Module - IntroductioninMetalWork
Module - IntroductioninMetalWork
Ignacio
E-mail Address: [email protected]
Module 1
Topic 1 Introduction in Metal Works
Overview
Course Description
This course deals with the various welding techniques in the industry,
including gas metal arc welding. In addition, an introduction to machining is also
provided to the students.
I. Objectives
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This is said to be the largest weldment made in this time period. The
metalworking method of forging was becoming a common process used for all
types of metal that could be forge-welded. This method was used in blacksmithing
even in the 20th century. My grandfather made very strong fireplace tools in the
1940s by forging (Figure 2). Today it is us.
Gas welding, brazing, and cutting with oxygen and coal gas (would be good
for West Virginia) or hydrogen came into their own in the late 1800s. Because of
its low flash point and its expansion in any conventional container, storing
acetylene was a problem. At one time an attempt was made to store it in a glass
bottle. This proved to be catastrophic. Then a steel container was used, and it also
was a failure.
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The safest method at the time was to place the gas in a steel container
filled with a concrete-like substance. The gas was absorbed in the porous material
and became relatively stable. Later, a cylinder that contained a much lighter
substance, similar to acoustic ceiling material, was found to be just as safe. This
storage method continues to be used today.
In the 1960s a fellow from Weston, W. Va., developed a torch that used
gasoline and oxygen. He believed that it was safer than acetylene and much less
expensive. It never really caught on because temperature variations caused liquid
to be dispersed from the torch at times, which sparked fires adjacent to the
operation mostly by artists at arts and crafts fairs.
World War I actually was the big push for the need for welding. The cost
and efficiency of welding far outweighed those of the riveting process. Riveting
required removing some material, and it was a two-person operation. Rosie the
Riveter became Rosie the Welder.
Ships were being built in the U.S. and Europe using arc welding. This activity
called for definition and standardization of welding language and usage.
In 1919 the American Welding Society was formed by the Wartime Welding
Committee. A gentleman named Comfort Avery Adams led the effort and helped
set the society's goals based on the criteria that it be "dedicated to the
advancement of welding and allied processes." This mission statement remains
broadly the same on the society's membership certificate.
Figure 2
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Metalwork
Many of the technical processes in use today are essentially the same as
those employed in ancient times. The early metalworker was familiar, for example,
with hammering, embossing, chasing, inlaying, gilding, wiredrawing, and the
application of niello, enamel, and gems.
All decorative metalwork was originally executed with the hammer. The
several parts of each article were hammered out separately and then were put
together by means of rivets, or they were pinned on a solid core (for soldering had
not yet been invented). In addition, plates of hammered copper could be shaped
into statues, the separate pieces being joined together with copper rivets. A life-
size Egyptian statue of the pharaoh Pepi I in the Egyptian museum, Cairo, is an
outstanding example of such work.
Embossing, or Repoussé
Embossing (or repoussé) is the art of raising ornament in relief from the
reverse side. The design is first drawn on the surface of the metal and the motifs
outlined with a tracer, which transfers the essential parts of the drawing to the
back of the plate. The plate is then embedded face down in an asphalt block and
the portions to be raised are hammered down into the yielding asphalt. Next the
plate is removed and re-embedded with the face uppermost. The hammering is
continued, this time forcing the background of the design into the asphalt. By a
series of these processes of hammering and re-embedding, followed finally by
chasing, the metal attains its finished appearance. There are three essential types
of tools—for tracing, for bossing, and for chasing—as well as a specialized tool, a
snarling iron or spring bar, which is used to reach otherwise inaccessible areas.
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Chasing
Engraving
Inlaying
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been moistened with a flux (a substance used to promote fusion), some of the
powder is spread on it and the metal strongly heated; the niello melts and runs
into the engraved channels. The excess niello is removed by scraping until the
filled channels are visible, and finally the surface is polished.
Enameling
Gilding
Gilding is the art of decorating wood, metal, plaster, glass, or other objects
with a covering or design of gold in leaf or powder form. The term also embraces
the similar application of silver, palladium, aluminum, and copper alloys.
Metals can initially be divided into two general classifications, and Steelworkers
work with both: ferrous and nonferrous metals.
Ferrous metals are those composed primarily of iron (atomic symbol Fe) and iron
alloys.
Nonferrous metals are those composed primarily of some element or elements
other than iron, although nonferrous metals or alloys sometimes contain a small
amount of iron as an alloying element or as an impurity.
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Ferrous Metals
Ferrous metals include all forms of iron and iron-base alloys, with small
percentages of carbon (steel, for example), and/or other elements added to
achieve desirable properties. Wrought iron, cast iron, carbon steels, alloy steels,
and tool steels are just a few examples. Ferrous metals are typically magnetic.
Iron
Iron ores are rocks and minerals from which metallic iron can be economically
extracted. The ores are usually rich in iron oxides and vary in color from dark grey,
bright yellow, deep purple, to rusty red. Iron ore is the raw material used to make
pig iron, which is one of the main raw materials used to make steel. Ninety-eight
percent of the mined iron ore is used to make steel.
Iron is produced by converting iron ore to pig iron using a blast furnace. Pig iron
is the intermediate product of smelting iron ore with coke, usually with limestone
as a flux. Pig iron has very high carbon content, typically 3.5–4.5%, which makes
it very brittle and not useful directly as a material except for limited applications.
From pig iron, many other types of iron and steel are produced by the addition or
deletion of carbon and alloys. The following briefly presents different types of iron
and steel made from iron. Steelworker Advanced will present additional
information about their properties.
Pig Iron — comparatively weak and brittle with limited use. Approximately ninety
percent is used to produce steel, although cast-iron pipe and some fittings and
valves are manufactured from pig iron.
Wrought Iron — made from pig iron with some slag mixed in during
manufacture, it is almost pure iron. Wrought iron usage diminished with the
increasing availability of mild steel in the late 19th century. Some items
traditionally produced from wrought iron included rivets, nails, chains, railway
couplings, water and steam pipes, nuts, bolts, handrails, and ornamental
ironworks. Many products still described as wrought iron, such as guardrails and
gates, are made of mild steel.
Cast Iron — any iron containing greater than 2% carbon alloy. It tends to be
brittle, except for malleable cast irons. Cast irons have a wide range of
applications, including pipes, machine and automotive industry parts such as
cylinder heads, cylinder blocks, and gearbox cases. A malleable cast iron is
produced through a prolonged annealing process.
Ingot Iron — a commercially pure iron (99.85% iron). It is easily formed, with
properties practically the same as the lowest carbon steel. In iron, the carbon
content is considered an impurity; in steel, the carbon content is considered an
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alloying element. The primary use for ingot iron is for galvanized and enameled
sheet.
Steel
Of all the different metals and materials that Steelworkers use, steel and
steel alloys are by far the most used and therefore the most important to study.
The development of the economical Bessemer process for manufacturing steel
revolutionized the American iron industry. Figure 1-1 shows the container vessel
used for the process.
With economical steel came skyscrapers, stronger and longer bridges, and
railroad tracks that did not collapse.
Steel is manufactured from pig iron by decreasing the amount of carbon and other
impurities and adding specific and controlled amounts of alloying elements during
the molten stage to produce the desired composition.
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Carbon steel is a term applied to a broad range of steel that falls between the
commercially pure ingot iron and the cast irons. This range of carbon steel may be
classified into four groups:
Low-Carbon Steel — tough and ductile, easily machined, formed, and welded,
but does not respond to any form of heat-treating except case hardening.
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Nonferrous Metals
*CAUTION
When working with lead, take proper precautions!
Lead dust, fumes, or vapors are highly poisonous!
Zinc — used on iron or steel in the form of a protective coating called galvanizing.
Tin — used as an important alloy adding resistance to corrosion.
Aluminum — easy to work with; good appearance; light in weight; needs alloys
added to increase strength.
Duralumin — one of the first strong structural aluminum alloys; now classified in
the metal working industries as 2017-T; “T” indicates heat-treated.
Alclad — a protective covering of a thin sheet of pure aluminum rolled onto the
surface of an aluminum alloy during manufacture.
Monel — an alloy in which nickel is the major element; harder and stronger than
either nickel or copper; acceptable substitute for steel in systems where corrosion
resistance is the primary concern
K-Monel — developed for greater strength and hardness than Monel; comparable
to heat-treated steel; used for instrument parts that must resist corrosion.
Inconel — provides good resistance to corrosion and retains its strength at high-
operating temperatures; often used in the exhaust systems of aircraft engines.
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Non-metals
Plastics
These are synthetic materials which can be moulded into desired shapes
under pressure with or without application of heat. These are now extensively
used in various industrial applications for their corrosion resistance, dimensional
stability and relatively low cost.
There are two main types of plastics:
a) Thermosetting plastics- Thermosetting plastics are formed under heat
and pressure. It initially softens and with increasing heat and pressure,
polymerisation takes place. This results in hardening of the material.
These plastics cannot be deformed or remoulded again under heat and
pressure. Some examples of thermosetting plastics are phenol
formaldehyde (Bakelite), phenol-furfural (Durite), epoxy resins, phenolic
resins etc.
b) Thermoplastics- Thermoplastics do not become hard with the
application of heat and pressure and no chemical change takes place.
They remain soft at elevated temperatures until they are hardened by
cooling. These can be re-melted and remoulded by application of heat
and pressure. Some examples of thermoplastics are cellulose nitrate
(celluloid), polythene, polyvinyl acetate, polyvinyl chloride ( PVC) etc.
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Assessment
A. Steel erector
B. Iron placer
C. Steel fabricator
D. Ironworker
A. steel
B. iron
C. nickel
D. copper
A. magnetic
B. nonmagnetic
C. copper colored
D. alloy-free
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4. Which type of iron is one of the main raw materials used to make steel?
A. Ingot
B. Cast
C. Pig
D. Wrought
A. Steel
B. Cast iron
C. Copper
D. Wrought iron
7. Cast iron is any iron containing greater than _____ alloy.
A. .5%
B. 1%
C. 1.5%
D. 2%
A. Remelting
B. Annealing
C. Plating
D. Alloying
9. What group of steel is best suited for the manufacture of crane hooks and
axles?
A. High carbon
B. Medium carbon
C. Mild carbon
D. Low carbon
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13. What common alloy steel is used to make high-quality hand tools?
A. Nickel steel
B. Chromium steel
C. Chrome Vanadium steel
D. Tungsten steel
14. Which of the following metals is nonferrous?
A. Cast iron
B. Carbon steel
C. Aluminum
D. Pig iron
A. Copper-Zinc
B. Copper-Lead
C. Copper-Aluminum
D. Copper-Tin
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16. What action does the letter “T” signify when used in conjunction with a
numbering system that classifies different aluminum alloys?
17. What manufacturing marks can you look for when a metal’s color does not
provide positive identification?
18. When applying the spark test to a metal, you notice the spark stream has
white shafts and forks only. What does this condition indicate about the
metal under test?
A. It is a high-carbon steel.
B. It is a low-carbon steel.
C. It is a nickel alloy.
D. It is a molybdenum alloy.
19. What metal produces a spark stream about 25 inches long with small and
repeating sparklers of small volume that are initially red in color?
A. Nickel
B. Stainless steel
C. Grey cast iron
D. Monel metal
20. Which of the following metals produces the shortest length spark stream?
A. High-carbon steel
B. Low-carbon steel
C. White cast iron
D. Nickel
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References
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