Casting, Joining and Surface Finishing
Three ways to shape and finish engineered products: casting molten metal in a mould, joining parts permanently or temporarily, and finishing surfaces to protect them from corrosion.
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Casting, joining and finishing
Engineering turns raw materials into finished products. This module covers three groups of process: casting, where molten metal is shaped in a mould; joining, where parts are fixed together permanently or temporarily; and surface finishing, which protects a product and improves its appearance.
Words for the processes
Learn these four terms before you compare the processes.
Permanent and temporary
Parts can be joined in two broad ways.
Justify the process you pick
To reach the top grades, justify the process you choose for a job, thinking about cost, strength, corrosion and whether the product must be taken apart, rather than just naming it.
Match the process to what it does
- casting
- welding
- galvanising
- riveting
- pouring molten metal into a mould to form a shape
- joining metal parts by melting them together
- coating steel with zinc to stop rust
- joining parts with metal pins that are hammered
Match the term to its meaning
- permanent join
- temporary join
- corrosion
- mould
- a join that cannot be undone without damage
- a join that can be taken apart
- the wearing away of metal, such as rust
- a hollow shape that gives cast metal its form
What is casting?
What is casting?
- Pouring molten metal into a mould to make a shape.
- Cutting metal with a saw.
- Bending metal into a curve.
- Joining two pieces of metal by melting their edges together.
Permanent joins
Select the TWO permanent joining methods.
- Welding.
- Riveting.
- Using nuts and bolts.
- Using screws.
Order the casting
Put the steps of casting in order, earliest first.
- The metal is heated until it melts
- The molten metal is poured into a mould
- The metal cools and sets into shape
- The finished part is removed from the mould
Summarise the processes
In _____, molten metal is poured into a mould to make a shape. Parts can be joined with a permanent join, such as _____, or a temporary join, such as nuts and _____. Surface finishing, such as _____, protects metal from _____.
Count the processes
How many groups of manufacturing process does this module cover: casting, joining and finishing?
Spot the two permanent joins
Tap the TWO permanent joining methods.
- welding
- riveting
- nuts and bolts
- screws
- a clamp
Casting, joining or finishing?
Decide which group each process belongs to.
- Pouring molten metal into a sand mould
- Welding two steel plates together
- Coating a gate with zinc to stop rust
Choose a join
A product must be opened for repair, so its parts need to come apart. Explain which type of join you would choose and why. Name a suitable joining method and give a reason.
- State whether a permanent or temporary join is needed
- Name a suitable joining method
- Explain why it suits a product that must be taken apart