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General Sheet Metal Shopwork DOCUMENT RESUME ED 231 427 JC 830 237 AUTHOR Bolin, William Everet; Orsak, Charles G.', Jr. TITLE Solar Energy: Materials, Materials Handling, and Fabrication Processes: Student Material. First Edition. INSTITUTION Navarro Coll., Corsicana, Tex. SPONS AGENCY National Science Foundation, Washington, D.C. PUB DATE 82 NOTE 447p.; For related documents, see JC 830 235-240. Materials developed in consortium with North Lake College, Brevard Community College, Cerro Coso Community College, and Malaspina College. PUB TYPE Guides - Non-Classroom Use (0554 EDRS PRICE MF01/PC18 Plus Postage. DESCRIPTORS Carpentry; Class Activities; Community Colleges; *Construction (Process); Electrical Systems; *Energy Occupations; Equipment; Glass; Measurement; Measurement Equipment; Plumbing; Power Technology; Safety; Safety'EducationI Sheet Metal Work; *Solar Energy; Technical Education; Two Year Colleges;' Welding IDENTIFIERS Insulation; Soldering ABSTRACT Detigned fOr student use in "Materials, Materials Handling, and Fagrication Processes," one of 11 courses in a 2-year associate degree program in solar technology, this_manual provides readings, exercises, worksheets, bibliographies, an& illustrations .for,13 courbe moduleg. The manual, which corresponds to an instructor gbide for the same course, covervt4Opllowing topics: (1), general shop safety; (2) units of measuringi.,aAd measuring devices; (3) hand tools/power tools and fasteners; 04'4welding; (5) carpentry; (6) sheet metal; (7) roofing, flashingy ana pOch pans; (8) soldering; (9) piping practices; cloy glazing materls; (11) material coatings and materials compatability; (12) insulation; and (13) electridal practices. (AIM) *********************************************************************** Reproductions supplied by EDRS are the best that can be made' * from the arigina.1 document. *********************************************************************** Co lomme-- MATERIALS, MATERIALS HANDLING AND FABRICATION PROCESSES Student Materia I rot "PERMISSION TO REPRODUU THIS MATERIAL HAS BEEN GRANTED BY C.G. Orsak TO THE EDUCATIONAL RESOURCES INFORMATION CENTER (ERIC)." U.S. DEPARTMENT OF EDUCATION NATIONAL INSTITUTE OF EDUCATION EDUCATIONAL RESOURCES INFORMATIDN CENTER tERlC This document has been reproduced as received from the person or organization originating it Minor changes have been made to improve reproduction quality Points of view or opinions stated in this docu ment do not necessarily represent official NIE position or policy NAVARRO COLLEGE CORSICANA/ TEXAS , Student Material MATERIALS, MATERIALS HANDLING, AND FABRICATION PROCESSES PRIME AUTHOR William Everet Bolin PROJECT DIRECTOR Charles G. Orsak, Jr. Navarro College TECIINICAL COORDINATORS William Everet Bolin North Lake-College Stephen Pamroy Navarro College Ray Mudrak Brevard Community College Jeff Jacobs Cerro Coso Community College Dr. Jim Slater Malaspina College FIRST EDMON 1982 Neither the United States Government, National'cience Foundation, nor Navarro College, its contractors or empZoyees makes any warrantY, expressedor implied% or assumes any legal obligation, liability or responsibility for the accuracy, completeness,or usefulness of the information presented, or represents that its use would,not infringe privately owned rights. Brand names, companynames, trademarks,, or other identifying symbols appearing in the test are used to clarify and identify and do not constitutea recommendation or endorsement. Materials developed by Navarro College in consortium with North Lake College, Brevard Community College, Cerro Coso Community College, Malaspina College, in cooperation with The National Science Foundation Project No. SED 80-19327. 114 MATERIALS, MATERIALS HANDLING AND FABRICATION PROCESSES Student Material CONTENTS Preface e .v AcknoUledgments. ...... ........ vii Use of Student Materials ix General Shop Safety IV-S-1 Units of Measuring and Measuring Devices IV-S-21 Hand Tools/Power Tools and Fasteners IV-S-35 Welding IV-S-63 Carpentry IV-S-95 Sheet Metal IV-S-141 Roofing, Flashing and Pitch Pans IV-S=173 Soldering IV-5-219 Piping Practices IV-S-237 Glazing Materials. IV-S-269 Material Coatings, Materials Compatability IV-S-329 Insulation fv-s- Electrical Practices IV-S-411 PREFACE The United States is facifig one of its most challenging decades in recent history. Fuel supply and inflationary prices have forced us to considee alternate energy sources as a means of preserving our standard Of living, industrial society, and economic stability. One such alternative is solar. Presently, foreign crude oil'provides the raw material for about one-half the liquid fuel production in the U.S. Political instability in foreign oil-producing countries underscores the need to decrease our ever-growing dependency on foreign energy sources and to lesser, our vulnerability , to such imports. Solar energy as an alternate can be used as a renewable domestic energy source and to supplement our increasing appetite for oil. To help bridg about the potential for solar energy, there must be a cadre of trained technicians to design, instafl, troubleshoot, and market solar energy so that the consumer can feel comfortable in the market's ability to service,and react to his/her solar energy needs. With the support of the National Science Foundation, Navarro College, in consortium with North Lake College, Brevard Community College, Cerro Coso Community College, and Malaspina College, has developed and pilot tested a two-year associate degree curriculum to train solar technicians. It can be duplicated or replicated by other educational institutions for their training needs. The two-year technician program prepares a person to: 1) apply knowledge to science and mathematics extensively and render direct technical assistance to scientists and engineers engaged in solar energy research and experimentation; // 2) design, plan, supervise, an& assist in installaeion of both simple and complex solar systems'and solar control devices; 3) supervise, or execute, the operation, maintenance and repair of simple and complex solar systems-and solar control systems; 4) design, plan, and estimate costs as a field representative or salesperson for a manufacturer or distributor of salar equipment; 5) prepare or interpret drawings and sketches and write specifications or'procedures for work related to solar systems; and 6) work,with and communicate with both the public and other employees regarding the entire field of solar energy. This curriculum consists of nine volumes: 1) an Instructor's Guide for the eleven solar courses, to include references, educational objectives, transparency masters, pre-tests and post-tests, and representative student labs; 2) an Implementation Guide addressing equipment, commitment, and elements to be considered before setting up a solar program; '3) Student Material for each of seven of the core solar courses: a) Materials, Materials Handling, and Fabrication Processes; b) Sizing, Design, and Retrofit; c) Collectors and Energy Storage; 0 Non-Residential Applications; e) Energy Conservation and Passive Design; f) Codes, Legalities, Consumerism, and Economics; g) Operational Diagnosis. ACKNOWLEDGMENTS Throughout this project, many people and institutions have contributed ,greatly to the development, pilot test, and completion of the solar technology curriculum. First, this project owes a debt of gratitude to the National Science Foundation whose support and encouragement have made thie project possible. Specifically, two individuals formerly with the National Science Foundation deserve recognition: Dr. Bill Aldridge and Dr. Gregg Edwards. Appreciation is° extended to thos members who served on the Advisory Committee and provided valuable input to module content, text format, and the pilot test plan and evaluation: Tom Hindes, (Chair for Phase II and III), Ohio State University. Dr. Phil DiLavore, (Chair for Phase I), Indiana State University. Dr. David Gavenda, University of Texas at Austin. Dr. Milton E. Larson, Colorado State University. Dr. Jeff Morehouse, Science Applications, Inc. Glenn Meredeith, President, Ham-Mer Consulting Ehgineers, Inc. Pearley Cunningham, Community College of Allegheny County. Dr. Max Jobe, (Evpluator), East Texas State University. It would have been impossible to complete this project andall the curriculum materials if it had not been for the Technical Coordinators and the Cooperating Institutions in this Consortium: William Everet Bolin, North Lake College, Dallas, Texas. Ray Mudrak, Brevard Community College, Titusville, Florida. Stephen Pomroy, Navarro College, Corsicana, Texas. Jeff Jacobs, Cerro Coso Community College, Ridgecrest,California. Dr. Jim Slater, Malaspina College, Nanaimo, British Columbia. A special thanks is sent to Dr. Pete Signell and hisstaff, Tom Burt and Jodee Fortino, and the resources at Michigan StateUniversity for their help in providing computer assistance to produce the printed-masters for the project and permanently store the curriculum intheir data bank. There are others who have contributed to the content, technicalauthority, and clerical tasks of the project who have made this alearning experience for us all: Charles Younger Mike Lowenstein (Director Phase I) Jim Knowles Art Meyers (Director Phase II) Bunnie Thompson Kay Garrett 'Shirley Farrow Pam Scarrow Julius Sigler Elna Baird Wayne Silva Sandra Foster Kevin O'Conner Estelle Alan Boyd Cynthia Bolin Pete Fry Jeremy Pereira Bob Takacs Carol Mitchell My personal thanks go to Bill Bolin for all hishelp, and to my wife
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