Table of Contents

Metalwork: A Comprehensive Guide to Skills and Techniques

Introduction to Metalwork
Content Areas & Competencies
Assessment Breakdown
Key Takeaways

Introduction

Metalwork is a foundational skill in engineering and manufacturing, covering material properties, fabrication techniques, and safety protocols. This guide breaks down core competencies, tools, and processes for learners and professionals.

Content Areas & Competencies

1. Materials

Competencies:

Differentiate ferrous (iron-based) vs. non-ferrous metals.
Explain alloys (brass, bronze, solder).
Describe properties and uses of metals (steel, aluminum, copper).

Key Topics:
✔ Steel types (mild, carbon, stainless)
✔ Non-ferrous metals (zinc, lead, tin)
✔ Alloy compositions and applications

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2. Safety

Competencies:

Follow workshop safety protocols.
Use tools and materials safely.

Key Topics:
✔ Accident prevention
✔ Hazardous material handling
✔ Machine tool safety

3. Tools

Competencies:

Identify measuring, marking, cutting, and holding tools.
Demonstrate basic manipulative skills.

Key Tools:
✔ Calipers, scribers, hacksaws
✔ Vices, clamps, chisels

4. Bench Work

Competencies:

Perform cutting, filing, threading, and chiseling.

Key Processes:
✔ Internal/external thread cutting
✔ Sheet metal sizing
✔ Hacksaw types and uses

5. Manufacturing Processes

Competencies:

Understand forging, sand casting, and die casting.
Identify casting defects.

Key Terms:
✔ Pattern preparation
✔ Melting/pouring equipment

6. Machine Tools & Processes

Competencies:

Operate lathes, milling machines, and grinders.

Key Machines:
✔ Power drills, grinding machines

7. Joining Processes

Competencies:

Compare arc vs. gas welding.
Apply soldering, brazing, and fastening.

Key Topics:
✔ Welding hazards (arc eye, fumes)
✔ Riveting faults and fixes

8. Heat Treatment

Competencies:

Explain annealing, hardening, and tempering.
Perform case hardening.

Key Processes:
✔ Stress relieving
✔ Quenchant selection

9. Plastics

Competencies:

Differentiate thermoplastics vs. thermosetting.
Demonstrate injection molding.

10. Finishes

Competencies:

Apply electroplating, galvanizing, and bluing.

Key Terms:
✔ Surface preparation
✔ Corrosion resistance

Assessment Breakdown

Cognitive Levels Weighting:

Content Area	Recall (15%)	Skill (25%)	Strategic Thinking (30%)	Extended Thinking (30%)	Total
Materials	1	2	3	3	9%
Manufacturing Processes	2	4	4	4	14%
Joining Processes	2	4	4	4	14%
Heat Treatment	2	2	2	3	9%
Total	15%	25%	30%	30%	100%

Key Takeaways

Highest weightings: Manufacturing, Joining, and Machine Tools (14% each).
60% of the assessment focuses on applied and critical thinking (Levels 3 & 4).
Safety and material knowledge are foundational (Levels 1 & 2).

Practical Tips: