Metalworker Training

Lesson 1 • Shop Environment and Layout

Introduces the organisation of a metalworking shop, tool zones, and workflow paths. Proper layout knowledge reduces hazards and improves efficiency.

Lesson 2 • Properties of Common Metals

Covers ferrous and non-ferrous metals, their physical and mechanical properties. Builds the material literacy needed for all subsequent fabrication decisions.

Lesson 3 • Hazard Recognition and Control

Teaches identification of mechanical, thermal, and chemical hazards in the shop. Students apply the hierarchy of controls to reduce risk before starting work.

Lesson 4 • Reading Drawings and Specifications

Introduces engineering drawings, symbols, and tolerances used in metalworking. Accurate drawing interpretation is essential for producing correct parts.

Lesson 1 • Surface Finishing by Hand

Covers deburring, polishing, and surface conditioning using hand methods. Clean, deburred edges are required before assembly and inspection.

Lesson 2 • Cutting and Chipping Hand Tools

Covers hacksaws, files, chisels, and snips for manual metal removal and shaping. Proper technique ensures clean cuts and extends tool life.

Lesson 3 • Clamping and Workholding Devices

Introduces vises, clamps, and V-blocks for securing workpieces during hand operations. Stable workholding is critical for accuracy and operator safety.

Lesson 4 • Layout and Marking Techniques

Teaches scribing, centre-punching, and layout fluid application for accurate part marking. Precise layout prevents costly errors during cutting and forming.

Lesson 1 • Power Tool Maintenance and Inspection

Covers pre-use inspection, lubrication, and storage of portable power tools. Routine maintenance prevents failures and extends equipment service life.

Lesson 2 • Reciprocating and Jig Saws

Covers blade selection and cutting technique for straight and curved metal cuts. These tools extend cutting capability beyond straight hacksaw work.

Lesson 3 • Portable Drills and Drill Bits

Teaches bit selection, speed settings, and drilling technique for various metals. Proper drilling prevents work-hardening, bit breakage, and inaccurate holes.

Lesson 4 • Pneumatic and Hydraulic Tools

Introduces air-powered chisels, riveters, and hydraulic presses used in fabrication. Students connect, operate, and maintain pneumatic and hydraulic circuits safely.

Lesson 1 • Abrasive Cutoff and Waterjet Overview

Introduces abrasive cutoff wheels and waterjet cutting principles for hard materials. Students understand process selection criteria based on material and tolerance needs.

Lesson 2 • Plasma Arc Cutting

Teaches plasma torch setup, consumable selection, and cutting of conductive metals. Plasma cutting delivers faster, cleaner cuts than oxyfuel on thin to medium stock.

Lesson 3 • Oxyfuel Cutting Fundamentals

Covers gas cylinder handling, torch setup, and flame cutting of ferrous metals. Oxyfuel cutting is the baseline thermal process for structural steel work.

Lesson 4 • Mechanical Cutting: Shears and Saws

Covers power shears, band saws, and cold saws for straight and contour cutting. Mechanical cutting produces burr-free edges without heat-affected zones.

Lesson 1 • Gas Tungsten Arc Welding

Covers tungsten preparation, filler rod selection, and GTAW technique on thin and precision work. GTAW produces the highest-quality welds on stainless steel and aluminium.

Lesson 2 • Weld Joint Design and Fit-Up

Introduces joint types, groove geometry, and fit-up tolerances required before welding. Correct fit-up directly determines weld quality and reduces distortion.

Lesson 3 • Gas Metal Arc Welding

Teaches wire selection, shielding gas setup, and GMAW technique for production welding. GMAW offers higher deposition rates and is widely used in fabrication shops.

Lesson 4 • Shielded Metal Arc Welding

Covers electrode selection, machine setup, and SMAW technique on flat and horizontal positions. SMAW is the foundational arc process used across structural and repair work.

Lesson 1 • Bending Theory and Bend Allowance

Covers neutral axis, springback, and bend allowance calculations for sheet and plate. Accurate calculations prevent scrap and ensure parts meet final dimensions.

Lesson 2 • Straightening and Distortion Correction

Covers flame straightening, press straightening, and peening to correct warped metal. Distortion control is essential after welding and forming operations.

Lesson 3 • Roll Forming and Plate Rolling

Covers three-roll and four-roll machine setup for producing cylinders and cones. Rolling is used for pressure vessels, ducts, and structural curved sections.

Lesson 4 • Tube and Pipe Bending

Introduces mandrel bending, rotary draw, and compression bending for tube and pipe. Correct technique prevents wall thinning, wrinkling, and ovality.

Lesson 1 • Lathe Setup and Turning Operations

Covers workholding, tool selection, and turning, facing, and parting on the engine lathe. The lathe is the most versatile single-point cutting machine in the shop.

Lesson 2 • Drilling, Reaming, and Tapping

Teaches drill press setup, reaming for precision holes, and tapping internal threads. Accurate hole production is required for fasteners, pins, and press fits.

Lesson 3 • Cutting Fluids and Tool Life

Covers coolant types, application methods, and tool wear monitoring for machining. Proper fluid use extends tool life and improves surface finish quality.

Lesson 4 • Threading on the Lathe

Teaches single-point threading, thread chasing, and thread measurement on the lathe. Accurate threads are critical for fastened and pressure-containing assemblies.

Lesson 1 • Non-Destructive Testing Overview

Introduces visual, dye penetrant, and magnetic particle testing for weld and part inspection. NDT methods detect surface and near-surface defects without damaging the part.

Lesson 2 • Surface Preparation and Cleaning

Teaches abrasive blasting, chemical cleaning, and mechanical surface prep before coating. Proper surface preparation is the most critical factor in coating adhesion.

Lesson 3 • Protective Coatings and Finishes

Covers primer, paint, and galvanising systems for corrosion protection of metal parts. Coating selection depends on service environment, substrate, and durability requirements.

Lesson 4 • Mechanical Fastening Methods

Covers bolted joints, rivets, and threaded inserts for assembling metal structures. Correct fastener selection and torque application ensure structural integrity.