Lesson 1 - Introduction to Metals

Topics:

Metals and metallurgy; Alloys; Internal structure of metals; Casting; Metalworking; Joining metals

Learning Objectives:
– Name five metals or alloys commonly used in industry.
– Name five mechanical properties of metals.
– Describe the uses of three metal alloys.
– Describe the metalworking processes of casting, forming, and machining. 

Lesson 2 - Properties of Metals

Topics:

Hardness; Ductility; Malleability; Toughness; Tensile strength; Stresses; Elasticity; Strain; Metal fatigue; Thermal expansion; Density

Learning Objectives:

– State the definitions of four mechanical properties of metals.
– Describe the three kinds of stress.
– List the ways in which a metal can fail.
– State the definition of elasticity.
– Demonstrate how to calculate the density of metal.

Lesson 3 - Manufacturing Processes

Topics:

Forging; Extrusion; Powder and sheet metal forming; Wire drawing

Learning Objectives:
– Name four kinds of molds used in casting.
– List the steps in making a sand mold.
– Describe the differences between hot-chamber and cold-chamber die casting.
– Describe extrusion.
– List the steps involved in making a part by powder metallurgy.

Lesson 4 - Iron and Steel

Topics:

Iron ore; Pig iron; Smelting; Cast, gray cast, white cast, malleable cast, ductile cast, and high-alloy cast iron; Steel

Learning Objectives:
– Name the commercial grades of cast iron.
– List the important mechanical properties of commercial grades of cast iron.
– Describe the forms in which carbon appears in commercial grades of cast iron.
– Describe the process of smelting.

Lesson 5 - Standard Steels

Topics:

Carbon in steels; Steel rolling, coding, and classification; Spark testing; Plate, strip, sheet steel; Structural steel; Alloy and stainless steel

Learning Objectives:
– State the definition of steel.
– Name the method by which a steel was made, based on its AISI code.
– Demonstrate how to conduct a spark test.
– Identify steel sheets having as-rolled edges and cut edges.
– Describe two differences between alloy steels and steels containing only iron and carbon.

Lesson 6 - Heat Treatment

Topics:

Welding; Repairing tools and machines; Castings; Forgings; Carbon content of steels; Science of heat treatment

Learning Objectives:
– Describe the two basic processes, and state the four major purposes, of heat treatment.
– Explain why distortion and cracking occur during welding.
– Explain how to anneal, harden, and temper a star drill.
– State the definitions of low-carbon, medium-carbon, and high-carbon steels.

Lesson 7 - Copper

Topics:

Production; Alloys; Machinability ratings; Electrical conductivity; Corrosion resistance; Annealing copper; Brasses; Bronzes; Casting

Learning Objectives:
– List the steps in producing copper from ore.
– List the contents of brass, Muntz metal, admiralty brass, bronze, nickel silver, aluminum bronze, and cupro-nickel.
– Describe dezincification in brass.
– Name the three groups of brasses, based on their zinc content, and the three categories of hardness.
– List the contents of red brass, and describe its uses.

Lesson 8 - Aluminum

Topics:

Properties and production; Alloys; Grades; Forming processes; Anodizing; Welding; Brazing and soldering; Safety

Learning Objectives:
– List advantages and disadvantages of the oxide coating on aluminum.
– State the definition of wrought-grade and casting-grade aluminums.
– Describe the advantages of aluminum-silicon alloys.
– Describe how aluminum is anodized.
– Name the classifications of aluminum solders.

Lesson 9 - Magnesium and Titanium

Topics:

Producing, extracting, melting, refining, alloying, extruding, rolling, forging, machining, and joining magnesium; Uses for and processing of titanium

Learning Objectives:

– Name the alloys of magnesium and titanium.
– List the useful properties of magnesium and titanium.
– Describe how to join magnesium alloys.
– Describe the precautions that must be taken when working with magnesium and titanium.
– Describe the uses of magnesium and titanium in industry.

Lesson 10 - Lead, Nickel, Tin, and Zinc

Topics:

Using, producing, fabricating, and joining lead; Using and producing nickel; Nickel alloys; Using and producing tin; Properties of tin; Tinplate; Tin alloys; Tin solders; Babbitt; Bronze; Using, producing, and machining zinc

Learning Objectives:

– Describe the properties and characteristics of lead.
– List the properties that are improved by adding nickel to stainless steel.
– Describe how tinplate in manufactured.
– Describe how zinc is refined and processed.