Lesson Plan

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Lesson Plan
Grade: Date: 25/02/2026
Subject: Design and Technology
Lesson Topic: Physical tests to determine the suitability of materials and components for the application of a finish.
Learning Objective/s:
  • Describe the purpose of physical testing in material selection for finishes.
  • Explain how hardness, tensile, impact, abrasion, corrosion, and surface‑roughness tests relate to finish performance.
  • Interpret test data to recommend appropriate surface‑preparation and coating strategies.
  • Apply safety and calibration procedures when conducting common material tests.
Materials Needed:
  • Projector and PowerPoint slides
  • Sample metal coupons for testing
  • Testing equipment (hardness tester, universal tensile machine, Charpy impact tester, Taber Abraser, salt‑spray chamber, profilometer)
  • Data recording worksheets
  • Safety goggles and gloves
 Introduction:
Begin with a short video showing paint failure on a cracked metal component, prompting students to consider why the substrate mattered. Recall prior learning on material properties and finish requirements. Explain that today they will explore key physical tests that inform finish selection, and success will be shown by correctly interpreting sample test data.
Lesson Structure:
  1. Do‑now (5') – Quick written response to “Why does surface preparation affect coating durability?”
  2. Mini‑lecture (10') – Overview of six physical tests and their relevance to finishes, using slides and a Vickers‑test diagram.
  3. Demonstration (15') – Live hardness test on a metal coupon; discuss indenter type, load, and reading.
  4. Group activity (20') – Teams analyse provided test‑data sheets (hardness, tensile, impact, abrasion, corrosion, roughness) and match each to suitable finish specifications.
  5. Practical stations (20') – Rotating stations: quick hardness measurement, video of abrasion test, observation of corrosion‑spray results.
  6. Plenary (10') – Whole‑class discussion summarising how test results guide material and finish choices; quick quiz (Kahoot) to check understanding.
Conclusion:
Recap that physical testing provides the quantitative evidence needed to select appropriate finishes and surface‑preparation methods. Students complete an exit ticket summarising one test and its implication for a chosen coating. For homework, they research a real‑world case where test data altered the finish specification.