Metals

Course Number: 715

The first six lessons of this course focus on the two most important commercial metals-iron and steel. Their origins, properties, and uses are described and shown in illustrations. The end of the course provides an overview of eight other important metals, their properties and uses, ranging from copper and aluminum to tin and zinc. In its entirety, this course provides a thorough overview of the principal metals in commercial use.

Recommended Contact Hours - 15

Chapter 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.

Chapter 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.

Chapter 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.

Chapter 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.

Chapter 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.

Chapter 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.

Chapter 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.

Chapter 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.

Chapter 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.

Chapter 10: Lead, Nickel, Tin, and Zinc

Topics: Lead properties, forms, and production; Nickel production and alloys; Tin properties, alloys, solder, babbit, and bronze; Zinc production and machining

Learning Objectives:

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