Intro to Welding Metallurgy WLDG 1337 Cody Edwards Office: AT 117 Office Hours Arranged (903)983-8162 E-mail cedwards@kilgore.edu Course Description: WELDING 1337.INTRODUCTION TO METALLURGY. Three hours credit. A study of ferrous and non-ferrous metals from the ore to the finished product. Emphasis on metal alloys, heat treating, hard surfacing, welding techniques, forging, foundry processes, and mechanical properties of metal including hardness, machinability and ductility. Course Learning Outcomes: The student will describe technical terms used in the various phases of metallurgy, from early history to classification of steel. The student will discuss ferrous and nonferrous metals and how they are processed and used in industries; and describe mechanical and physical properties, surface treatments, and heat treatments of metals. Three lecture hours each week (3-3-0) Course Rationale: The growing demand for qualified welder has necessitated the availability of a curriculum designed to meet the needs of the welding industry. Students graduating from the program will have a good understanding of the related and technical information associated with blueprints. Graduates should be able to read and interpret prints as required for entry into industry. Course Outcomes/SCANS Competencies: This course is designed as a lecture. Students should master and demonstrate the following to procedures to a satisfactory level according to industry standards. (1) Extracting Metals from Ores 1. Discuss the various steps, basic materials, and principles involved in making pig iron. 2. Discuss various steel-making processes. 3. Discuss several processes used in producing nonferrous metals. (2) The Manufacture of Steel Products 1. Discuss how steel is formed into various shapes and products. 2. Discuss the advantages of some processes over others for a given product. (3) Identification and Selection of Iron and Steel 1. Discuss different types of ferrous metals by various means of shop testing. 2. Select and discuss several commercial shafting alloys with various surface finishes. (4) Identification of Nonferrous Metal 1. Classify and discuss some nonferrous metals by a numerical system and identify 1
others by testing methods. 2. List and discuss the general appearance and use of the various nonferrous metals. (5) The Mechanical and Physical properties of Metals 1. Discuss, define, and describe the mechanical and physical properties of metals. 2. Discuss the various testing machines and their uses. (6) Using Rockwell and Brinell hardness Testers 1. Discuss the difference between hardness and tensile strength. 2. Discuss how decarburization affects the test results. (7) The Crystalline Structures of Metals 1. Discuss the various phases of crystalline structures of metals. 2. Discuss the various aspects of solid solutions. (8) Phase Diagrams and the Iron-Carbon Diagram 1. Discuss the four types of cast iron. 2. Discuss and define austenite 3. Discuss the meaning of eutectoid and how it differs from eutectic. (9) Hardening and Tempering of Plain Carbon Steel 1. Discuss the many problems encountered with water- hardening tool steel. 2. Discuss the advantages of using air- and oil- hardening. 3. Discuss why steel is tempered after it is hardened. (10) Annealing, Normalizing, and Stress Relieving 1. Discuss and explain the principles of and the differences among the various kinds of annealing processes. 2. Discuss the essential difference between full anneal and stress relieving. (11)I-T Diagrams and Cooling Curves 1. Discuss the hardening ability of steels and their quenching rates by using information gained from the I-T diagrams. 2. Discuss certain micro structures of transformation products produced at various temperatures (12)Hardening ability of Steels and Tempered Martensite 1. Explain the methods of determining and evaluating the depth of hardening of various steels. 2. Discuss the best time to temper. (13) Heat Treating Equipment and Procedures 2
1. Discuss the proper heat-treating procedures for most tool steels. 2. Discuss three kinds of furnaces used for heat treating steels. (14) Heat Treating of Non-Ferrous Metals 1. Discuss the reasons underlying the processes of solution heat treatment and precipitation hardening in which hardening takes place 2. Discuss and define: precipitation heat treatment, artificial aging, over ageing, and solution heat treatment (15) The Effects of Machining on Metals 1. Discuss how metal cutting affects the surface grain structure of metals. 2. Discuss and describe machining behavior of different metals, the machinability ratings, tool materials, and cutting fluids. SCANS COMPETENCIES 1 Reading 2 Writing 3 Mathematics 4 Listening/Speaking 5 Thinking 6 Personal Qualities 7 Workplace 8 Technology Educational Materials: Instructional Material Service, Texas A&M University, College Station. Course Outline Unit 1 Extracting Metals from Ores 1. Discuss the various steps, basic materials, and principles involved in making pig iron. 2. Discuss various steel-making processes. 3. Discuss several processes used in producing nonferrous metals. Unit 2 The Manufacture of Steel Products 1. Discuss how steel is formed into various shapes and products. 2. Discuss the advantages of some processes over others for a given product. Unit 3 Identification and Selection of Iron and Steel 1. Discuss different types of ferrous metals by various means of shop testing. 2. Select and discuss several commercial shafting alloys with various surface finishes. Unit 4 Identification of Nonferrous Metal 1. Classify and discuss some nonferrous metals by a numerical system and identify others by testing methods. 2. List and discuss the general appearance and use of the various nonferrous metals. Unit 5 The Mechanical and Physical properties of Metals 1. Discuss, define, and describe the mechanical and physical properties of metals. 2. Discuss the various testing machines and their uses. 3
Unit 6 Using Rockwell and Brinell hardness Testers 1. Discuss the difference between hardness and tensile strength. 2. Discuss how decarburization affects the test results. Unit 7 The Crystalline Structures of Metals 1. Discuss the various phases of crystalline structures of metals. 2. Discuss the various aspects of solid solutions. Unit 8 Phase Diagrams and the Iron-Carbon Diagram 1. Discuss the four types of cast iron. 2. Discuss and define austenite 3. Discuss the meaning of eutectoid and how it differs from eutectic. Unit 9 Hardening and Tempering of Plain Carbon Steel 1. Discuss the many problems encountered with water- hardening tool steel. 2. Discuss the advantages of using air- and oil- hardening. 3. Discuss why steel is tempered after it is hardened. Unit 10 Annealing, Normalizing, and Stress Relieving 1. Discuss and explain the principles of and the differences among the various kinds of annealing processes. 2. Discuss the essential difference between full anneal and stress relieving. Unit 11 I-T Diagrams and Cooling Curves 1. Discuss the hardening ability of steels and their quenching rates by using information gained from the I-T diagrams. 2. Discuss certain micro structures of transformation products produced at various temperatures Unit 12 Hardening ability of Steels and Tempered Martensite 1. Explain the methods of determining and evaluating the depth of hardening of various steels. 2. Discuss the best time to temper. Unit 13 Heat Treating Equipment and Procedures 1. Discuss the proper heat-treating procedures for most tool steels. 2. Discuss three kinds of furnaces used for heat treating steels. Unit 14 Heat Treating of Non-Ferrous Metals 1. Discuss the reasons underlying the processes of solution heat treatment and precipitation hardening in which hardening takes place 2. Discuss and define: precipitation heat treatment, artificial aging, over ageing, and solution heat treatment Unit 15 The Effects of Machining on Metals 1. Discuss how metal cutting affects the surface grain structure of metals. 2. Discuss and describe machining behavior of different metals, the machinability ratings, tool materials, and cutting fluids. 4
Classroom Policies: Attendance Kilgore College requires punctuality and regular class attendance. An absence is defined, as a student s not being in class. Tardiness can also be considered absence if it becomes excessive. An instructor may drop a student when lack of attendance prohibits the student from meeting course objectives or when the student has excessive absences. Excessive absences are defined as two weeks of instruction in a long term or no more than 12.5% of the total hours of instruction in any term. 1. Student earns 15 points per day if he or she is not late for class or does not leave early. 2. Student loses 15 points if absent. 3. Student WILL be counted ABSENT if they are not present and signed in for class on or before the start time of the class according to the clock in the building and shop! 4. The student is allowed a minimum of 3 consecutive or 4 cumulative absences before being dropped. 5. Students are allowed to makeup excused absences. Within two weeks of the excused absences. 6. Tardiness is not excepted and is considered an absence. Civility Students are expected to assist in maintaining a classroom environment that is conducive to learning. Inappropriate or distractive classroom behavior is prohibited in order to assure that everyone has opportunity to gain from time spent in class. Should a disruptive classroom incident occur, the faculty member in charge may remove the student on either a temporary or permanent basis. Students have the right to appeal through appropriate channels. Additional Specific Requirements for this Course All students are required to wear appropriate dress attire in the welding shop (no baggy pants or loose articles of clothing), and observe all safety requirements. The welding department will not tolerate any use of electronic devices (cell phones, and other similar items) (left to the discretion of the instructor). Evaluation, Grading: A. Grading Criteria: Written tests from text 40% Lab exercises 20% Homework from text 20% Final Exam 20% B. Determination of Grade 90-100 = A 80-89 = B 70-79 = C 60-69 = D 59-BELOW=F 5
Student may Drop with a W prior to completion of 75% of the course. ADA Statement Kilgore College is committed to making reasonable accommodations to assist individuals with disabilities in reaching their academic potential. If you choose to request accommodations for a documented disability which may impact your performance, attendance, or grades in this course, you must first register with the Office of Disability Services. Please note that classroom accommodations cannot be provided prior to your instructor s receipt of an accommodation letter from the Office of Disability Services. For more information about accommodations, please contact the Disability Services office on the second floor of the Devall Student Center: (903) 983-8206. Academic Honesty Statement: It is the responsibility of students and faculty to help maintain scholastic integrity at the college by refusing to participate in or tolerate scholastic dishonesty. Plagiarism and other forms of academic dishonesty undermine the very purpose of the college and diminish the value of education. Specific sanctions for academic dishonesty are outlined in the Kilgore College student handbook available in the office the Vice-President of Student Development, located in the Student Center (903) 983-8188. Disclaimer: The Instructor reserves the right to make modifications in content and schedule as necessary to promote the best education possible within prevailing conditions affecting this course. 6