ferrous and non-ferrous metals
4 detailed 50-minute lessons with teaching scripts, worked examples, parent guides, and assessment criteria.
Lesson Overview
Total Lessons: 4
Tier: Foundation and Higher
Duration: 50 minutes per lesson (200 minutes total)
Exam Boards: AQA, Edexcel, OCR, Eduqas, CCEA
Tier: Foundation and Higher
Duration: 50 minutes per lesson (200 minutes total)
Exam Boards: AQA, Edexcel, OCR, Eduqas, CCEA
Learning Objectives
- Explain the key ideas of ferrous and non-ferrous metals
- Apply ferrous and non-ferrous metals to exam-style questions
- Develop independent study skills
- Build cross-topic connections
Prerequisites
- Read the revision notes for ferrous and non-ferrous metals first (GCSE Revise summary)
- Key vocab to pre-teach: D&T Exam Tips
- Basic skills: reading the summary notes and answering the practice questions there
Materials & Equipment
- Exercise book, coloured pens
- Ruler
- Printed revision notes (link below)
- Internet for videos (see Resources)
Lesson 1: Introduction: ferrous and non-ferrous metals
Duration: 50 minutes
Starter Activity (5 minutes)
Quick Recall
Write down everything you already know about ferrous and non-ferrous metals. Then check against the key terms: D&T Exam Tips. Use a mini-whiteboard or paper.
Main Content (35 minutes)
Parent/Teacher Guide:
Before lesson: Read the script below. Pre-teach key vocab: D&T Exam Tips.
If stuck: Re-read the revision notes (link above), then break the content into smaller steps.
Extension: See the Stretch & Challenge ideas in Lesson 4.
Before lesson: Read the script below. Pre-teach key vocab: D&T Exam Tips.
If stuck: Re-read the revision notes (link above), then break the content into smaller steps.
Extension: See the Stretch & Challenge ideas in Lesson 4.
Teaching Script (35 mins):
Mins 0-5 - Hook: "Today: ferrous and non-ferrous metals. By the end you will be able to answer exam questions on it unaided. It connects to the rest of Design and Technology because the ideas here recur across the spec."
Mins 5-20 - Direct Instruction: Work through the core ideas below one at a time; after each, ask your student to explain it back in their own words.
Mins 20-30 - Guided Practice: Model the worked example together, then let your student attempt the first practice question with guidance.
Mins 30-35 - Independent Practice: 2-3 practice questions from Lesson 3 below, with immediate feedback.
Mins 0-5 - Hook: "Today: ferrous and non-ferrous metals. By the end you will be able to answer exam questions on it unaided. It connects to the rest of Design and Technology because the ideas here recur across the spec."
Mins 5-20 - Direct Instruction: Work through the core ideas below one at a time; after each, ask your student to explain it back in their own words.
Mins 20-30 - Guided Practice: Model the worked example together, then let your student attempt the first practice question with guidance.
Mins 30-35 - Independent Practice: 2-3 practice questions from Lesson 3 below, with immediate feedback.
First Look
Start with the revision notes summary, then attempt: Explain why stainless steel is used for surgical instruments whereas mild steel is not, despite both being ferrous metals.
Plenary (5 minutes)
Check Out
Your student states one thing they learned and one question they still have about ferrous and non-ferrous metals.
Lesson 2: Core Concepts: ferrous and non-ferrous metals
Duration: 50 minutes
Starter Activity (5 minutes)
Review Previous Lesson
Quick recap: write 3 key points from Lesson 1 on ferrous and non-ferrous metals. Check them against the notes below.
Main Content (35 minutes)
Key Fact: Ferrous metals contain iron - magnetic, prone to rust (except stainless). Mild steel: low carbon, ductile, weldable. Stainless steel: chromium content prevents corrosion - cutlery, medical instruments.
Key Fact: Cast iron: high carbon (2-4%), excellent compressive strength, self-lubricating - engine blocks, manhole covers.
Key Fact: Aluminium: lightweight (1/3 steel's density), corrosion-resistant (oxide layer), excellent conductor - aircraft, cans, window frames.
Key Fact: Copper: excellent electrical and thermal conductor, ductile, malleable, antimicrobial - wiring, plumbing, PCBs.
Key Fact: Brass: copper-zinc alloy - gold appearance, corrosion resistant, low friction, machinable - decorative hardware, valves, musical instruments.
D&T Exam Tips: For metal questions: 1) Classify as ferrous/non-ferrous, 2) State key properties with data, 3) Link to product requirements, 4) Consider surface treatments (galvanising, anodising).
| Term | Meaning | Example |
|---|---|---|
| Mild steel | Ferrous | 7850 |
| Stainless 304 | Ferrous | 7900 |
| Cast iron | Ferrous | 7200 |
| Aluminium 6061 | Non-ferrous | 2700 |
| Copper | Non-ferrous | 8900 |
| Brass | Non-ferrous | 8500 |
Practice (10 minutes)
Q: Explain why stainless steel is used for surgical instruments whereas mild steel is not, despite both being ferrous metals.
Answer: Stainless steel has 10.5%+ chromium which forms a passive chromium oxide layer - self-healing, prevents rust even when scratched. Mild steel has no chromium and rusts rapidly.
Plenary (5 minutes)
Explain Back
Your student teaches the key points back to you without looking. Fill any gaps immediately.
Lesson 3: Application: ferrous and non-ferrous metals
Duration: 50 minutes
Starter Activity (5 minutes)
Quick Recall
Recall the key terms: D&T Exam Tips. Define each in one sentence.
Main Content (35 minutes)
Parent/Teacher Guide: Let your student attempt each question alone first, then compare with the model answer. Award method marks for correct working even if the final answer is wrong.
Q1: Explain why stainless steel is used for surgical instruments whereas mild steel is not, despite both being ferrous metals.
Answer: Stainless steel has 10.5%+ chromium which forms a passive chromium oxide layer - self-healing, prevents rust even when scratched. Mild steel has no chromium and rusts rapidly.
Q2: Justify the use of aluminium rather than steel for aircraft fuselage construction.
Answer: Aluminium: density 2.7 g/cm3 vs steel 7.8 - 1/3 the weight, crucial for fuel efficiency; corrosion-resistant; good strength-to-weight when alloyed. Trade-off: more expensive and less stiff.
Q3: A product designer needs a gold-coloured, corrosion-resistant material for a door handle. Compare brass and gold-anodised aluminium.
Answer: Brass: genuine gold appearance, naturally corrosion-resistant, heavy and tactile (premium feel), low friction, antimicrobial. Gold-anodised aluminium: lighter, cheaper, coating can scratch to reveal silver beneath. For a door handle: brass is superior.
Plenary (5 minutes)
Error Review
Review any questions answered incorrectly. Identify whether the error was knowledge, method, or reading the question.
Lesson 4: Exam Practice: ferrous and non-ferrous metals
Duration: 50 minutes
Starter Activity (5 minutes)
Command Words
Review what these command words require: state (one point), describe (say what happens), explain (say why), compare (both sides), evaluate (judgement).
Main Content (35 minutes)
Extended Answer
Extended question: Full-Mark Response A company is designing a lightweight camping stove. Compare aluminium and mild steel for the main body, justifying your recommendation with reference to at least four properties. <div class="
A grade 9 response will: compare Density (aluminium 2.7 vs steel 7.8 g/cm3), Thermal conductivity (205 vs 50 W/mK), Corrosion (aluminium oxide layer vs steel rusts), Strength (steel stronger but aluminium thicker walls can match strength while remaining lighter). Conclusion: aluminium for the main body.
Exam Tips: Ferrous = contains iron (think ferrum = Latin for iron) | Know that stainless steel is ferrous but does not rust - explain WHY (chromium oxide layer) | State alloy composition: brass = copper + zinc, bronze = copper + tin
Common Errors: Watch Out! Students often make mistakes here. Wrong: All metals are magnetic because they are metals. Correct: Only ferrous metals (containing iron) are magnetic - mild steel, cast iron. Non-ferrous metals (aluminium, copper, brass, gold, silver) are NOT magnetic. Some stainless steel grades are weakly magnetic due to crystal structure.
Stretch & Challenge (Grade 8-9):
- Synoptic links: explain how ferrous and non-ferrous metals connects to another Design and Technology topic you have studied
- Real-world: research one real-world use or example of ferrous and non-ferrous metals
- Critical: "What are the limitations of the models used in ferrous and non-ferrous metals?"
Plenary (5 minutes)
Assessment Criteria
- Got it: Confident explanation + correct worked examples
- Getting there: Main points OK, needs support with detail
- Not yet: Confused on key concepts - re-run Lesson 2
Homework & Consolidation
- Consolidation: Re-answer any Lesson 3 practice questions answered incorrectly (20 mins)
- Retrieval: Write flashcards for the key terms: D&T Exam Tips (10 mins)
- Exam practice: One past-paper question on ferrous and non-ferrous metals from the board websites (15 mins)
- Extension: Explain ferrous and non-ferrous metals to someone else in your own words (10 mins)