Metalwork KEY WORDS METALWORK KEYWORDS Keywords with pictures to trigger your memory. A Revision tool for Junior Certificate Metalwork.

Published by Professional Development Service for Teachers (PDST) Junior Certificate School Programme Blackrock Education Centre, Kill Avenue, Dún Laoghaire, Co. Dublin Phone: 01 2365000 Email: [email protected]

First Published 2016

Copyright ©PDST, JCSP.

The Professional Development Service for Teachers (PDST), The Junior Certificate School Programme (JCSP), the Literacy and Numeracy Strategy, the Demonstration Library Project and the Delivering Equality of Opportunity in Schools (DEIS) Action Plan are funded by the Teacher Education Section of the Department of Education and Skills (DES).

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The purpose of this publication is to enhance teaching and learning within the Junior Certificate School Programme.

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Author: Alma Ui Fhlannchadha

Scoil Phobail Mhic Dara, Carna, Co.na Gaillimhe 1 NATURES MATERIAL

PERIODIC TABLE OF ELEMENTS

ELEMENTS MATERIAL

Iron (Fe) Steel

Carbon (C) Brass

Copper (Cu) PVC 2 NATURES MATERIAL

States

Solid

Liquid

Gas

LIQUID

SOLID GAS

Water

Ice Steam 3 METAL

Ferrous= With Iron

FERROUS

Iron

Steel

Mild Steel

Carbon Steel

Cast Steel

High Speed Steels

Steel Tools

Stainless Steel 4 METAL

Non-Ferrous= Without Iron

NON-FERROUS

Aluminium

Copper

Lead

Zinc

Tin

Brass

ALLOYS

Bronze Soft Solder 5 METAL

PROPERTIES OF METAL

Strength Hardness

Ductility

Stiffness Malleability

Brittle

Plasticity Elasticity

Conductivity 6 METAL

THE FURNACE

ELECTRICAL ARC FURNACE

Power cables Electrodes Hatch for iron ore, lime and other material Oxygen inlet Door for Tapping spout removing slag for molten iron

Iron ore

BASIC OXYGEN FURNACE

O2

Coolant in Fumes Out Moveable Seal

Taphole Oxygen Lance Gas Space

Steel Shell Molten Slag Molten Iron Lining 7 METAL

THE FURNACE

BLAST FURNACE

Waste Gases

Iron Ore, Coke and Limestone

Firebrick Lining

Hot Air

Molten Slag Outlet for Slag

Outlet for Iron Molten Iron 8 PLASTICS AND WOOD

THERMOPLASTICS

Acrylic Polyethelene PVC Nylon

THERMOSETTING PLASTICS

Polyester Resins Polyurethane 9 PLASTICS AND WOOD

Sawing Polishing

Filing Joining

Drilling Shaping with Heat & Bending

Tapping Pressure Shaping 10 WOOD

SOFTWOODS

Red Deal Red Cedar Parana Pine

Larch White Deal 11 WOOD

HARDWOODS

Mahogany Teak Beech

Oak Ash 12 WOOD

MANUFACTURED BOARDS

Plywood Block-Board

Chipboard Harboard 13 SAFETY

Equipment and Clothing Hair Personal Care

Shoes Dangers to Skin

Dust and Flames Eye Protection

Health Behaviour 14 SAFETY

Operating Floor Bench Machines

Protective Cleaning Storage and Measures Machines Handling

Heating Fire Fire Hazards Materials Extinguishers 15 & MEASURING

TOOLS

Scriber

Ruler

Try

Punch

Dividers

Compass

Odd Leg 16 MARKING OUT & MEASURING

TOOLS

Outside Calipers

Bevel

Engineers Protractor

Centre Square

Combination Set

Inside Calipers 17 MARKING OUT & MEASURING

TOOLS

Key Set

Surface Plate

Scribing Block

V-Block

Micrometer 18 MARKING OUT & MEASURING

TOOLS

Vernier Calipers

Wire

Thread Gauge

Radius Gauge

Feeler Blade 19 GENERAL BENCH WORK

FILING Cross Filing

Draw Filing

Square

Half Round File

Round File

Square

Triangular

TOOLS

Vises

Clamps

Bench

Hand Vise

Vise Clamps 20 GENERAL BENCH WORK

THE Handle

Tightening Nut Blade Direction of Junior Teeth Hacksaw

ENGINEERING

Ball Pein

Cross Pein

Soft Hammers 21 DRILLING

DRILLING MACHINE

Guard Motor

Stop

Column

Chuck Table

Base

Table 22 DRILLING

ELECTRIC HAND DRILL

Chuck

Electric Hand Drill Key

Drillbits 23 DRILLING

Heart (A) Centre Point

Ø Diameter (B) Pilot Hole

Flank Tapping Hole

AB Ø 24 DRILLING

CHISELLED EDGE C C Heel C

The Pad D The Shank D D

(C) Blind Hole

(D) Counterbored E E E (E) Countersunk 25 FITTING & ASSEMBLING

TAPPING

Tapping

Taper Tap

Second Tap

Plug Tap

Plug Tap 26 FITTING & ASSEMBLING

SCREWING

Die

Stock

Cutting a Thread 27 FITTING & ASSEMBLING

THREADS

A

D

C E B

(A) Crest

(B) Root

(C) Flank

(D) Pitch

(E) Thread Angle 28 THREADS, BOLTS & NUTS

Isometric (C)

Buttress (B)

Square (A)

Acme (D)

Plain Washer Plain Hex Nut 29 THREADS, BOLTS & NUTS

Bolt Lock Nut

Nylock Castle Nut

Wing Nut Spring Washer 30 SCREWS, STUDS, RIVETING

Hex Head

Cheese Head

Raised Head

Round Head

Grub Screw 31 SCREWS, STUDS, RIVETING

THREADS

Button Head

Countersunk Head

Pan Head

Flat Head

Pop Rivet 32 SPANNERS & SCREWDRIVERS

Open Spanner

Ring Spanner

Adjustabe Spanner

Stilson

Box Spanner

Socket Spanner 33 SPANNERS & SCREWDRIVERS

Flat Screwdriver

Philips Screwdriver

Pliers

Allen Key

Vise Grips SOLDERING, BRAZING 34 & GLUING

Soft Soldering

Fluxes

Soldering Irons

Sliver Solder

Pilot Light

Gas Torch

Oven

Brazing

Spelter

Brazing Flux

Brazing Fireplace

Glueing 35 COLD

Sheet Metalwork Folding Bars

Snips Groove

Mallet Stakes

Ball Pein Hammer Joints 36 COLD FORMING

Tools

Hammer or Mallet

Hollowing

Straightening

Raising

Smoothing

Turning/Twisting

Scrolls

Hallmarks 37 HOT WORKING

FORGE

Anvil Sets

Sledge Hammer Punch

Hardie Flatter 38 HOT WORKING

FIRE TOOLS HEAT TREATMENT

Slice Hardening

Poker

Rake Annealing

Forge Normalising

Crust/Face Hardening 39 LATHE WORK

LATHE

Bed Carriage

Head Stock Tool Post

Tail Stock Cutting Tools 40 LATHE WORK

WORK

FACING OFF

TURNING

DRILLING

KNURLING

PARTING OFF

COMPUTER

CNC LATHE