Explain — 4 marks
A manufacturer is designing a new bicycle frame. They are considering three materials: steel (an alloy), carbon fibre composite, and aluminium alloy. The frame needs to be strong, lightweight, and durable for use in different weather conditions.
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Explain why steel, which is an alloy of iron and carbon, is stronger than pure iron.
[1 mark]
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Explain why a carbon fibre composite would be more suitable than pure polymer for a bicycle frame that needs to be both lightweight and strong.
[2 marks]
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Explain why aluminium alloy is more resistant to corrosion than pure iron when exposed to wet weather conditions.
[1 mark]
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Compare — 3 marks
A manufacturing company needs to select a material for making kitchen worktops. They are considering three options: a ceramic tile surface, a polymer-based laminate, and a composite material made from wood fibres bonded with resin.
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Compare the thermal properties of the ceramic tile and the polymer laminate for use as a kitchen worktop.
[2 marks]
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Explain one advantage and one disadvantage of using a composite material instead of a pure ceramic for this application.
[1 mark]
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Explain — 4 marks
A manufacturer produces sports equipment using different materials. They need to decide between using carbon fibre reinforced polymer (CFRP) composite or aluminium alloy for a new bicycle frame. The CFRP composite consists of carbon fibres embedded in an epoxy resin matrix. The aluminium alloy is made by adding copper and magnesium to pure aluminium.
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Explain why the aluminium alloy has different properties to pure aluminium.
[1 mark]
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Explain why the carbon fibre reinforced polymer composite is stronger than the epoxy resin alone, despite both being polymers.
[2 marks]
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The bicycle frame must be both strong and lightweight. Explain which material (CFRP composite or aluminium alloy) would be more suitable for this application, considering both the structure of the material and its properties.
[1 mark]
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Calculate — 2 marks
A manufacturer produces brass door handles. Brass is an alloy containing copper and zinc. Each handle has a mass of 400 g and contains 35% zinc by mass.
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(01.1) Calculate the mass of zinc in one brass handle.
[1 mark]
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(01.2) The manufacturer has 70 kg of zinc available. Calculate the maximum number of brass handles that can be produced.
[1 mark]
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- (01.1) 140 (g) / 0.35 × 400 = 140
- (01.2) 500 (handles) / 70 000 ÷ 140 = 500 / 70 ÷ 0.14 = 500
Evaluate — 3 marks
A kitchenware company is designing new cooking equipment. The design team are considering stainless steel (an alloy of iron, chromium and carbon), ceramic coatings, and silicone rubber (a polymer) for different components.
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(01.1) State one property of stainless steel that makes it different from pure iron.
[1 mark]
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(01.2) Evaluate the use of silicone rubber rather than stainless steel for the handles of saucepans.
[2 marks]
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- (01.1) harder / stronger / more durable
- (01.1) more resistant to corrosion
- (01.1) melts at a lower temperature
- (01.2) silicone is a poor conductor of heat / good thermal insulator
- (01.2) so the handle stays cool to touch / prevents burns when the pan is hot
GCSE Perfect