Metals in the Plant

Table of Contents

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:

• 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.

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