IND4-4 selects and uses a range of relevant materials for specific purposes
Whilst undertaking activities in the metals workshop you will encounter and work with a variety of different metals. This range of materials utilised attempts to take advantage of the different material properties embodied in each. Individual metals each have different properties, making some more suitable than others for a certain purpose.
The metals listed below are commonly found in high school metalwork rooms.
- Pure metals: consisting entirely of that one metal, which you will find on the periodic table in Science.
- Alloys: consist of two or more metals mixed together to form a different type of metal.
- Coated metals: these being one metal coated with another.
Complete the learning activity in your workbooks by researching the appearance, composition, and uses of a variety of listed materials.
Aluminium is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one-third that of steel. Aluminium is a natural element and can be found on the periodic table. This metal is commonly mixed with copper and zinc to create other alloy materials. Aluminium is a lightweight material used to manufacture cans for food products and building products such as window frames.
Copper is a chemical element with the symbol Cu (from Latin: cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkish-orange color. Copper is used as a conductor of heat and electricity, as a building material, and as a constituent of various metal alloys, such as sterling silver used in jewelry, cupronickel used to make marine hardware and coins, and constantan used in strain gauges and thermocouples for temperature measurement.
Copper is one of the few metals that can occur in nature in a directly usable metallic form (native metals). This led to very early human use in several regions, from c. 8000 BC. Thousands of years later, it was the first metal to be smelted from sulfide ores, c. 5000 BC; the first metal to be cast into a shape in a mold, c. 4000 BC; and the first metal to be purposely alloyed with another metal, tin, to create bronze, c. 3500 BC.
The term Mild Steel applies to all low carbon steel that does not contain any alloying elements in its makeup and has a carbon content that does not exceed 0.25%. Bright mild steel bar is usually a carbon steel alloy which has had the surface condition improved by drawing, peeling or grinding over the hot rolled finish supplied by the steel mill. Mild Steel is used in mechanical engineering applications for parts that will not be subject to high stress. Compared to normal Mild Steel, bright Mild Steel provides tighter sectional tolerances, increased straightness, and a much cleaner surface. The main advantage of cold drawn Steel is that Steel can be brought closer to the finished machine size, providing reduce machining costs. Another benefit of bright Steel bars is a marked increase in physical strength over hot rolled bars of the same section.
Black mild steel is steel direct from a hot rolling forming process, which still has a scale coating on its surface, is not precise in its dimensions, nor straightness or flatness. It is used for general non-critical work, especially where welding is performed. Black Mild steel has a dark blue oily surface and is not as accurate as bright mild steel because bright steel undergoes additional processes to produce higher quality material. Mild steel is reasonably soft and ductile. It is easily cut and machined and is a good material to practice welding on. The reason for this is its carbon content, which varies between 0.15% and 0.3%. Some of the uses of Mild Steel are Ship Hulls, Garden Gates, Girders, General Structural Steel, etc.
Stainless Steels is also classed as an Alloy Steel. The main alloying elements are Nickel and Chromium. It has a very high resistance to corrosion and as a result is ideal for areas where clenliness is important. Resistance to corrosion and staining, low maintenance, and familiar luster make stainless steel an ideal material for many applications where both the strength of steel and corrosion resistance are required. Moreover, stainless steel can be rolled into sheets, plates, bars, wire, and tubing. These can be used in cookware, cutlery, surgical instruments, major appliances, vehicles, construction material in large buildings, industrial equipment (e.g., in paper mills, chemical plants, water treatment), and storage tanks and tankers for chemicals and food products.
Brass is an alloy of copper and zinc, in proportions which can be varied to achieve varying mechanical, electrical, and chemical properties. Brass is similar to bronze, another alloy containing copper that uses tin instead of zinc. Historically, the distinction between the two alloys has been less consistent and clear and modern practice in museums and archaeology increasingly avoids both terms for historical objects in favor of the more general "copper alloy".
Brass has long been a popular material for decoration due to its bright, gold-like appearance; being used for drawer pulls and doorknobs. It has also been widely used to make utensils due to properties such as having a low melting point, high workability (both with hand tools and with modern turning and milling machines), durability, and electrical and thermal conductivity.
Brass is still commonly used in applications where corrosion resistance and low friction are required, such as locks, hinges, gears, bearings, ammunition casings, zippers, plumbing, hose couplings, valves, and electrical plugs and sockets. It is used extensively for musical instruments such as horns and bells, and also used as a substitute for copper in making costume jewelry, fashion jewelry, and other imitation jewelry. The composition of brass, generally 66% copper and 34% zinc, makes it a favorable substitute for copper based jewelry, as it exhibits greater resistance to corrosion. Brass is not suitable for such items as boat propellers because the zinc reacts with minerals in salt water, leaving porous copper behind. The tin in bronze will not react with these minerals.
Brass is often used in situations in which it is important that sparks not be struck, such as in fittings and tools used near flammable or explosive materials
Tinplate consists of sheets of steel, coated with a thin layer of tin. Before the advent of cheap milled steel the backing metal was iron. While once more widely used, the primary use of tinplate now is the manufacture of tin cans. Tinplate is made by rolling the steel (or formerly iron) in a rolling mill, removing any mill scale by pickling it in acid and then coating it with a thin layer of tin. Plates were once produced individually (or in small groups) in what became known as a pack mill. In the late 1920s pack mills began to be replaced by strip mills which produced larger quantities more economically. Formerly, tinplate was used for cheap pots, pans and other holloware. This kind of holloware was also known as tinware and the people who made it were tinplate workers.
For many purposes, tinplate has been replaced by galvanised (zinc-coated) vessels, though not for cooking as zinc is poisonous. The zinc layer prevents the iron from rusting through sacrificial protection with the zinc oxidizing instead of the iron, whereas tin will only protect the iron if the tin-surface remains unbroken.
Galvanized iron is the same as standard iron, the only difference is that it features a layer of zinc. The added layer of zinc helps to protect the iron from rust and corrosion. Without it, the iron will be exposed to moisture and oxygen from its surrounding environment. If left unchecked, this will trigger a chemical reaction with the iron known as oxidation. Oxidation will cause the iron to rust and corrode.
Galvanised construction steel is the most common use for galvanised metal, and hundreds of thousands of tons of steel products are galvanised annually worldwide. In developed countries most larger cities have several galvanising factories, and many items of steel manufacture are galvanised for protection. Typically these include: street furniture, building frameworks, balconies, verandahs, staircases, ladders, walkways, and more. Hot dip galvanised steel is also used for making steel frames as a basic construction material for steel frame buildings.
IND4-3 identifies and uses a range of hand and machine tools to produce quality practical projects
Sheet metal guillotines are an important piece of equipment in sheet metal fabrication; they can be used to create clean, accurate cuts in sheet metal and are relatively easy to maintain. Unfortunately, they can also be dangerous machines if not used and treated correctly. Your teacher will conduct a demonstration on how to safely operate the guillotine for cutting the components of your carry tray project out of galvanised sheet metal.
The Magnabend is a machine for folding sheet metal and is a common item used in the metalwork environment. It can be used to bend both magnetic metals like galvanised steel and non-magnetic metals such as brass and aluminium. The machine is different from other folders as it clamps the workpiece with a powerful electromagnet rather than by mechanical means. The machine is essentially a long electromagnetic bed with a steel clamp bar located above. In operation, a piece of sheet metal is placed on the electromagnetic bed. The clamp bar is then placed into position and once the electromagnet is turned on the sheet metal is clamped in place by an electromagnetic force.
Steel Rules are precision measuring instruments, showing graduations at at 0.5mm, 1mm, 5mm and 10mm intervals (see adjacent image). Great care must be taken to get accurate measurements using a steel rule. Steel rules are used in woodworking for their accuracy and durability. In woodworking, it is important to be accurate to the millimetre. The rule differs from the ruler in that the zero measurement aligns exactly with the end of the rule, whereas with the ruler, it does not.
A scriber is a hand tool used in metal work to mark lines on workpieces, prior to machining. Some scribers have a point at both ends. It is used by dragging the point over the surface of the workpiece to leave a shallow scratch on its surface.
A center punch is a hand held tool with one end sharpened to a point while the other end is flat so it can be struck. This tool is struck by a hammer to mark the center of a point. It is usually used to mark the center of where you want to drill a hole. The mark, a dimple or indent, also assists to stop the drill bit from “wandering” from where you want the hole. The punch can be used by carpenters as well as metal workers.
Aviation snips are designed to cut sheet metal in a straight line(yellow) or curves to the right with the waste material on the right (green) or curves to the left with the waste material on the left (red). You can use the snips with either hand, but if you're right-handed you'll find it easier to use green snips for many types of cuts.
A mallet is a kind of hammer, often made of wood and usually has a relatively large head. Mallets are used in various industries, by carpenters, furniture makers, sheet metal workers and upholstery work. It is a tool of preference for wood workers using chisels with plastic, metal, or wooden handles, as they give a softened strike with a positive drive. The Tinsman mallet is used to shape or bend sheet metal.
A machinist square or engineer's square is the metalworkers' equivalent of a try square. It consists of a steel blade inserted and either welded or pinned into a heavier body at an angle of 90°. Usually a small notch is present at the inside corner of the square. This prevents small particles from accumulating at the juncture and affecting the square's reading. In use, the body is aligned against the one edge of the object and the blade is presented to the end or body of the object. If the end is being checked, then a strong light source behind the square will show any mismatch between the blade of the square and the end of the object. The purpose of this action is to check for squareness or to mark out the body of the workpiece.
A bench vice is an essential and integral tool used in metalworking, woodworking, and some other manufacturing applications. It is mounted on workbenches and its main function is to hold the workpiece safely and securely. It features two parallel jaws as part of the design. Keep the workpiece in the vice close as possible to the jaws to prevent vibration when sawing, filing, etc. Support the end of extra-long work with an adjustable stand, saw horse, or box rather than putting extra strain on the vice.
A panbrake or finger brake is a metalworking machine that allows the bending of sheet metal. The brake consists of a flat surface onto which the material is placed, and a clamping bar which will come down and hold the material firmly during the bend. This clamping action may be manual, automatic or operated using a foot pedal. The front, gate-like, plate of the machine is hinged and may be lifted, forcing the material extended over a straight edge to bend to follow the plate. In a box-and-pan brake (also known as a finger brake), the clamping bar includes several removable blocks, which may be removed and rearranged to permit bending of restricted areas of a piece of sheet metal or of already partially formed pieces.
Oddleg calipers are used mainly to scribe lines parallel to the edge of metal (or plastics) - they are used for much the same reason that a woodworker might use a Marking Gauge. Oddlegs can also be used to find the centre of a disc by first estimating its radius then scribing a number of arcs from different points around the circumference. The various arcs will enclose a small area in which the centre must lie and so can be judged.
Note: To make scribed lines stand out more, bright steel can be coated with Marking Blue (or a felt tipped pen) whilst black steel or rusty metal can first be rubbed with chalk.
A ball-peen or ball pein hammer, also known as a machinist's hammer, is a type of peening hammer used in metalworking. It has two heads, one flat and the other, called the peen, rounded. It is distinguished from a cross-peen hammer, diagonal-peen hammer, point-peen hammer, or chisel-peen hammer by having a hemispherical peen. The flat side is used for striking punches and chisels and the rounded head, is useful for tasks such as rounding off edges of metal pins.
IND4-5 selects and uses communication techniques when designing, making and evaluating projects and ideas
Below are a series of working drawings for you to reference while constructing the carry tray project in the metals workshop. Read through these drawings and become familiar with the dimensions and Vee notch cuts you need to complete for each component of your project prior to folding. For more detailed information on the production process, refer to the steps of construction section below these images.
IND4-2 applies a design process in the modification of projects
Mark out on the galvanised sheet steel which is 0.4 mm thick, 300mm on each edge using a scribe and steel rule.
Cut the 300mm strip of metal using the Guillotiene.
Measure and cut from that strip a 300mm square
Once the 300mm x 300mm piece of Gal. Steel is cut recheck the piece for squareness using the large builders square. If it is not square redraw the lines at 90 degrees to an edge and again recut on the Guillotine.
Mark out lines parallel to each edge of the metal in 10mm using theJenny Callipers (Odd Leg Callipers). This is marking out what will be the safety edges of the sides. This is done to make the edge of the sheet metal safer and also to make the edge stiffer and stronger.
Reset the Jenny Callipers to 15mm for the tabs that will hold the sides of the Carry Box (this 15mm is marked on the adjacent sides to the safety edges. Mark out the V Shaped notches where each bend will be formed.
Centre punch and drill a 2.5 mm dia hole at the end of each notch so that the sheet metal does not buckle when it is folded.
Using Straight Bladed Tinsnips cut out the Waste material for the notches and corners. Remember only to cut to the holes and not beyond them.
The safety edge is bent first on the Magnabend. The Gal. Metal is positioned onto the Magnabend so that the line where the bend is to be sits in the gap between the base plate and the forming bar. A mandrel plate is positioned exactly on the line to be bent. Fold to maximum angle position.
Reposition the mandrel now on top of the partial bend. Turn the Magnabend on again and this will flatten the bend completely.
Repeat steps 1 & 2 for the second safety edge.
Select the mandrel plates so that they just fit between the Safety edges so that they don’t get crushed. Now bend up the tabs to 90 degrees so that the three tabs fold at the same time.
Turn the metal around and repeat to the other side.
Reselect the mandrels so that they will fit in between the tabs (that have just been folded). Fold the side up to an angle of 90 degrees.
Repeat for the other side.
Using the drawing for the Ends for the Carry Box mark out and cut 2 pieces of Galvanised metal, they should measure 90mm tall and 210mm wide (this will depend on the accuracy of your job)
Place each End into your Base, label one end AA and the other BB. Using your own job mark the edges of the sides onto the edge of the Ends.
Using the drawing mark out the fold lines for the safety edges.
Cut the two Ends out with the Tinsnips and the guillotine (ensure you cut on the outside of the line NOT the fold lines).
Fold the safety edges on each.
Using the Spot Welder join the Ends to the Base.
Using the drawing for the Handle of the Carry Box mark out and cut 1 piece of Galvanised metal. It should measure 300mm long and 80mm wide (this will again depend on the accuracy of your job)
Mark out all fold lines using a Rule, Scriber and Jenny Callipers.
Centre Punch and drill a 2.5 mm dia hole at the end of each notch.
Using Tinsnips cut out the Waste material for the notches.
Fold the safety edges and then fold the tabs to 90 degree
Fold the sides up to 90 degrees, ensure that the outside tabs stay on the outside of the centre of the Handle.
Ensure that the handle fits between the 2 ends.
Using pliers gently fold over the top tab of the Ends to 90 degrees (inwards).
Place and hold the handle under each tab.
Carefully squash the tabs over the ends of the handle, ensure that the handle fits neatly under the tab.
Using the spot welder again, spot weld the ends of the handle onto the ends.
Using the alphabet punches, punch your name or initials into one end of your Carry Box to ensure it is easy to identify.
IND4-8 evaluates products in terms of functional use and aesthetics
In this section of your work report, you need to complete a final evaluation of your project. Follow the 'evaluate' section of the ALARM scaffold and use the template below as a guide.
You must IDENTIFY what your project is
DESCRIBE what it looks like and how it was made.
EXPLAIN how you made it and why was it done this way
ANALYSE the overall quality of your project and identify why your project is or isn’t of a good quality
EVALUATE the overall quality of the work you have done, give details of what is good and what parts are bad, and give a reason why.