Metal and Non-metals

• Methods of identification of steel
• Non-ferrous metals and Alloys
• Copper Alloys
• Lead and its alloys
• Zinc and its alloys
• Tin and Tin Alloys
• Aluminium
• Non-Metals

Metals used in sheet metal work

• Black iron sheets
• Galvanised iron sheets
• Stainless sheets
• Copper sheet
• Aluminium sheet
• Tinned plae
• Lead sheets

Standard Wire Gauge

Common metals and alloys and their melting points

• Engineering materials may be ferrous, non-ferrous metal and alloys.

Physical and mechanical properties of metals

• Physical properties
• Mechanical properties

Weldability of metals

• Necessity of weldability of metals

Identitification of metals

• Tests to identify metals
• Identification at ferrous metals
• Identification of Non-ferrous metals

Methods of designating steel

• Steel designation based on mechanical properties
• Designation based on chemical composition
• Unalloyed steel
• Unalloyed tool steel
• Unalloyed free cutting steels
• Low and medium alloy steel
• High alloy steel
• High alloy tool steel
• High alloy free cutting steel

Colour code of metal

• Color bands and dots

Cast Iron (Types)

• Types of cast iron

Steel (Plain carbon steel)

Hardness testing methods

• Brinell hardness testing method
• Vicker hardness
• Rockwell hardness testing
• Shore hardness testing

Tensile testing method

• Tensile strength of material
• The tensile test for metals

Impact Strength

• Impact strength
• Test specimen of izod test
• Charpy test
• Test specimen for charpy test

Weld defects – causes and remedies

• Welding defects

Casting defects, causes and remedies

• Scrap diagnosis for casting

Inspection of weld (NDT) – Visual inspection

• Necessity of inspection
• Types of tests
• Visual inspection
• Visual inspection before welding
• Visual inspection during welding
• Inspection after welding
• Check points for inspection
• Measuring gauges used for inspection

Methods of Non-destructive test

• Common non-destructive testing
• Special non-destructive tests
• Visual inspection
• Leak or pressure test
• Radiographic test
• Gamma ray test
• Magnetic particle test

Destructive Test

• Nick break test
• Free bend test
• Advantages and limitations
• Examination of fractured weld
• Tensile test
• Guided bend test
• Impact test
• Fatigue test

Safety, precautions in heat treatment shop

Heat treatment of plain carbon steels

• Heat treatment process and purposes

Hardening and tempering

• What is hardening?
• Purpose of hardening
• The principle of hardening
• Process of hardening
• Soaking time
• Cooling
• The quenching medium
• Tempering
• Purpose of tempering the steel
• Process of tempering
• Tempering temperature

Annealing of steel

• Annealing process

Normal Steel

Surface hardening of steel

• Types of surface hardening
• Case hardening
• Carburising
• Pack carburising
• Liquid Carburising
• Gas carburising
• Tempering

Nitriding

• Gas nitriding
• Nitriding in salt bath
• Advantages

Flame hardening

Induction hardening

Different structure of steel (plain carbon)

• Zero per cent carbon
• Plain carbon steel

The heating and slow cooling of steel

Effects of carbon in steel

Heating steel for heat treatment

• Critical temperatures
• Soaking
• Soaking time
• Heating the steel
• Preheating
• Quenching

Temperature measuring instruments

• Seger cone method
• Pyrometer for temperature measurement
• Types of pyrometer
• Thermo-Electric pyrometer
• Optical pyrometer
• Radiation pyrometer

Types of furnaces

• Furnaces for specific heat treatment
• Muffle furnace
• Pit furnace
• Continuous heat treating furnace
• Conveyor furnace

Safety precautions – painting section

• Safety in paint store
• Safety to painters
• Safety in working place

Surface preparation

• Advantages of good surface preparation
• Removal of protective coating
• Removal of rust and surface contaminants
• Heating process
• Solvent wiping process
• Grit or sand blasting
• Phosphating process

Tools used in surface preparation

• Dust brush
• Wire brush
• Chisel knife
• Moulding knife
• Scrapping knife
• Emery sheet
• Sand paper
• Cloth Emery
• Water proof emery

Primer

• Types of primer
• Red oxide primer

Paint Brushes

• Flat brush
• Round brush
• Curve brush
• Roller brush
• Advantages of roller brush
• Disadvantages
• Artist brush
• Hints on handling paint brushes

Putty

Spray painting

• Air compressor and its parts
• Air filter
• Flexible hose pipe
• Parts of spray gun
• Paint container

Quality of paint and painting

• Viscosity of paint
• Elcometer
• Gloss meter
• Color of paint checking

Factors to be considered for the quality of paint film

• Blistering
• Remedy
• Flaking
• Causes
• Remedies
• Orange peel

Types of paint and its application

• Pigment
• Thinner/solvent
• Plasticizer
• Driers/accelerators
• Inhibitors
• Anti-Skinning agent
• Anti-Settling agent
• Types of paints
• Aluminium paints and its application
• Polyurethane paint (Two pack)
• Advantages of pupaints
• Disadvantages
• Hammers one finish paints
• Application
• Filler
• Undercoat and its application
• Enamel and its application
• Primer
• Wash primer

Stenciling and Marking

• Stenciling
• Preservation of stencil
• Types of stencil
• Negative type
• Stencil media
• Advantages and limitation of stencil media
• Advantages of stenciling process
• Limitation of stenciling process

Powder coating

• Metal cleaning and pre-treatment
• Drying
• Manufacturing of powders
• Curing
• Advantages of powder coating
• Disadvantages
• Uses of powder coating application

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