Course | Madison College Outline of Instruction

32420331Metal Processes 2

Course Information

Description

This study of metals provides instruction in sheetmetal work, soldering and brazing, forging and heat treatment, grinding, tool sharpening, metal casting, MIG and TIG welding, metal fabrication and the repair of metal objects.

Total Credits

Course Competencies

Perform shop safety

Assessment Strategies

in lab performance

Criteria

you use required eye protection for welding and machine shop

you dress appropriately

you demonstrate welding safety procedures

you use the grinder and drill press safety

you protect tools, equipment and manuals

you maintain clean and organized work areas

you demonstrate conservative use of shop supplies
Perform measurement

Assessment Strategies

on a written evaluation

in the lab during a project layout procedure

Criteria

you measure with a steel rule to within the print specifications

you measure with a micrometer - English and Metric to within the print specifications

you measure with a dial caliper to within the print specifications

you measure with a dial indicator to within the print specifications

you use a digital readout (DRO) per print specifications

you layout projects to within tolerance specified on print handout
Perform grinding

Assessment Strategies

in lab performance

Criteria

you grind a drill bit with appropriate angles

you grind a lathe bit with appropriate angles

you grind the appropriate angles for a chisel, center punch and/or prick punch
Operate drill press

Assessment Strategies

in lab performance

Criteria

you select proper drill bit per application including using a tap drill chart

you calculate the RPM and set the drill press speed

you set up and drill stock per print

you ream stock per print

you counterbore stock per print

you countersink stock per print
Operate lathe

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you set up and face stock in a 3-jaw chuck, 4-jaw chuck, collet, and/or turn between centers to print specifications

you perform a threading or parting operation to print specifications

you perform a drilling and/or reaming procedure on the lathe to print specifications

you identify lathe components

you identify lathe component functions
Perform filing

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you draw file stock per print specifications

you file corner radii per print specifications

you use proper filing technique

you use file terminology
Perform threading

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you identify thread sizes

you tap stock per print

you identify parts of a thread

you use threading terminology

you identify tap drill size per tap

you perform a threading operation to print specifications
Perform oxy-acetylene welding

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you select tip size for application

you select oxygen and acetylene line pressures for tip size

you perform puddling in the flat position

you perform a corner weld in the flat position

you perform a puddle bead in the flat position

you perform a lap weld in the flat position

you perform a butt weld in the flat position

you perform an edge weld in the flat position

you perform a stringer weld with filler in the flat position

weld passes a root bend test

you use welding terminology
Perform oxy-acetylene cutting

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you select correct tip size for application

you select correct oxygen and acetylene line pressure for tip size

you perform cutting

you use welding terminology
Perform oxy-acetylene brazing

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you select correct tip size for application

you select correct oxygen and acetylene line pressure for the tip size

you perform a butt braze in the flat position

you perform a lap braze in the flat position

you perform a braze stringer in the flat position

you use welding terminology
Perform Shielded Metal Arc Welding

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you set up power source

welding is appropriate width

welding is appropriate height

welding has appropriate amount of spatter for selected electrode

welding is performed on specified metal

you perform flat position stringer beads using a E6013

you perform flat position stringer beads using a E6010

you perform flat position stringer beads using a E7014

you perform flat position stringer beads using a E7018

you perform flat position stringer beads using a E6011

you perform flat position fillet welds using a E6013

you perform flat position fillet welds using a E6010

you perform flat position fillet welds using a E7014

you perform flat position fillet welds using a E7018

weld passes a face bend test on butt welds

you identify characteristics of power supply set-up

you identify manipulation techniques for electrodes

you use welding terminology
Perform Gas Metal Arc Welding

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you explain GMAW set-up procedure

you use a welding calculator to determine proper voltage and wire feed

you calculate the wire feed speed of an unknown wire feeder

you use welding terminology

you set up MIG welding machine

you perform all welds on specified material

you perform a lap joint fillet weld

you perform a outside corner weld

you weld an exhaust pipe lap joint as if mounted on a vehicle

welding is appropriate width

welding has appropriate amount of spatter for selected electrode

welding is appropriate height
Perform Gas Tungsten Arc Welding

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you explain GTAW set-up procedure

you use a welding calculator to determine proper amperage and gas flow rate

you use welding terminology

you set up constant voltage welding machine

you select appropriate tungsten for selected material

you perform all welds on specified material

you perform a flat position puddle bead on aluminum using filler

you perform a flat position puddle bead on aluminum without filler

you perform a flat position puddle bead on stainless steel using filler

you perform a flat position puddle bead on stainless steel without filler

you perform a flat position puddle bead on mild steel using filler

you perform a flat position puddle bead on mild steel without filler

welding is appropriate width

welding is appropriate height

welding has appropriate amount of spatter for selected electrode
Perform plasma arc cutting

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you identify basic plasma arc cutting functions

you set up plasma arc cutting machine

you perform a cut in sheet steel

you perform a cut in aluminum

you perform a cut in stainless steel
Perform milling

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you identify the axis of the horizontal mill

you identify the axis of the vertical mill

you calculate the speed and feed rates for the selected material in the selected mill

you mill slot in steering wheel puller project as per print using a horizontal mill

you mill stock per print using vertical mill
Perform soft soldering

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you identify the temperatures at which different soldering processes take place

you use soldering terminology

you perform correct material preparation for the soldering process

you perform the soldering process as assigned

soldering is smooth

soldering is continuous with no gaps
Perform forging

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you use forging terminology

you explain the "upsetting process"

you perform the drawing out process on the alignment bar

you perform the forging process as assigned

forging is smooth

forging is prepared to print
Perform heat treatment of carbon steel

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you use appropriate heat treatment terminology

you identify heat treatable metals

you harden rolling head bar from forging process

you temper rolling head bar from forging process

you case harden the various tips for the punch project