MSCE Metalwork case studies

MSCE Metalwork · Put your knowledge to work in context.

The MSCE Metalwork examination is the Malawi School Certificate of Education subject paper for candidates who have studied metalwork and fabrication at secondary school. It is taken by school candidates completing Form 4 and by private candidates preparing for the certificate, and it serves as evidence of practical workshop competence for entry into apprenticeship, technician training, or employment in workshops, fabrication shops, and maintenance settings. The MSCE Metalwork case studies are 5 cases and about 5,488 words.

Winter Welding Bay: Metal Fume Under a Closed Roof

Your workshop is a 6 m × 9 m × 3 m bay with a roller shutter at each end and a 900 mm roof vent. In December both shutters stay closed to keep the heat in.

845 words, about 4 min 2

Coastal Handrail Brackets: Alloy and Joint Selection

An outdoor coastal walkway, 80 m from salt water with regular wind-driven spray, needs 120 handrail brackets. Each bracket is a 6 mm plate welded to a 60 × 60 × 5 mm square hollow section post and bolted with four M10 bolts to concrete plinths cast in situ.

1,132 words, about 6 min 3

10 mm Fillet, 180 A and a Cold Root

A subcontractor is welding 10 mm thick S275 gusset plates to a 150 × 90 channel with 15 mm leg-length fillet welds, one pass per side, using manual GMAW with 0.8 mm solid wire, 80% Ar/20% CO2 at 18 L/min, 180 A, 20 V, 6 m/min wire feed and 250 mm/min travel. The first three brackets passed a visual inspection, but after grinding a toe and running a dye-penetrant check the inspector found a straight line of lack-of-sidewall fusion along one toe and undercut measured at 0.8 mm.

1,092 words, about 5 min 4

Chisels That Chip: Hardening 0.8% Carbon

A toolroom is making 25 cold chisels from 8 mm hexagonal 0.8% carbon bar (certified 0.78% C, 0.25% Mn), forged to shape and ground to a 60° included edge. The current process is: heat the whole chisel in an open forge to a bright orange, hold 'until it looks even', quench the cutting 40 mm vertically in cold water, polish, then draw to a dark straw colour with a gas torch and air cool.

1,183 words, about 6 min 5

Taper, Chatter and a Step on a 250 mm Shaft

You must turn 20 shafts from 45 mm hot-rolled mild steel bar to Ø36.00/35.95 mm over a 250 mm length, with a 1.6 µm Ra finish on the bearing journal. The lathe is a 1.5 kW centre lathe with a worn three-jaw scroll chuck used for every part.

1,236 words, about 6 min