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). All rights reserved. The purpose of this publication is to enhance teaching and learning within the Junior Certificate School Programme. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means for commercial gain without prior written permission of the publisher. Every effort has been made to ensure that this book contains accurate information. However, PDST, JCSP, its agents and the authors shall not be liable for any loss or damage suffered by readers as a result of any information contained herein. 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 MARKING OUT & MEASURING TOOLS Scriber Ruler Try Square Punch Dividers Compass Odd Leg Calipers 16 MARKING OUT & MEASURING TOOLS Outside Calipers Bevel Engineers Protractor Centre Square Combination Set Inside Calipers 17 MARKING OUT & MEASURING TOOLS Key Set Ruler Surface Plate Scribing Block V-Block Micrometer 18 MARKING OUT & MEASURING TOOLS Vernier Calipers Wire Gauge Thread Gauge Radius Gauge Feeler Blade 19 GENERAL BENCH WORK FILING Cross Filing Draw Filing Square File Half Round File Round File Square Triangular TOOLS Vises Clamps Bench Vise Hand Vise Vise Clamps 20 GENERAL BENCH WORK THE HACKSAW Handle Tightening Nut Blade Direction of Junior Teeth Hacksaw ENGINEERING HAMMERS Ball Pein Hammer Cross Pein Soft Hammers 21 DRILLING DRILLING MACHINE Guard Motor Stop Column Chuck Table Clamp 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 Wrench 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 FORMING Sheet Metalwork Folding Bars Snips Groove Punch 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 Tempering Rake Annealing Forge Tongs 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 .