Metalwork: A Comprehensive Guide to Skills and Techniques
Table of Contents
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:
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Differentiate ferrous (iron-based) vs. non-ferrous metals.
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Explain alloys (brass, bronze, solder).
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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
2. Safety
Competencies:
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Follow workshop safety protocols.
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Use tools and materials safely.
Key Topics: ✔ Accident prevention ✔ Hazardous material handling ✔ Machine tool safety
3. Tools
Competencies:
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Identify measuring, marking, cutting, and holding tools.
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Demonstrate basic manipulative skills.
Key Tools: ✔ Calipers, scribers, hacksaws ✔ Vices, clamps, chisels
4. Bench Work
Competencies:
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Perform cutting, filing, threading, and chiseling.
Key Processes: ✔ Internal/external thread cutting ✔ Sheet metal sizing ✔ Hacksaw types and uses
5. Manufacturing Processes
Competencies:
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Understand forging, sand casting, and die casting.
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Identify casting defects.
Key Terms: ✔ Pattern preparation ✔ Melting/pouring equipment
6. Machine Tools & Processes
Competencies:
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Operate lathes, milling machines, and grinders.
Key Machines: ✔ Power drills, grinding machines
7. Joining Processes
Competencies:
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Compare arc vs. gas welding.
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Apply soldering, brazing, and fastening.
Key Topics: ✔ Welding hazards (arc eye, fumes) ✔ Riveting faults and fixes
8. Heat Treatment
Competencies:
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Explain annealing, hardening, and tempering.
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Perform case hardening.
Key Processes: ✔ Stress relieving ✔ Quenchant selection
9. Plastics
Competencies:
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Differentiate thermoplastics vs. thermosetting.
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Demonstrate injection molding.
10. Finishes
Competencies:
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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
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Highest weightings: Manufacturing, Joining, and Machine Tools (14% each).
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60% of the assessment focuses on applied and critical thinking (Levels 3 & 4).
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Safety and material knowledge are foundational (Levels 1 & 2).
Practical Tips:
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Practice welding and casting in supervised workshops.
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Use flowcharts to compare heat treatment processes.
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Memorize tool types with flashcards.