MSCE Metalwork study plan

Identify and explain the purpose of five types of personal protective equipment (PPE) used in a metalwork workshop, giving one specific example of a task for each.

List and describe four common workshop hazards (e.g., flying chips, sharp edges, electrical, fire) and the control measures for each.

Demonstrate the correct procedure for setting up a bench vice and a drilling machine, including safety checks before use.

Select the correct file for a given task (e.g., roughing, finishing, draw filing) and explain the consequences of using the wrong file.

Produce a hand-filed square block from mild steel to within ±0.2 mm on all dimensions, using safe filing technique.

Measure and mark out a metal workpiece using a steel rule, try square, scriber, and centre punch, achieving layout lines within ±0.1 mm.

Drill and tap a through hole (M6) in mild steel, correctly selecting drill size, tap drill, and lubricant, and verifying thread fit with a go/no-go gauge.

Explain the difference between a first-angle and third-angle projection, and sketch a simple bracket in both.

Identify and correctly use at least four measuring instruments (vernier caliper, micrometer, feeler gauge, engineer's square) and record readings to the instrument's resolution.

Perform a go/no-go inspection of a tapped hole and a filed surface using the appropriate gauges.

Classify five common engineering metals (mild steel, high-carbon steel, aluminium alloy, copper, stainless steel) by composition and typical properties.

Explain the effect of carbon content on the hardness and weldability of steel, and select an appropriate steel for a given application.

Describe the stages of heat treatment (annealing, normalising, hardening, tempering) and the purpose of each for a high-carbon steel sample.

Perform a simple hardness test (file test) on heat-treated and untreated steel samples and record the observed differences.

Forge a simple chisel or centre punch from high-carbon steel, including correct heating, shaping, and initial hardening/tempering.

Prepare and solder a copper lap joint using soft solder and flux, achieving a smooth fillet and full capillary action.

Explain the difference between soldering, brazing, and braze welding in terms of temperature, filler metal, and joint strength.

Select and install three types of mechanical fasteners (bolt, set screw, rivet) in a metal assembly, demonstrating correct hole sizing and torque.

Lay out and fabricate a simple sheet metal box or tray from galvanised steel, including bend allowance calculation and edge treatment.

Inspect a soldered and a riveted joint for defects (e.g., voids, loose rivets) and propose corrective action.

Identify and explain the purpose of five key components of oxy-acetylene welding equipment (regulators, hoses, flashback arrestors, torches, nozzles).

Set up and shut down an oxy-acetylene welding station following a safe procedure, including leak testing and pressure setting.

Produce a bead-on-plate weld on mild steel using the oxy-acetylene process, maintaining a stable flame and consistent travel speed.

Describe the three types of flames (neutral, oxidising, carburising) and their applications.

Perform a straight cut on mild steel plate using a thermal cutting torch, keeping within ±1 mm of a marked line.

Explain the difference between MMA (stick) and MIG welding in terms of equipment, electrode/wire, and typical applications.

Produce a single-pass fillet weld on mild steel using the MMA process, with correct electrode angle and arc length.

Identify and explain the purpose of five safety controls specific to arc welding (welding helmet, fume extraction, grounding, screens, fire watch).

Set up a bench drill or pedestal drill for a drilling operation, including speed selection and workholding.

Perform a simple turning operation on a lathe (facing and parallel turning) to within ±0.1 mm, under supervision.

Interpret a detailed engineering drawing of a simple assembly, extracting all dimensions, tolerances, and surface finish requirements.

Create a hand-drawn orthographic projection (front, top, side) of a given metal component, including a title block and scale.

Prepare a step-by-step project plan for fabricating a small metal project (e.g., a toolmaker's clamp), listing materials, tools, and sequence of operations.

Calculate bend allowances and develop a flat pattern for a simple sheet metal component from a drawing.

Review a project plan for potential hazards and incorporate at least three safety controls.

Complete a timed 40-question mock examination covering all domains, achieving at least 75% overall.

Review all incorrect answers from the mock exam and produce a one-page summary of weak areas with corrective actions.

Demonstrate safe working practices in a workshop practical session, including correct PPE, tool use, and housekeeping.

Explain the selection criteria for a metal for a given application, considering mechanical properties, cost, and manufacturability.

Produce a final reflective summary of the 8-week study period, identifying three key skills developed and two areas for further improvement.