline structure f metals, space lattice structures, grain sizes, crystal grwth, slidificatin the cmpsitin and structure f plastics: thermplastics - lng chain mlecules, thermsetting plastics - crss-linking c-plymerisatin the peridic table, atmic bnding, inic bnding, cvalent bnding and metallic bnding Yu need t recrd the utcmes f the task as part f yur research reprt fr this assignment. Task 2: Testing and evaluatin f engineering materials Assessment Criterin 2.1 Yur task is t: investigate thermal equilibrium diagrams fr cmmn allys draw detailed cnclusins abut prperties f materials based upn yur investigatins test a wide range f materials using destructive and nn-destructive methds analyse and evaluate the infrmatin btained frm yur testing in depth, judging its relevance and value Yu will need t: use test equipment safely while utilising sme (r all) f the fllwing: tensile testing using tensmeter hardness testing, Brinell, Vickers, Shre-sclerscpe impact testing Charpy / Izd fatigue testing Mdel Assignment Issued September 2008 5 Unit F558: Selectin and applicatin f engineering materials
cmpressin testing penetrant methds f testing radigraphy/ X-ray /ultrasnics Yu need t recrd the utcmes f the task as part f yur research reprt fr this assignment. Task 3: Prcessing methds Assessment Criterin 3.1 Yur task is t: investigate the effects f different prcessing methds by testing and analysing samples which have been frmed and wrked in different ways, which may include: crystal frms caused by casting, grain structure in ht frged cmpnents/cld frmed r turned cmpnents changes caused by wrk hardening and deep drawing heat treatment, annealing, nrmalising, hardening and tempering the heating and frming f thermplastic materials the heating and frming f thermsetting plastic materials the effects f allying melting pints, strength Yu need t recrd the utcmes f the task as part f yur research reprt fr this assignment. Task 4: Safety factrs and mdes f failure Assessment Criterin 4.1 Yur task is t: investigate and research safety factrs and mdes f failure Yu will need t: Identify examples where failure has ccurred and the measures engineering designers take t: anticipate risk minimise risk Shw cnsideratin and understanding f: safe wrking stress unifrmity f material 6 Mdel Assignment Issued September 2008 Unit F558: Selectin and applicatin f engineering materials
types f lading: static r dynamic effects f failure effects f wear effects f crrsin n materials Yu need t recrd the utcmes f the task as part f yur research reprt fr this assignment. Task 5: Standard frms and selectin f materials Assessment Criterin 5.1 Yu will need t select an engineered prduct made frm a wide range f engineering materials fr cnsideratin during this task. Yur task is t: analyse the prduct and investigate each material used in its manufacture t establish the: identity f the materials prperties f the materials material s standard frms reasns fr their selectin Yu will need t: prvide evidence f the riginal frms in which the materials were supplied and the prcess used t manufacture the prduct. Yu need t recrd the utcmes f the task as part f yur research reprt fr this assignment. Task 6: New and smart materials Assessment Criterin 6.1 Yur task is t: investigate the key features f new and smart materials and their ptential applicatins analyse and evaluate the infrmatin and knwledge gained and apply this t suggest pssible engineering applicatins fr these new materials present a persuasive argument t influence thers twards the use f new r smart materials. Yu will need t: develp an awareness f latest develpments in a develping technlgy have knwledge f materials such as Shape Memry Allys (SMAs) and intelligent catings Mdel Assignment Issued September 2008 7 Unit F558: Selectin and applicatin f engineering materials
be up t date n new materials and applicatins as they becme available be able t discuss (influence) with thers the values and merits f using these new materials Yu need t recrd the utcmes f the task as part f yur research reprt fr this assignment. 8 Mdel Assignment Issued September 2008 Unit F558: Selectin and applicatin f engineering materials
Mdel Assignment: Tutr Infrmatin OCR Level 3 Principal Learning in Engineering Unit F558: Selectin and applicatin f engineering materials OCR 2008 9
Guidance fr Centres 1 General 1.1 OCR mdel assignments are issued free t participating centres and are als available t dwnlad frm ur website: www.cr.rg.uk. 1.2 Centres may chse t: use OCR mdel assignments fr frmal summative assessment f learners tailr OCR mdel assignments fr frmal summative assessment f learners It is intended that this mdel assignment can be used by centres withut mdificatin. Hwever, in rder t prvide apprpriate cntextualisatin, imprve access r increase lcal relevance, centres may tailr the mdel assignments within set parameters. Details f the scpe f adaptatin are prvided in the Ntes fr Tutrs sectin f this dcument. 1.3 This assignment has been designed t meet the full assessment requirements f the unit. Learners will need t take part in a planned learning prgramme that cvers the underpinning knwledge and skills f the unit. 2 Befre carrying ut the assignment 2.1 Learners shuld be prvided with a cpy f the Learner Infrmatin sectin f this assignment r the centre adapted mdel assignment. 2.2 Learners may carry ut preparatins prir t undertaking the tasks; there is n time limit fr this. 3 When cmpleting the assignment 3.1 All assessment evidence must be prduced under cntrlled cnditins s that the verall level f permit cntrl secures validity and reliability, prvides gd manageability fr all invlved and allws teachers t authenticate the wrk cnfidently. Further guidance n cntrlled cnditins is prvided within the OCR Principal Learning Handbk. 3.2 Learners shuld be allwed 32 guided learning hurs (glh) t cmplete all f the tasks. The amunt f time may vary depending n the nature f the tasks and the ability f individual learners. It is suggested that evidence is prduced in several sessins. 3.3 Each learner must prduce individual and authentic evidence fr each task within the assignment. 10 Mdel Assignment Issued September 2008 Unit F558: Selectin and applicatin f engineering materials
3.4 Centre staff may give supprt and guidance t learners. This supprt and guidance shuld fcus n checking that learners understand what is expected f them. It is nt acceptable fr presenters t prvide mdel answers r t wrk thrugh answers in detail. 3.5 Learners may use infrmatin frm any relevant surce t help them with prducing evidence fr the tasks. 3.6 Learners must be guided n the use f infrmatin frm ther surces t ensure that cnfidentiality is maintained at all times. 4 After cmpleting the assignment 4.1 Learners evidence is assessed by the centre s assessr against the qualificatin specificatin cntained in the Principal Learning Handbk. When marking learners' wrk, centres must use the descriptrs prvided within the unit. Fr further infrmatin abut assessment please refer t the sectin n Assessment and Mderatin in the Principal Learning Handbk. 4.2 Assessrs decisins shuld be quality assured acrss the centre thrugh internal mderatin. Fr further infrmatin abut internal mderatin please refer t the sectin n Assessment and Mderatin in the Principal Learning Handbk. 5 Presentatin f wrk 5.1 Centres may wish t discurage learners frm excessive use f plastic wallets fr presentatin f their evidence as this may hinder the assessment prcess. Instead centres may wish t encurage learners t present their wrk s that it is easily accessible, e.g. spiral bund, stapled bklet, CD-ROM. 6 Acceptable evidence 6.1 Fr guidance n generatin and cllectin f evidence please refer t the sectin n Assessment and Mderatin in the Principal Learning Handbk. 7 Plagiarism and unauthrised cllabratin 7.1 Centres shuld have adequate prcedures in place t ensure that plagiarism and unauthrised cllabratin are identified and respnded t. 7.2 When supervising tasks, teachers are expected t: ffer learners advice abut hw best t apprach such tasks infrm learners f the ramificatins f unfair practice exercise cntinuing supervisin f wrk in rder t mnitr prgress and t prevent plagiarism ensure all cpied materials is suitably acknwledged ensure cpied material is nt given credit in the assessment prcess Mdel Assignment Issued September 2008 11 Unit F558: Selectin and applicatin f engineering materials
7.3 As with all cntrlled assessments, the presenter must be satisfied that the wrk submitted fr assessment is the learner's wn wrk. 12 Mdel Assignment Issued September 2008 Unit F558: Selectin and applicatin f engineering materials
Ntes fr Tutrs Intrductin t the Tasks The tasks have been designed t enable learners t demnstrate their knwledge and understanding f the selectin and applicatin f engineering materials. Learners will als be able t present persuasive arguments t influence thers twards the use f new r smart materials. The mdel assignment has been designed s that all f the assessment criteria in Unit F558 are addressed. Care, guidance and supprt will be required t assist learners with the selectin f a suitable prduct which cntains a wide range f materials t ensure there is sufficient scpe t address all the requirements f the assessment criteria. Learners will need t: understand the prperties f materials, their availability and cst implicatins and crrectly specify materials fr different engineering applicatins understand the key features and applicatins f new, mdern and smart materials investigate what causes materials t deterirate and understand hw this can be prevented use mathematical and scientific principles (Level 3 Units F563 and F564) within engineering metallurgy There are direct links with the cntent f Units F563 and F564 f this Principal Learning. There are practical elements t this unit and centres will need t emply suitable safety prcedures especially during the testing f materials. These guidance ntes shuld be used in cnjunctin with the unit specificatin and Principal Learning Handbk. Scpe f permitted Mdel Assignment mdificatin The mdel assignment is self-cntained in its present frm. The set f tasks frm a cherent whle addressing all the assessment criteria. N changes t the assessment criteria are permitted Mdel Assignment Issued September 2008 13 Unit F558: Selectin and applicatin f engineering materials
When cmpleting this mdel assignment it may be pssible t generate evidence fr cmpleting a task in a variety f frmats. This list is nt exhaustive and will depend n the apprach taken t cmplete the task r mdel assignment. In sme cases the task r mdel assignment will require a specific frmat fr the utcme and this will be clearly marked in the table. Depending n the apprach taken t the mdel assignments it may als be pssible t demnstrate additinal PLTS cverage and sme additinal pprtunities have been listed belw. Task activity Nature f evidence generated Ptential Assessment Criteria cverage Task 1 Atmic structures, peridicity and classificatin f engineering materials. Task 2 Testing and evaluatin f engineering materials. The research reprt will cntain evidence f understanding f: the crystalline structure f metals, space lattice structures, grain sizes, crystal grwth, slidificatin the cmpsitin and structure f plastics-therm plastics lng chain mlecules, therm-setting plastics- crss-linking c-plymerisatin the peridic table, atmic bnding inic bnding, cvalent bnding, metallic bnding. The research reprt will cntain evidence f testing and understanding f: thermal equilibrium diagrams fr cmmn allys thermal expansin stress strain diagrams fr metals and plastics tensile testing using tensmeter hardness testing, Brinell, Vckers, Shre-sclerscpe impact testing Charpy / Izd fatigue testing cmpressin testing equipment safety penetrant methds f testing radigraphy/x-ray /ultrasnics Assessment Criterin 1.1 PLTS IE1 IE2 IE4 IE6 Assessment Criterin 2.1 PLTS IE2 IE4 IE6 EP3 SM3 RL5 14 Mdel Assignment Issued September 2008 Unit F558: Selectin and applicatin f engineering materials
Task 3 Prcessing methds Task 4 Understand factrs f safety and mdes f failure f engineering materials. Task 5 Standard frms and selectin f materials. Task 6 New and smart materials and their ptential applicatins. The research reprt will cntain evidence f understanding f: crystal frms caused by casting, grain structure in ht frged cmpnents/cld frmed r turned cmpnents, changes caused by wrk hardening, deep drawing heat treatment, annealing, nrmalising, hardening, tempering the heating and frming f thermplastic materials. the heating and frming f thermsetting materials the effects f allying melting pints, strength The research reprt will cntain evidence f cnsideratin and understanding f: safe wrking stress unifrmity f material type f lading static r dynamic effects f failure effects f wear and effects f crrsin n materials The research reprt will cntain evidence f understanding and use f: material data charts t select materials fr perfrmance requirements, prcessing selectin, Yung s mdulus/ density, Yung s mdulus/cst, strength/density, strength/tughness, strength/elngatin, strength/cst, strength/maximum service temperature, specific stiffness/specific strength, electrical resistivity/ cst, recycling fractin/cst, energy cntent/cst prcess selectin, cmparative csts, batch sizes, material csts, start-up csts, running csts, ttal csts. reference t manufacturers data sheets and catalgues t surce cmmn materials The research reprt will cntain evidence f: an awareness f latest develpments in a develping technlgy knwledge f materials such as Shape Memry Allys (SMAs) and intelligent catings shuld be cnstantly updated by new materials and applicatins, as they becme available. Assessment Criterin 3.1 PLTS IE1 IE2 IE4 IE6 Assessment Criterin 4.1 PLTS IE2 Assessment Criterin 5.1 PLTS nne Assessment Criterin 6.1 PLTS IE1 RL3 Mdel Assignment Issued September 2008 15 Unit F558: Selectin and applicatin f engineering materials
an ability t discuss with thers the values and merits f using these new materials EP2 16 Mdel Assignment Issued September 2008 Unit F558: Selectin and applicatin f engineering materials