Learn/NECO SSCE/Syllabus/Metal WorkStudy this course in LearnPractice opens in your NECO SSCE workspace after you sign in. Questions and lecture notes stay there.Practice this courseOpen lecture notesOfficial rules, eligibility, and dates stay on the NECO SSCE guide.course outlineGeneral safety in the workshop.Potential sources of accidents. Measures to avoid accidents.Personal safety. Safety clothings: goggles apron, gloves, boots with hard toe caps, helmet.Safety rules and precautions in a metal workshop.Metals.Description of metals: physical and mechanical properties.Types of Metals:Ferrous metals: pig iron, wrought iron, cast iron and steels.Non Ferrous Metals: aluminium, zinc, copper, tin and lead.Non-ferrous alloys: brass, bronze, solders and duralumin.Constituents and properties.Uses of Metals: Construction of auto bodies, frames, structural members of building and bridges.Selection of suitable metals for specific jobs.Production of MetalsTypes of metals and their ores:copper-pyrite, aluminium bauxite, iron – hematite, zinc calamine, lead - gelina, tin – tin ore (cassiterite).Methods of extraction: open pit and underground.Processes of smelting and refining: Blast furnace, Bessemer converter, open hearth, crucible, cupola electric arc and high frequency induction furnace and reverberating furnace.Forms of metal supply: billets, blooms and slabs.Hand Tools and Bench Work.Hand tools.Hand tools: care and maintenance.Measuring tools: linear and angular. Steel rule, angle plate and scriber, etc.Bench vice, hand vice, G-clamp, chuck, etc.Cold chisels, hacksaw, files, taps and dies.Engineers' hammers, mallets.Screwdrivers, spanners, drifts, etc.BenchworkFiling, chiselling, threading and sawing.Care and maintenance of toolsNeed for maintenance.Heat treatment of metals.Importance of heat treatment of metals.Heat Treatment processes.AnnealingCase hardeningHardeningTemperingNormalizingMaterials and Equipment for heat treatment of metals.Materials used as cooling media for heat treatment of metals: coal, brine, water, air, oil and ash.Equipment: furnaces, pyrometer, oven quenching tanks, blacksmith forge, oxy-acetylene flame.Tempering colours and temperature ranges.Safety precautions.Hand forging.Principles of forgingDefinition of forgingImportance of forgingTypes of forging: cold, hot and drop forging.Forging tools and Equipment.anvil, hammer, top and bottom swages, hardies, fullers, tongs and heart forge.Forging operationsfullering, upsetting, bending, drawing down, punching, flattening, cutting, twisting and swaging.Safety precautions.Foundry Work.Principles of Casting:Definition and importance of casting.Method of casting: sand casting.Materials and equipment for sand casting.Processes: pattern making (single piece, split and flat back), moulding, melting and pouring, dismantling and fettling.Core making (box, sand).Casting defects (types and causes)Safety precautions.Metal JoiningTypes: temporary and permanent.Temporary metal joining processes.Explanation, identification and uses of common fasteners: Bolts, Nuts, Pins and Screws.Soft SolderingTools and equipment. Types of joints and processes.Hard solderingTools and equipment. Types of joints and processes. Procedure for making hard soldered joints.Gas and Electric Arc Welding.Welding equipment, welding operation, welding flames. Welding techniques and safety.RivetingTools and equipment, types of rivets and joints.Safety precautions.Sheet Metalwork.Selection of materials,Low carbon sheet, galvanised sheet, tin plate, copper, aluminium and brass sheet.Standard gauges.Tools and Equipment:Stakes, Hammers, Mallets, Snips, Hand lever, Shears, Folding bar, Sand bag and Slip roll.Pattern development and cutting.Methods of Pattern development: types, layout, and cutting out of patterns.Basic Fabrication processes: Bending, Raising, Hallowing, Sinking, Expanding and Contracting.Joints and joiningTypes of joints: lap, grooves, seams.Methods of joining:Self - tapping screw.Soft soldering.SeamingSafety precautions.Machine Tools and processes.Drilling, Drilling machines and reamingDescription, types of tools and setting up.Types of drilling machines: sensitive, pillar and radial.Drilling faults & remediesGrinding, Description of grinding operations.Types of grinding wheels and setting up of grinding operation.Power sawing:Description, types of tools and machines.Setting up of machine for power sawing.Lathe and lathe turning operations.Parts and functions of the centre lathe: the bed, headstock, tailstock, carriage feed and thread cutting mechanism.Operations on the centre lathe: parting off, knurling and taper - turning.Work holding devices: 3 and 4 – jaw chucks, collets, face plates, catch plates and mandrels.other accessories, steadies and centres.Shaping MachinesTypes of shapers: swivel, tilting and universal tableParts of a shaping machine and their functionsPedestal, ram, saddle, table and driving mechanism.Cutting tools materials and holders.Cutting lubricants and coolants (soluble oil, straight cutting oil, soda solution).Care, maintenance and safety precautions.Finishes and decorative processes.Types of finishes and decorative processespolishing and buffing, spot facing, planishing, colouring, plating, etching, lacquering, pickling and enamellingDesign.Identifying the ProblemProblem areas: market, classroom, lorry park, workshop.Problem definition: benefits to be derived from finding solution(s) to the problem identified.Generating possible solutionsInvestigation procedures and possible solutions: interviews, observation, visits, reading journals, books, photographs, sketches of solution alternatives.Generation of possible solution.Selecting the best solution by: simplicity/ complexity, availability of materials and cost.Freehand sketching, working drawings, prototype, testing and production.
