Course | Madison College Outline of Instruction

32462335Metal Processes for Maintenance

Course Information

Description

Includes machine shop operations, sheet metal work, soldering and brazing, forging and heat treatment, grinding, tool sharpening, metal casting and other metal applications as related to industrial machinery repair.

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

you sign safety contract as per instructor
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 using computer operated digital measuring tools

you use a digital readout (DRO) per print specifications

you layout projects to within tolerance specified on print handout
Use basic types of hand metal cutting tools

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you identify the appropriate chisel or punch for the assigned task

you demonstrate the selection and use of the appropriate saw blade

you demonstrate the selection and use of the appropriate shear

you demonstrate the selection and use of the appropriate aviation snips

you follow all personal and environmental safety practices

you perform basic hand metal cutting operations appropriately
Determine the properties of various types of metals

Assessment Strategies

through written evaluation

in a lab performance

Criteria

you explain the physical properties of different types of metals

you explain the mechanical properties of different types of metals

you determine the hardness of metal of different types of metals

you determine what makes metals heat treatable

you identify different types of metals

you investigate what happens to metal as it is heated
Perform grinding

Assessment Strategies

in lab performance

Criteria

you dress grinding wheels

you grind a drill bit with appropriate angles

you grind a lathe bit with appropriate angles

you grind the appropriate angles for a chisel

you grind the appropriate angles for a center punch

you grind the appropriate angles for a prick punch

you surface grind a straight edge
Sharpen drill bits

Assessment Strategies

in lab performance

Criteria

you manufacture a drill gauge

you sharpen twist drill by hand using the drill gauge

you sharpen twist drill by machine using the drill gauge
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 specifications

you ream stock per print specifications

you counterbore stock per print specifications

you countersink stock per print specifications
Operate lathe

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you identify lathe components

you identify lathe component functions

you set up and face stock in a 3-jaw chuck to print specifications

you set up and face stock in a 4-jaw chuck to print specifications

you set up and face stock in a collet to print specifications

you set up and face stock in a turn between centers to print specifications

you perform a threading operation to print specifications

you perform a parting operation to print specifications

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

you perform knurling on the lathe to print specifications
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 filing terminology

you use file card to clean files
Perform threading

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you identify thread sizes (UNC, UNF, UNXF, ANC, ANF, ANXF, ACME, Square, NPT, Metric)

you tap stock per print specifications

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 stringer weld with filler 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

weld passes a root bend test

you use welding terminology and symbols
Perform broaching

Criteria

you identify broach sizes

you tool up the selected device for broaching in the hydraulic press

you perform the broaching process on the selected device to print specifications

you measure the selected device to ensure that it is within tolerances in the print specifications
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 straight cutting of 1/4" hot rolled steel

you perform hole cutting of 1/4" hot rolled steel

you identify drag lines and kerf of your oxy-acetylene cut

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 braze stringer in the flat position

you perform a butt braze in the flat position

you perform a lap braze in the flat position

you face bend butt braze project to meet specifications

you use All-State brazing rod to perform penetration test
Perform Shielded Metal Arc Welding

Assessment Strategies

in lab performance

on a written evaluation

Criteria

you identify characteristics of power supply set-up

you set up power source

you identify manipulation techniques for electrodes

welding is appropriate width

welding is appropriate height

welding has appropriate amount of spatter for selected electrode

you perform horizontal position stringer beads using a E6011

you perform vertical position stringer beads using a E6011

you perform horizontal position fillet welds using a E6011

you perform vertical position fillet welds using a E6011

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 welding terminology

welding is appropriate width

welding is appropriate height

welding has appropriate amount of spatter for selected electrode

you calculate the wire feed speed of the wire feeder

you set up MIG welding machine

you perform all welds on specified material

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

you perform flat bead weld

you perform a lap joint fillet weld

you perform a outside corner weld

you perform a butt joint weld

you perform a fillet joint weld

you perform root bend test on welded joint
Perform Gas Tungsten Arc Welding

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you explain GTAW set-up procedure

you use welding terminology

welding is appropriate height

welding is appropriate width

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

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 has appropriate amount of spatter for selected electrode

you perform root bend test on welding project
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

you perform strength test on solder project.
Manufacture tool boxes and sheet metal guards

Assessment Strategies

on a written evaluation

in lab performance

Criteria

you use sheet metal terminology

you shear sheet metal for tool box layout

you transfer measurements and lay out hems, bends and cut-outs for tool box

you use hand shears to cut tool box blank

you hem the tool box blank on the hemming machine

you fold the tool box blank on the apron or cornice brake

you fold tool box on box and pan brake to complete to specifications

you spot weld tabs and corners using the electric spot welder

you solder corners and joints to water tight specifications
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

This Outline is under development.