Sample Schemes of Work and
Lesson Plans
Engineering
OCR Level 3 Principal Learning in Engineering H811
Unit F558: Selection & application of engineering materials
This Support Material booklet is designed to accompany the OCR Engineering Diploma
specification for teaching from September 2008.
© OCR 2009
Contents
Contents
2
Sample Scheme of Work: OCR Level 3 Principal Learning in Engineering H811 Unit
F558: Selection and application of engineering materials
3
Sample Lesson Plan: OCR Level 3 Principal Learning in Engineering H811 Unit
F558: Selection and application of engineering materials
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11
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F558:
Selection and application of engineering materials
Suggested
teaching time
4 hours
Topic outline
Topic
Investigate a product
Suggested teaching and homework
activities
Suggested resources
Points to note
Overview: This unit is assessed internally via a controlled assignment in which the learners must analyse materials for a product and produce a research
report. The main feature of this unit is the selection of an engineered product for analysis. The learners should be encouraged and guided to select a
suitable product for study, which contains a wide range of materials. Information could be communicated in the form of a presentation to a group of
learners; this could be electronically using the current OCR standard.
This unit will enable learners to find out about the structure, properties and classification of engineering materials. Learners will:

Apply their understanding of the properties of materials, design, cost and availability to correctly specify materials for different engineering applications.

Develop an understanding of the key features and applications of new, modern and smart materials.

Investigate what causes materials to deteriorate and how this can be prevented.

Learn how to use mathematical and scientific principles (Level 3 Unit F563 Mathematical techniques and applications for engineers and Unit F564
Scientific principles and applications for engineers) within engineering metallurgy. A feature of the unit is the analysis of an engineered product, which
results in learners identifying materials used in its manufacture and providing evidence of the properties, which led to their selection.
The practical work and the selection of materials for certain applications may contribute to other units such as Unit F557 Applications of computer aided
designing and Unit F562 Innovative design and enterprise
There are many opportunities for Learners to develop and demonstrate their PLT’s in this unit.
= Innovative teaching idea
Engineering Diploma
= ICT opportunity
3 of 12
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F558:
Selection and application of engineering materials
Suggested
teaching time
4 hours
Topic
Investigate a product
Topic outline
Suggested teaching and homework
activities
Suggested resources
Points to note
Learners will be able to:
1.

Suitable products e.g. battery powered
tools, laptops, etc with a range of materials
to analyse

This topic should take a number of lessons
to complete


Tools for disassemble

Manufacturers diagrams and parts list
It is assumed that learners have acquired
some experience of material
testing/selection at KS4 and this topic will
built on that

Materials selection charts


Internet access
This topic enables learners to both acquire
the required knowledge and understanding
and the skills required for the controlled
assessment task.

Caution, warnings about disassembling
mains voltage items should be stressed to
the learners if applicable
Learners to disassemble or be presented
with a previously sectioned product
2. Group activity to identify all the materials
Select an engineered product
used in the product and the properties they
made from a wide range of
posses
engineering materials. Analyse
the product and investigate
3. Groups to compare results and check with
each material used in its
manufacturers data if available
manufacture to establish the
4. Class discussion on the reasons why each
identity of the material, its
material was selected by the designers and
properties, standard forms and
possible alternatives
the reasons for its selection.
Provide evidence for the
original forms in which the
materials were supplied and
the process used to
manufacture
= Innovative teaching idea
4 of 12

Glossary of materials properties e.g.
stiffness, hardness, malleability etc
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F558:
Selection and application of engineering materials
Suggested
teaching time
4 hours
Topic
Investigate a product
Topic outline
Suggested teaching and homework
activities
Suggested resources
Points to note
Learners will:
1.

Examples

This topic should take a number of lessons
to complete

Materials selection charts

This topic enables learners to both acquire
the required knowledge and understanding
and the skills required for the controlled
assessment task.
Develop knowledge and
understanding of material
selection and the form that
they are supplied in
= Innovative teaching idea
Engineering Diploma
2.
Presenters to continue the theme of the
previous topic and stimulate discussion on
the standard forms that materials come in
Group activity to investigate the form and
processes that produced the components
in the selected product

Internet access

Materials and reference sources

Videos of similar product being made
= ICT opportunity
5 of 12
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F558:
Selection and application of engineering materials
Suggested
teaching time
20 hours
Topic
Test and investigate materials properties
Topic outline
Suggested teaching and homework
activities
Suggested resources
Points to note
Learners will be able to:
1.

Ideally a visit to a HE/materials testing
establishment, time permitting

This topic will take a number of lessons to
complete

Testing facilities and consumables


Data recording hardware and software
It is assumed that learners have acquired
some experience of material
testing/selection at KS4 and this topic will
built on that

Experiment workbook to complete


Background information on a range of
testing methods both destructive and nondestructive
This topic enables learners to both acquire
the required knowledge and understanding
and the skills required for the controlled
assessment task.
Group activity to perform a range of tests
on various material types, ideally linked to
topic product selected (EL)
Plan and carry out research
into atomic structures, amount 2. Learners to record results and compare
materials properties/selection in first topic
of bonding, periodicity and
classification of engineering
3. Depending on the testing equipment
materials. Analyse and
available learners need to be introduced to
evaluate information, judging
other form of material testing that exists
its relevance and value. Apply
knowledge to the
consideration of materials for a
particular application. Propose
practical ways forward for
using the knowledge gained
Investigate thermal equilibrium
= Innovative teaching idea
6 of 12
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F558:
Selection and application of engineering materials
Suggested
teaching time
20 hours
Topic outline
diagrams for common alloys
and draw conclusions about
properties of materials; test
materials using destructive
and non-destructive methods,
analyse and evaluate
information, judging its value
in the context of an
engineered product. Propose
practical ways forward for
using the knowledge gained
Topic
Test and investigate materials properties
Suggested teaching and homework
activities
1.
Group activity to analyse and evaluate the
findings from the tests carried out
2.
Groups to research the structure of the
materials and document the findings
3.
Class discussion on the types of process
and treatments that materials may be
subjected to
4. Groups to document the changes to
materials after treatment/processing
Suggested resources
Points to note

Examples of metallic and non metallic
samples

This topic will take a number of lessons to
complete

Samples materials pre and post processing
for comparison


Internet access
This topic enables learners to both acquire
the required knowledge and understanding
and the skills required for the controlled
assessment task.

Materials and reference sources
Investigate the effects of
different processing methods
by testing and analysing
samples, which have been
formed and worked, in
different ways. Use this
= Innovative teaching idea
Engineering Diploma
= ICT opportunity
7 of 12
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F558:
Selection and application of engineering materials
Suggested
teaching time
20 hours
Topic outline
Topic
Test and investigate materials properties
Suggested teaching and homework
activities
Suggested resources
Points to note
knowledge to understand why
particular materials have been
chosen in the context of a
specific engineered product.
Propose practical ways
forward for using the
knowledge gained
= Innovative teaching idea
8 of 12
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F558:
Selection and application of engineering materials
Suggested
teaching time
3 hours
Topic
Causes of metal failure
Topic outline
Suggested teaching and homework
activities
Suggested resources
Points to note
Learners will be able to:
1.
Presenters to introduce the topic with a
recap on destructive testing and materials
operating safety factors

Back ground info on product/materials
factors of safety

This topic with take a number of lessons to
complete
2.
Groups to research documented case
studies of failures, ideally missing out the
remedies or prevention taken Groups to
come up with solutions that the engineers
could have taken to minimise the risk of
failure
Videos, case studies of failures and remedies
covering types of loading, effect of wear and
corrosion etc. Examples include:

This topic enables learners to both acquire
the required knowledge and understanding
and the skills required for the controlled
assessment task.
Investigate and research
safety factors and modes of
failure. Identify actual
examples of where failure has
occurred and the measures
engineering designers take to
anticipate, minimise and take
risks
= Innovative teaching idea
Engineering Diploma

Comet airliner crash

Aloha Airlines Flight 243

Space Shuttle Challenger Accident 1986

Hyatt Regency walkway collapse

Hatfield rail crash

Internet access
= ICT opportunity
9 of 12
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F558:
Selection and application of engineering materials
Suggested
teaching time
1 hour
Topic
New and smart materials
Topic outline
Suggested teaching and homework
activities
Suggested resources
Points to note
Learners will be able to:
1.


This topic with take one lesson to complete

This topic enables learners to both acquire
the required knowledge and understanding
and the skills required for the controlled
assessment task.
Presenter led introduction of new and
smart materials but without applications
2. Group activity to identify applications for
Investigate a new or smart
the materials given above
material. Analyse and evaluate
the information and knowledge 3. Learners to produce a short PowerPoint
gained. Act on these
explaining selected material
experiences when suggesting
possible engineering
applications for these new
materials. Present a
persuasive argument to
influence others towards the
use of new or smart materials
= Innovative teaching idea
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Back ground info, for example Piezoelectric,
photocromic, electrochromism, shape
memory alloys, ferrofluid etc
= ICT opportunity
Engineering Diploma
Sample Diploma Lesson Plan
OCR Level 3 Principal Learning in
Engineering H811 Unit F558: Selection and
application of engineering materials
New or smart materials
OCR recognises that the teaching of this qualification above will vary greatly from school to school
and from teacher to teacher. With that in mind this lesson plan is offered, as a possible approach
but will be subject to modifications by the individual teacher.
Lesson length is assumed to be one hour.
Learning Objectives for the Lesson
Objective 1
Learners can explain what a new or smart material is
Objective 2
Learners can list the features of a new or smart material
Objective 3
Learners can suggest applications for a new or smart material
Recap of Previous Experience and Prior Knowledge
Learners have been introduced to a range of engineering materials and:

can identify a range of materials in a selected product

can present an argument on a materials selection

understands materials structures and behaviours
Content
Time
Content
5 minutes
Presenter led introduction of what new or smart materials are with examples to
show
10 minutes
Group activity to identify uses for presented materials
15 minutes
Group feedback to whole class of their suggestions of uses for the materials
10 minutes
Presenter to led a consolidation of the suggested uses and if necessary present
correct/current uses
10 minutes
Learners to produce a PowerPoint to exemplify their chosen new or smart
Engineering Diploma
11 of 12
Sample Diploma Lesson Plan
material
Consolidation
Time
Content
10 minutes
Group discussion on what the future may hold for yet undiscovered materials
Homework
Learners to complete their PowerPoint examples
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Engineering Diploma