Metal Technology Classes...

Metal Technology Classes with Dr. Lyle

Metals One students construct two projects as part of the Introduction to Technology Education Materials Course. Students first construct a sheet metal box with a lid. During this project they learn how to layout and cut sheet metal using a squaring shears and aviation shears. Once the projects are cut they use a bar folder and box and pan brake to create hems and bends in their box. The students then use a spot-welder to connect their box together. They then file and sand their box to prepare it for spray painting. 

Students are working on box layout and cutting.

The second project consists of an iron puzzle project. Students may choose from two different puzzle ideas. The students then cut material using a hacksaw for their project. Students learn how to deburr their parts using a grinder and sanding machines. Students are then taught how to setup and use an oxyacetylene torch to bend their puzzle pieces. Once the pieces are bent, the students use the oxyacetylene torch to braze their pieces together.

Two students working on bending puzzle pieces with the oxyacetylene torch.

Metals Two students construct four projects as part of their semester of Metals II. Students first construct a sheet metal tool box with a lid and lift out tray. During this project they further learn how to layout and cut sheet metal while improving their skills on the squaring shears and aviation shears. Once the projects are cut they use a bar folder, box and pan brake and hand benders to create hems and bends in their box. The students then use a spotwelder to connect their box, lid and tray together. Students create all parts of the box except for the hinge and four nuts and bolts for assembly. They use the torch to bend handles from ¼” round stock and press out handle holders from 16 gauge sheet metal. They then file and sand their box to prepare it for spray painting and customization.

A student working on securing his handle to his tool box.

The second project consists of a cross peen hammer. The students cut material using a horizontal bandsaw for their project. After cutting and deburring their pieces students are introduced to the metal lathe. On the metal lathe students are taught many basic lathe operations that include facing, drilling, turning to a specific diameter, knurling and threading. They use these operations to machine the hammer handle and head. Further work on the head is done on a vertical milling machine. Students learn basic operations that include squaring material, cutting slots, milling angles and drilling. Precision measurement is also stressed as part of the hammer project, working to within thousandths of an inch.

Student working on vertical Milling machine cutting hammerhead

A third project students work on is a wrought iron lamp with sheet metal shade. Students use the forge to heat and bend steel for lamp legs. A piece of pipe is cut and threaded using a die for the center of the lamp. Once the legs and pipe are done students are introduced to mig welding to fasten their lamp together. Students also construct a sheet metal shade for the lamp using techniques learned from the tool box project.

A student mig welding their wrought iron lamp together.

The last project that students work on is a foundry project. Students select a pattern and learn how to ram up a sand mold for the casting process. Once the project is poured, students then clean their casting and prepare it for finishing.

Student pouring aluminum into their sand mold.