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Topic
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General Description of Subject Matter
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Practical Applications of Metallurgy
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Define metallurgy, explain what a metallurgist does, describe how metallurgy knowledge can be used to solve industrial problems, state whey the study of metallurgy can be a valuable asset.
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Metallurgical and chemical terminology
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State the meaning of basic metallurgy terminology, explain how chemistry is related to metallurgy, and define chemical terms such as element, compound, solution, atom. Describe metals and alloys
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Hardness
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Explain what hardness is, describe how the hardness testing methods, discuss how each hardness testing methods works, convert between hardness scales.
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Metal properties
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Explain the relationship between strength, hardness, and ductility; calculate simple tensile, compressive, torsional, and flexural stresses. Compare the various types of stresses that materials must withstand, define and calculate percent elongation and strain. Compare elastic and plastic deformation, describe stress-strain diagrams for common materials, explain modulus of elasticity, determine lateral strain using Poisson’s ratio. Describe types of corrosion; explain thermal properties such as melting point, coefficient of thermal expansion, thermal conductivity and specific heat.
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What is steel
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Describe the composition of steel, identify the differences between steel and iron, and use the steel numbering system to identify various types of steel. Identify the effects of different alloying elements on steel. Describe various kinds of carbon steel and alloy steel, compare the different types of cast iron.
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Manufacture of iron and steel
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Identify the basic steps in the production of steel. Describe how cast iron is made, identify the properties and uses of iron ore and pig iron. Differentiate between common steel making and cast iron making processes. Discuss how rolling mills change steel ingots into different shapes.
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Crystal Structure
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Explain how a crystal is formed in metal; discuss the formation of space lattice structures and dendrites. Describe the appearance of atoms inside crystals. Explain how temperature affects the growth of a crystal. Tell what is meant by grain size.
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Failure and deformation of metal
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Explain what happens inside a piece of metal when it breaks, state what is meant by deformation of metal, summarize the different types of metal failure or breakage. Describe work hardening and its applications.
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Iron carbon diagram
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Describe five important structural forms of steel and iron; identify the transformation regions and other major elements of an iron carbon diagram. Use an iron carbon diagram to determine the steel structures that occur at various combinations of temperature and percentages of carbon. Explain how different cooling techniques are used to produce mechanical properties on steel. Use an iron carbon diagram to determine the temperature to which steel must be heated to cause tit to harden.
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Microstructural Analysis
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Compare different structures of steel under a microscope, describe the microscopic appearance of ferrite, pearlite, cementite, austenite, and martensite. Recognize ferrite, pearlite, cementite, austenite, and martensite by looking at their microstructures. Prepare a sample of metal for microscopic observation.
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Heat treating and quenching
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Explain heat treating processes, describe the effects and purpose of quenching, and discuss the four stages that metal goes through as it is quenched. Identify common quenching mediums and techniques and describe how they affect metal.
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Annealing and normalizing
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Describe the purpose of annealing and normalizing; explain how annealing and normalizing affect the hardness, strength and brittleness of metal. Describe how annealing and normalizing affect the crystal structure of metal. Identify three different types of annealing processes. List the different ways in which annealing and normalizing affect metal compared to quenching.
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Isothermal transformation diagrams
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Explain the purpose of an isothermal transformation (IT) diagram and how it is used; recognize the difference in usage between and I-T diagram and an iron carbon phase diagram. Determine whether material will become stronger during the heat treat process by evaluating it I-T diagram. Compare different industrial I-T diagrams; plot a temperature time line on an I-T diagram.
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Tempering
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Explain the purpose of tempering, identify characteristics of tempered steel. Discuss some practical aspects of tempering, describe common tempering methods, explain how tempering affects distortion and hardness.
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Surface hardening
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Explain the principles of surface hardening identify metallurgical applications for surface hardening; describe the three basic surface hardening methods. Identify eight different processes used to case harden materials. Compare the advantages and disadvantages of each surface hardening process.
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Processing nonferrous metals
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Identify and explain the basic processing methods used for nonferrous metals, describe the different types of atomic structures in metals. Explain the principles of alloying and the structural effects produced by alloying elements. Summarize the effects of cold working on metal. Recognize how precipitation hardening is applied to improve the properties of nonferrous alloys. Use phase diagrams to identify the various structures that occur in alloy systems.
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Aluminum and aluminum alloys
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Describe the desirable properties of aluminum and aluminum alloys; explain how aluminum is refined, list common applications of aluminum and aluminum alloys. Explain how alloying, cold working, and precipitation hardening can be used to change the properties of aluminum.
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Copper, bronze, and brass
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List and explain the desirable properties of copper and its alloys. Explain how copper is refined from copper ore; describe the favorable properties of bronze and brass. Explain the effects of work hardening and precipitation hardening on copper and its alloys.
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Magnesium, zinc, tin and specialty metals
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Identify the properties and commercial applications of magnesium, zinc, tin, and other nonferrous metals. Describe how the die casting process is used to produce parts from magnesium and zinc, explain the use of tin alloys in wave soldering and other joining processes, list the properties and applications of nickel based super alloys and titanium. Recognize how intermetallic compounds are formed.
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