-
Chapter 1
Introduction to Types and Identification of Metal
Topics 1.0.0 Basic Metal Types
2.0.0 Basic Metal Identification
To hear audio, click on the box.
Overview In the Seabees, the Steelworker (SW) rating is
recognized as the resident expert on the use of metal. SWs lay
airfields, erect towers, assemble pontoon causeways, reinforce
concrete, and erect buildings. They also use their expertise to
fabricate all types of metal objects, repair metal items, and
resurface worn machinery parts.
Steelworkers need to know the two basic types of metal and be
able to provide initial identification. While they primarily work
with the ferrous metals of iron and steel, they also need to be
able to identify and become familiar with the nonferrous metals
coming into more use each day.
In the civilian arena, the term Steelworker generally refers to
those who make iron and steel in the many steel plants, while the
term Ironworker refers to those in the construction industry who
fabricate and build with iron and steel.
This chapter will present an introductory explanation of the
basic types of metal and provide initial instruction on using
simple tests to establish their identity. For a more in-depth
presentation about the properties and uses of metal, refer to
Steelworker Advanced.
Objectives When you have completed this chapter, you will be
able to do the following:
1. Identify the basic metal types.
2. Describe identification procedures associated with basic
metals.
Prerequisites None
This course map shows all of the chapters in Steelworker Basic.
The suggested training order begins at the bottom and proceeds up.
Skill levels increase as you advance on the course map.
NAVEDTRA 14250A 1-1
-
NAVEDTRA 14250A 1-2
Introduction to Reinforcing Steel
S T E E L W O R K E R
B A S I C
Introduction to Structural Steel
Pre-Engineered Structures:
Buildings, K-Spans, Towers and Antennas
Rigging
Wire rope
Fiber Line
Layout and Fabrication of Sheet-Metal and Fiberglass Duct
Welding Quality Control
Flux Core Arc Welding-FCAW
Gas-Metal Arc Welding-GMAW
Gas-Tungsten Arc Welding-GTAW
Shielded Metal Arc Welding-SMAW
Plasma Arc Cutting Operations
Soldering, Brazing, Braze Welding, Wearfacing
Gas Welding
Gas Cutting
Introduction to Welding
Basic Heat Treatment
Introduction to Types and Identification of Metal
-
Features of this Manual This manual has several features which
make it easy to use online.
Figure and table numbers in the text are italicized. The figure
or table is either next to or below the text that refers to it.
The first time a glossary term appears in the text, it is bold
and italicized. When your cursor crosses over that word or phrase,
a popup box displays with the appropriate definition.
Audio and video clips are included in the text, with an
italicized instruction telling you where to click to activate
it.
Review questions that apply to a section are listed under the
Test Your Knowledge banner at the end of the section. Select the
answer you choose. If the answer is correct, you will be taken to
the next section heading. If the answer is incorrect, you will be
taken to the area in the chapter where the information is for
review. When you have completed your review, select anywhere in
that area to return to the review question. Try to answer the
question again.
Review questions are included at the end of this chapter. Select
the answer you choose. If the answer is correct, you will be taken
to the next question. If the answer is incorrect, you will be taken
to the area in the chapter where the information is for review.
When you have completed your review, select anywhere in that area
to return to the review question. Try to answer the question
again.
NAVEDTRA 14250A 1-3
-
1.0.0 BASIC METAL TYPES Metals can initially be divided into two
general classifications, and Steelworkers work with both: ferrous
and nonferrous metals.
Ferrous metals are those composed primarily of iron (atomic
symbol Fe) and iron alloys.
Nonferrous metals are those composed primarily of some element
or elements other than iron, although nonferrous metals or alloys
sometimes contain a small amount of iron as an alloying element or
as an impurity.
1.1.0 Ferrous Metals Ferrous metals include all forms of iron
and iron-base alloys, with small percentages of carbon (steel, for
example), and/or other elements added to achieve desirable
properties. Wrought iron, cast iron, carbon steels, alloy steels,
and tool steels are just a few examples. Ferrous metals are
typically magnetic.
1.1.1 Iron
Iron ores are rocks and minerals from which metallic iron can be
economically extracted. The ores are usually rich in iron oxides
and vary in color from dark grey, bright yellow, deep purple, to
rusty red. Iron ore is the raw material used to make pig iron,
which is one of the main raw materials used to make steel.
Ninety-eight percent of the mined iron ore is used to make
steel.
Iron is produced by converting iron ore to pig iron using a
blast furnace. Pig iron is the intermediate product of smelting
iron ore with coke, usually with limestone as a flux. Pig iron has
very high carbon content, typically 3.54.5%, which makes it very
brittle and not useful directly as a material except for limited
applications.
From pig iron, many other types of iron and steel are produced
by the addition or deletion of carbon and alloys. The following
briefly presents different types of iron and steel made from iron.
Steelworker Advanced will present additional information about
their properties.
Pig Iron comparatively weak and brittle with limited use.
Approximately ninety percent is used to produce steel, although
cast-iron pipe and some fittings and valves are manufactured from
pig iron.
Wrought Iron made from pig iron with some slag mixed in during
manufacture, it is almost pure iron. Wrought iron usage diminished
with the increasing availability of mild steel in the late 19th
century. Some items traditionally produced from wrought iron
included rivets, nails, chains, railway couplings, water and steam
pipes, nuts, bolts, handrails, and ornamental ironworks. Many
products still described as wrought iron, such as guardrails and
gates, are made of mild steel.
Cast Iron any iron containing greater than 2% carbon alloy. It
tends to be brittle, except for malleable cast irons. Cast irons
have a wide range of applications, including pipes, machine and
automotive industry parts such as cylinder heads, cylinder blocks,
and gearbox cases. A malleable cast iron is produced through a
prolonged annealing process.
Ingot Iron a commercially pure iron (99.85% iron). It is easily
formed, with properties practically the same as the lowest carbon
steel. In iron, the carbon content is considered an impurity; in
steel, the carbon content is considered an
NAVEDTRA 14250A 1-4
-
alloying element. The primary use for ingot iron is for
galvanized and enameled sheet.
1.1.2 Steel
Of all the different metals and materials that Steelworkers use,
steel and steel alloys are by far the most used and therefore the
most important to study.
The development of the economical Bessemer process for
manufacturing steel revolutionized the American iron industry.
Figure 1-1 shows the container vessel used for the process.
With economical steel came skyscrapers, stronger and longer
bridges, and railroad tracks that did not collapse.
Steel is manufactured from pig iron by decreasing the amount of
carbon and other impurities and adding specific and controlled
amounts of alloying elements during the molten stage to produce the
desired composition.
Figure 1-1 Example of a Bessemer Converter.
The composition of a particular steel is determined by its
application and the specifications developed by the following:
American Society for Testing and Materials (ASTM)
American Society of Mechanical Engineers (ASME)
Society of Automotive Engineers (SAE)
American Iron and Steel Institute (AISI)
Carbon steel is a term applied to a broad range of steel that
falls between the commercially pure ingot iron and the cast irons.
This range of carbon steel may be classified into four groups:
Low-Carbon Steel tough and ductile, easily machined, formed, and
welded, but does not respond to any form of heat-treating except
case hardening.
NAVEDTRA 14250A 1-5
-
Medium-Carbon Steel strong and hard but cannot be welded or
worked as easily as the low-carbon steels. They are used for crane
hooks, axels, shafts, setscrews and so on.
High-Carbon Steel responds well to heat treatment and can be
welded with special electrodes, but the process must include
preheating and stress-relieving procedures to prevent cracks in the
weld areas.
Very High-Carbon Steel similar to high-carbon, it responds well
to heat treatment and can be welded with special electrodes, but
the process must include preheating and stress-relieving procedures
to prevent cracks in the weld areas. Both steels are used for dies,
cutting tools, mill tools, railroad car wheels, chisels, knives,
and so on.
High-strength steels are covered by American Society for Testing
and Materials (ASTM) specifications.
Low-Alloy, High-Strength, Tempered Structural Steel special low
carbon steel that contains specific, small amounts of alloying
elements. Structural members made from these high-strength steels
may have smaller cross-sectional areas than common structural
steels and still have equal or greater strength. This type of steel
is much tougher than low-carbon steels, so the shearing machines
must have twice the capacity required for low-carbon steels.
Stainless steels are classified by the American Iron and Steel
Institute (AISI) and classified into two general series:
Stainless Steel 200-300 series known as Austenitic
[aw-stuh-nit-ik]. This type of steel is very tough and ductile in
the as-welded condition; therefore, it is ideal for welding and
requires no annealing under normal atmospheric conditions. The most
widely used are the normally nonmagnetic chromium nickel
steels.
Stainless Steel 400 series further subdivided according to their
crystalline structure into two general groups:
o Ferritic [fer-rit-ik]. Chromium non-hardenable by heat
treatment and normally used in the annealed or soft condition, they
are magnetic and frequently used for decorative trim and equipment
subjected to high pressures and temperatures.
o Martensitic [mahr-tn-zit-ik] Chromium readily hardened by heat
treatment, they are magnetic and used where high strength,
corrosion resistance, and ductility are required.
Alloy steels derive their properties primarily from the presence
of some alloying element other than carbon, but alloy steels always
contain traces of other elements as well. One or more of these
elements may be added to the steel during the manufacturing process
to produce the desired characteristics.
Alloy steels may be produced in structural sections, sheets,
plates, and bars for use in the as-rolled condition, and these
steels can obtain better physical properties than are possible with
hot-rolled carbon steels.
These alloys are used in structures where the strength of
material is especially important, for example in bridge members,
railroad cars, dump bodies, dozer blades, and crane booms. The
following list describes some of the common alloy steels:
Nickel Steels used in the manufacture of aircraft parts such as
propellers and airframe support members.
NAVEDTRA 14250A 1-6
-
Chromium Steels used for the races and balls in antifriction
bearings; highly resistant to corrosion and to scale.
Chrome Vanadium Steel used for crankshafts, gears, axles, and
other items that require high strength; also used in the
manufacture of high-quality hand tools such as wrenches and
sockets.
Tungsten Steel expensive to produce, its use is largely
restricted to the manufacture of drills, lathe tools, milling
cutters, and similar cutting tools.
Molybdenum used in place of tungsten to make the cheaper grades
of high-speed steel and in carbon molybdenum high-pressure
tubing.
Manganese Steels use depends upon the properties desired:
o Small amounts produce strong, free-machining steels. o Larger
amounts produce a somewhat brittle steel. o Still larger amounts
produce a steel that is tough and very resistant to
wear after proper heat treatment.
1.2.0 Nonferrous Metals Nonferrous metals contain either no iron
or only insignificant amounts used as an alloy, and are
nonmagnetic. The following list will introduce you to some of the
common nonferrous metals that SWs may encounter and/or work with.
Additional information about their properties and usage is
available in Steelworker Advanced.
Copper one of the most popular commercial metals; used with many
alloys; frequently used to give a protective coating to sheets and
rods and to make ball floats, containers, and soldering
coppers.
True Brass an alloy of copper and zinc, sometimes with
additional alloys for specific properties; sheets and strips are
available in several grades.
Bronze a combination of 84% copper and 16% tin, and the best
metal available before steel-making techniques were developed; the
name bronze is currently applied to any copper-based alloy that
looks like bronze.
Copper-Nickel Alloys nickel adds resistance to wear and
corrosion; some alloys used for saltwater piping systems; other
sheet forms used to construct small storage tanks and hot-water
reservoirs.
Lead a heavy metal, but soft and malleable; surface is grayish
in color, but after scratching or scraping it, the actual color of
the metal appears white.
CAUTION When working with lead, take proper precautions! Lead
dust, fumes, or vapors are highly poisonous!
Zinc used on iron or steel in the form of a protective coating
called galvanizing.
Tin used as an important alloy adding resistance to
corrosion.
Aluminum easy to work with; good appearance; light in weight;
needs alloys added to increase strength.
NAVEDTRA 14250A 1-7
-
Duralumin one of the first strong structural aluminum alloys;
now classified in the metal working industries as 2017-T; T
indicates heat-treated.
Alclad a protective covering of a thin sheet of pure aluminum
rolled onto the surface of an aluminum alloy during
manufacture.
Monel an alloy in which nickel is the major element; harder and
stronger than either nickel or copper; acceptable substitute for
steel in systems where corrosion resistance is the primary
concern
K-Monel developed for greater strength and hardness than Monel;
comparable to heat-treated steel; used for instrument parts that
must resist corrosion.
Inconel provides good resistance to corrosion and retains its
strength at high-operating temperatures; often used in the exhaust
systems of aircraft engines.
2.0.0 BASIC METAL IDENTIFICATION When you are selecting a metal
to use in fabrication, to perform a mechanical repair, or even to
determine if the metal is weldable, you must be able to identify
its basic type.
A number of field identification methods can be used to identify
a piece of metal. Some common methods are surface appearance, spark
test, chip test, magnet test, and occasionally a hardness test.
2.1.0 Surface Appearance Sometimes you can identify a metal
simply by its surface appearance. Table 1-1 indicates the surface
colors of some of the more common metals.
NAVEDTRA 14250A 1-8
-
Table 1-1 Surface Appearance of Some Common Metals
Metal Color Color and Structure
Unfinished, unbroken surface Freshly filed surface Newly
fractured surface
Aluminum Light gray White White: finely crystalline
Brass and Bronze Reddish-yellow, yellow-green, or brown
Reddish-yellow to yellowish-white
Red to yellow
Copper Reddish-brown to green Bright copper color Bright red
Iron, Cast-gray Dull gray Light silvery gray Dark gray:
crystalline
Iron, Cast-white Dull gray Silvery white Silvery white:
crystalline
Iron, Malleable Dull gray Light silvery gray Dark gray: finely
crystalline
Iron, Wrought Light gray Light silvery gray Bright gray
Lead White to gray White Light gray: crystalline
Monel metals Dark gray Light gray Light gray
Nickel Dark gray Bright silvery white Off-white
Steel, Cast and Steel, Low-carbon
Dark gray Bright silvery gray Bright gray
Steel, High-carbon Dark gray Bright silvery gray Light gray
Steel, Stainless Dark gray Bright silvery gray Medium gray
As you can see by studying the table, a metals surface
appearance can help you identify it, and if you are unsure, you can
obtain further information by studying a fresh filing or a fresh
fracture. If a surface examination does not provide you with enough
information for a positive identification, it should give you
enough information to place the metal into a class.
In addition to the color of the metal, distinctive marks left
from manufacturing also help in determining the identity of the
metal.
Cast iron and malleable iron usually show evidence of the sand
mold.
Low-carbon steel often shows forging marks.
High-carbon steel shows either forging or rolling marks.
Inspecting the surface texture by feel may also provide another
clue to its identity.
Stainless steel, in the unfinished state, is slightly rough.
Wrought iron, copper, brass, bronze, nickel, and Monel are
smooth.
Lead is smooth but has a velvety appearance.
When visual clues from surface appearance, filings, fractures,
manufacturing marks, or textural clues from the feel of the
surfaces do not give enough information to allow positive
identification, other tests become necessary.
NAVEDTRA 14250A 1-9
-
Some are complicated and require equipment Seabees do not
usually have. However, the following are a few additional simple
tests, which are reliable when done by a skilled person: spark
test, chip test, magnetic tests, hardness test.
2.2.0 Spark Test You perform the spark test by holding a sample
of the unidentified material against an abrasive wheel and visually
inspecting the spark stream. This test is fast, economical,
convenient, easily accomplished, and requires no special
equipment.
As you become a more experienced Steelworker, you will be able
to identify the sample metals with considerable accuracy. You can
use this test to identify scrap-salvaged metal, which is
particularly important when you are selecting material for cast
iron or cast steel heat treatment.
When you hold a piece of iron or steel (ferrous metals) in
contact with a high-speed abrasive wheel, small particles of the
metal are torn loose so rapidly that they become red-hot. These
small particles of metal fly away from the wheel, and glow as they
follow a trajectory path called the carrier line, which is easily
followed with the eye, especially when observed against a dark
background.
The sparks (or lack of sparks) given off can help you identify
the metal. Features you should look for include:
length of the spark stream
form of the sparks
color(s) of the sparks
Refer to Figure 1-2 through Figure 1-8 for illustrations of the
various terms used in referring to the basic spark forms produced
during spark testing.
Figure 1-3 Example of spark
testing term-SHAFT.
Figure 1-4 Example of
spark testing term-FORK.
Figure 1-2 Example of spark testing term-
STREAM.
NAVEDTRA 14250A 1-10
-
Steels that have the same carbon content but include different
alloying elements are difficult to identify; the alloys have an
effect on the carrier lines, the bursts themselves, or the forms of
the characteristic bursts in the spark picture.
The alloying element may slow or accelerate the carbon spark, or
make the carrier line lighter or darker in color. For example:
Molybdenum appears as a detached, orange-colored spearhead on
the end of the carrier line.
Nickel appears to suppress the effect of the carbon burst;
however, you can identify the nickel spark by tiny blocks of
brilliant white light.
Silicon suppresses the carbon burst even more than nickel; the
carrier line usually ends abruptly in a white flash of light.
You can perform spark testing with either a portable or a
stationary grinder, but in either case, the outer rim speed of the
wheel should be not less than 4,500 feet per minute with a clean,
very hard, rather coarse abrasive wheel. Each point is necessary to
produce a true spark
When you conduct a spark test, hold the metal on the abrasive
wheel in a position that will allow the carrier line to cross your
line of vision. By trial and error, you will soon find what
pressure you need in order to get a stream of the proper length
without reducing the speed of the grinder. In addition to reducing
the grinders speed, excessive pressure
Figure 1-8 Example of spark testing term-BUD BREAK ARROW.
Figure 1-5 Example of spark
testing term-SPRIGS.
Figure 1-6 Example of spark
testing term-DASHES.
Figure 1-7 Example of spark
testing term-APPENDAGES.
NAVEDTRA 14250A 1-11
-
against the wheel can increase the temperature of the spark
stream, which in turn increases the temperature of the burst and
gives the appearance of a higher carbon content than actually is
present.
Use the following technique when making the test:
Watch a point about one third of the distance from the tail end
of the spark stream.
Watch only those sparks that cross your line of vision and try
to form a mental image of the individual spark.
Fix this spark image in your mind and then examine the whole
spark picture.
An abrasive wheel on a grinder traveling at high speed requires
respect, and you need to review some of the safety precautions
associated with this tool (Figure 1-9).
Never use a cracked or out of balance wheel.
o Vibration can cause the wheel to shatter, and when an abrasive
wheel shatters, it can be disastrous for personnel standing in line
with the wheel.
Always check the wheel for secure mounting and cracks before
using.
When you install a new wheel on a grinder, be sure it is the
correct size and designated RPM.
o As you increase a wheels radius, the peripheral speed at the
rim increases even though the rpms remain the same. Thus, if you
use an oversized wheel, there is a distinct danger the peripheral
speed can become so great that the consequent centrifugal force can
cause the wheel to fly apart. Guards are placed on grinders as
protection in case a wheel should shatter, but they cannot provide
total protection.
Never use a grinder when the guards have been removed.
o When you turn the grinder on, stand to one side; this places
you out of line with the wheels centrifugal force in case the wheel
should burst.
Never overload a grinder or put sideways pressure against the
wheel unless it is expressly built to withstand such use.
Always wear appropriate safety goggles or a face shield while
using the grinder.
Ensure the work rest is adjusted to the minimum clearance for
the wheel, and move the work across the entire face of the
wheel.
o This helps eliminate grooving and minimizes the need for wheel
dressing, thus prolonging the life of the wheel.
Figure 1-9 Example of a grinders OSHA-designated safety
points.
NAVEDTRA 14250A 1-12
-
Keep your fingers clear of the abrasive surface, and do not
allow rags or clothing to become entangled in the wheel.
Do not wear gloves while using an abrasive wheel.
Never hold metal with tongs while grinding.
Never grind nonferrous metals on a wheel intended for ferrous
metals.
o Misuse can clog the pores of the abrasive material with metal
buildup, which in turn can cause the wheel to become unbalanced and
fly apart.
Grinding wheels require frequent reconditioning.
Dressing is the term you use to describe the cleaning of the
working face of an abrasive wheel.
Proper dressing breaks away dull abrasive grains, smoothes the
surface, and removes grooves.
The wheel dresser shown in Figure 1-10 is used for dressing
grinding wheels on bench and pedestal grinders.
Figure 1-10 Typical wheel dresser.
Refer now to Figure 1-11 through Figure 1-16 for examples of
spark testing results for specific identified material.
NAVEDTRA 14250A 1-13
-
Low-carbon steel
Spark stream is white.
Spark stream is about 70 inches long.
Volume is moderately large.
A few sparklers may occur at any place and are forked.
Figure 1-11 Example of low-carbon and cast steel spark
stream.
High-carbon steel
Spark stream is white.
Spark stream is about 55 inches long.
Volume is larger than low-carbon steel.
Sparklers are small and repeating.
Figure 1-12 Example of high-carbon spark stream.
NAVEDTRA 14250A 1-14
-
Gray cast iron
Spark stream near the wheel is red.
Spark stream in the outer portion is straw colored.
Spark stream is about 25 inches long.
Volume is rather small.
Sparklers are small and repeating.
Figure 1-13 Example of gray cast iron spark stream.
Monel and Nickel
Spark stream is orange.
Spark stream forms short wavy streaks.
Volume is small.
There are no sparklers.
Because of their similar spark pictures, you must use some other
method to distinguish monel from nickel.
Figure 1-14 Example of monel and nickel spark streams.
NAVEDTRA 14250A 1-15
-
Stainless steel
Spark stream next to the wheel is straw colored.
Spark stream at the end is white.
Spark stream is about 50 inches long.
Volume is moderate with few sparklers.
Sparklers are forked.
Figure 1-15 Example of stainless steel spark stream.
Wrought iron
Spark stream next to the wheel is straw colored.
Spark stream at the end is brighter red.
Spark stream is about 65 inches long.
Volume is large with few sparklers.
Sparklers are forked near the end of the stream.
Figure 1-16 Example of wrought iron spark stream.
One way to become proficient in identifying ferrous metals by
spark testing is to practice by testing yourself in the blind.
Gather an assortment of known metals for testing. Make individual
samples so similar that size and shape will not reveal their
identities. Number each sample and prepare a master list of correct
names with corresponding numbers.
Then, without looking at the number on the sample, spark test it
and call out its name to someone assigned to check your
identification against the names and numbers on the list. Repeating
this self-testing practice will give you some of the experience you
need to become proficient in identifying individual samples.
NAVEDTRA 14250A 1-16
-
2.3.0 Chip Test Another simple field test you can use to
identify an unknown piece of metal is the chip test. You perform
the chip test by removing a small amount of material from the test
piece with a sharp, cold chisel. The material you remove can vary
from small, broken fragments to a continuous strip. The chip may
have smooth, sharp edges, may be coarse-grained or fine-grained, or
may have saw-like edges.
The size of the chip is important in identifying the metal, as
well as the ease with which you can accomplish the chipping. Refer
to Table 1-2 for information to help you identify various metals by
the chip test.
Table 1-2 Metal Identification by Chip Test
Metal Chip Characteristics
Aluminum and Aluminum Alloys
Smooth with saw tooth edges. A chip can be cut as a continuous
strip.
Brass and Bronze Smooth with saw tooth edges. These metals are
easily cut, but chips are more brittle than chips of copper.
Continuous strip is not easily cut.
Copper Smooth with saw tooth edges where cut. Metal is easily
cut as a continuous strip.
Iron, Cast-white Small brittle fragments. Chipped surfaces are
not smooth.
Iron, Cast-gray About 1/8 inch in length. Metal is not easily
chipped; therefore, chips break off and prevent smooth cut.
Iron, Malleable Vary from 1/4 to 3/8 inch in length (larger than
chips from cast iron). Metal is tough and hard to chip.
Iron, Wrought Smooth edges. Metal is easily cut or chipped, and
a chip can be made as a continuous strip.
Lead Any shape may be obtained because the metal is so soft that
it can be cut with a knife.
Monel Smooth edges. Continuous strips can be cut. Metal chips
easily.
Nickel Smooth edges. Continuous strips can be cut. Metal chips
easily.
Steel, Cast and Steel, Low-carbon
Smooth edges. Metal is easily cut or chipped, and a chip can be
taken off as a continuous strip.
Steel, High-carbon Show a fine-grain structure. Edges of chips
are lighter in color than chips of low-carbon steel. Metal is hard,
but can be chipped in a continuous strip.
2.4.0 Magnetic Test A magnet test is another method you can use
to aid in a metals general identification. Remember: ferrous metals
are iron-based alloys and normally magnetic; nonferrous metals are
nonmagnetic. This test is not 100 percent accurate because some
stainless steels are nonmagnetic, but it can aid in the first
differentiation of most metals. When dealing with stainless steel,
there is no substitute for experience.
2.5.0 Hardness Test Hardness is the property of a material to
resist permanent indentation. One simple way to check for hardness
in a piece of metal is to file a small portion of it. If it is soft
enough to be machined with regular tooling, the file will cut it.
If it is too hard to machine, the file
NAVEDTRA 14250A 1-17
-
will not cut it. This method will indicate whether the material
being tested is softer or harder than the file, but it will not
tell exactly how soft or hard it is.
The file can also be used to determine the harder of two pieces
of metal; the file will cut the softer metal faster and easier. The
file method should be used only in situations when the exact
hardness is not required. This test has the added advantage of
needing very little in the way of time, equipment, and
experience.
Because there are several methods of measuring exact hardness,
the hardness of a material is always specified in terms of the
particular test used to measure this property. Rockwell, Vickers,
or Brinell are some of the methods of testing.
Of these tests, Rockwell is the one most frequently used, and
requires a Rockwell hardness testing machine. The basic principle
used in the Rockwell test is that a hard material can penetrate a
softer one, and the amount of penetration is measured and compared
to a scale.
For ferrous metals, usually harder than nonferrous metals, a
diamond tip is used for depth penetration measurement and the
hardness is indicated by a Rockwell C number. On nonferrous metals,
which are softer, a metal ball is used for surface indentation
measurement and the hardness is indicated by a Rockwell B
number.
Consider lead and steel for an idea of the property of hardness.
Lead can be scratched with a pointed wooden stick, but steel cannot
because it is harder than lead.
You can get a more complete explanation of the various methods
used to determine the hardness of a material from commercial books
or books located in your base library.
Summary This chapter has introduced you to the basics of the
different types of metals and the simple field and shop methods you
can use to identify them. From here, you can begin to build on your
experiences to become a seasoned Steelworker considered a resident
expert on metals. Steelworker Advanced will provide additional,
in-depth information about metal properties in their varied
compositions and alloys, along with a discussion of additional
uses.
NAVEDTRA 14250A 1-18
-
Review Questions (Select the Correct Response)1. What term is
used to describe the equivalent of the Steelworker rating in
civilian
construction?
A. Steel erector B. Iron placer C. Steel fabricator D.
Ironworker
2. A material must be primarily composed of _____ to be
considered a ferrous
metal.
A. steel B. iron C. nickel D. copper
3. Ferrous metals are typically _____.
A. magnetic B. nonmagnetic C. copper colored D. alloy-free
4. Which type of iron is one of the main raw materials used to
make steel?
A. Ingot B. Cast C. Pig D. Wrought
5. What characteristic of pig iron limits its use?
A. It is comparatively weak and brittle. B. It is difficult to
remelt. C. It cannot be combined with other metals. D. It is used
exclusively for manufacturing cast-iron pipe.
6. What material do Steelworkers use the most?
A. Steel B. Cast iron C. Copper D. Wrought iron
NAVEDTRA 14250A 1-19
-
7. Cast iron is any iron containing greater than _____
alloy.
A. .5% B. 1% C. 1.5% D. 2%
8. What process is used to produce malleability in cast
iron?
A. Remelting B. Annealing C. Plating D. Alloying
9. What group of steel is best suited for the manufacture of
crane hooks and axles?
A. High carbon B. Medium carbon C. Mild carbon D. Low carbon
10. What groups specifications cover high-strength steels?
A. American Society for Testing and Materials (ASTM) B. American
Society of Mechanical Engineers (ASME)
C. Society of Automotive Engineers (SAE) D. American Iron and
Steel Institute (AISI)
11. What groups specifications cover stainless steels?
A. American Society for Testing and Materials (ASTM) B. American
Society of Mechanical Engineers (ASME) C. Society of Automotive
Engineers (SAE) D. American Iron and Steel Institute (AISI)
12. What stainless steel is normally nonmagnetic?
A. Martensitic-chromium of the 300 series B. Austenitic
chromium-nickel of the 300 series C. Ferritic-austenite of the 400
series D. Ferritic-chromium of the 400 series
13. What common alloy steel is used to make high-quality hand
tools?
A. Nickel steel B. Chromium steel C. Chrome Vanadium steel D.
Tungsten steel
NAVEDTRA 14250A 1-20
-
14. Which of the following metals is nonferrous?
A. Cast iron B. Carbon steel C. Aluminum D. Pig iron
15. What combination of elements in proper proportion make
bronze?
A. Copper-Zinc B. Copper-Lead C. Copper-Aluminum D.
Copper-Tin
16. What action does the letter T signify when used in
conjunction with a numbering
system that classifies different aluminum alloys?
A. The metal has been heat-treated. B. The alloying elements
have been tempered. C. The major alloying element has been tested.
D. The metal has been covered with a tungsten-rolled cover.
17. What manufacturing marks can you look for when a metals
color does not
provide positive identification?
A. Evidence of a sand mold B. Forging marks C. Rolling marks D.
All of the above
18. When applying the spark test to a metal, you notice the
spark stream has white
shafts and forks only. What does this condition indicate about
the metal under test?
A. It is a high-carbon steel. B. It is a low-carbon steel. C. It
is a nickel alloy. D. It is a molybdenum alloy.
19. What metal produces a spark stream about 25 inches long with
small and
repeating sparklers of small volume that are initially red in
color?
A. Nickel B. Stainless steel C. Grey cast iron D. Monel
metal
NAVEDTRA 14250A 1-21
-
20. Which of the following metals produces the shortest length
spark stream?
A. High-carbon steel B. Low-carbon steel C. White cast iron D.
Nickel
21. You perform the chip test by removing a small amount of
material from the test
piece with a _____.
A. sharp, cold chisel B. drill press with inch bit C. hack saw
D. cut-off saw
22. (True or False) You can depend on a magnetic test for 100%
accuracy to
determine a ferrous metal.
A. True B. False
NAVEDTRA 14250A 1-22
-
Trade Terms Introduced in this Chapter Annealing Subjecting
(glass or metal) to a process of heating and
slow cooling in order to toughen and reduce brittleness.
Austenitic Consisting mainly of austenite, which is a
nonmagnetic solid solution of ferric carbide, or carbon in iron
used in making corrosion-resistant steel.
Bessemer process Named for Sir Henry Bessemer, an industrial
process for the manufacture of steel from molten pig iron. The
principle involved is that of oxidation of the impurities in the
iron by the oxygen of air that is blown through the molten iron;
the heat of oxidation raises the temperature of the mass and keeps
it molten during operation.
Ferritic Consisting of the pure iron constituent of ferrous
metals, as distinguished from the iron carbides.
Ferrous An adjective used to indicate the presence of iron. The
word is derived from the Latin word ferrum ("iron"). Ferrous metals
include steel and pig iron (with a carbon content of a few percent)
and alloys of iron with other metals (such as stainless steel).
Ingot A material, usually metal, that is cast into a shape
suitable for further processing. Ingots require a second procedure
of shaping, such as cold/hot working, cutting or milling to produce
a useful final product.
Malleable Capable of great deformation without breaking, when
subject to compressive stress.
Martensitic Consisting of a solid solution of iron and up to one
percent of carbon, the chief constituent of hardened carbon tool
steels.
Nonferrous The term used to indicate metals other than iron and
alloys that do not contain an appreciable amount of iron.
NAVEDTRA 14250A 1-23
-
Additional Resources and References This chapter is intended to
present thorough resources for task training. The following
reference works are suggested for further study. This is optional
material for continued education rather than for task training.
Althouse, Andrew D., Carl H. Turnquist, and William A. Bowditch,
Modern Welding, Goodheart-Wilcox Co. Inc., 1970.
Giachino and Weeks, Welding Skills, American Technical
Publishers Inc., 1985. Welding Theory and Application, TM 9-237,
Department of the Army Technical Manual, Headquarters, Department
of the Army, Washington D.C., 1976.
NAVEDTRA 14250A 1-24
-
CSFE Nonresident Training Course User Update CSFE makes every
effort to keep their manuals up-to-date and free of technical
errors. We appreciate your help in this process. If you have an
idea for improving this manual, or if you find an error, a
typographical mistake, or an inaccuracy in CSFE manuals, please
write or email us, using this form or a photocopy. Be sure to
include the exact chapter number, topic, detailed description, and
correction, if applicable. Your input will be brought to the
attention of the Technical Review Committee. Thank you for your
assistance. Write: CSFE N7A
3502 Goodspeed St. Port Hueneme, CA 93130
FAX: 805/982-5508
E-mail: [email protected]
Rate____ Course
Name_____________________________________________
Revision Date__________ Chapter Number____ Page
Number(s)____________
Description
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
(Optional) Correction
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
(Optional) Your Name and Address
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
NAVEDTRA 14250A 1-25
SW Basic Full Volume.pdfInstruction PageSW Basic CoverSW Basic
CopyrightSW B Table of ContentsSW Basic Ch 1 Introduction to Types
and Identification of MetalChapter 1Introduction to Types and
Identification of
MetalTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 BASIC METAL TYPES1.1.0 Ferrous Metals1.1.1 Iron1.1.2
Steel
1.2.0 Nonferrous Metals
2.0.0 BASIC METAL IDENTIFICATION2.1.0 Surface Appearance2.2.0
Spark Test2.3.0 Chip Test2.4.0 Magnetic Test2.5.0 Hardness Test
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 2 Basic Heat TreatmentChapter 2Basic Heat
TreatmentTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 HEAT TREATMENT THEORY2.0.0 STAGES of HEAT
TREATMENT2.1.0 Heating Stage2.2.0 Soaking Stage2.3.0 Cooling
Stage
3.0.0 RECOGNIZING HEAT COLORS for STEEL4.0.0 TYPES of HEAT
TREATMENT4.1.0 Annealing4.1.1 Ferrous Metal4.1.2 Nonferrous
Metal
4.2.0 Normalizing4.3.0 Hardening4.3.1 Case Hardening4.3.1.1
Carburizing4.3.1.2 Cyaniding4.3.1.3 Nitriding4.3.2 Flame
Hardening
4.4.0 Tempering
5.0.0 QUENCHING MEDIA5.1.0 Liquid Quenching5.1.1 Water5.1.2
Brine5.1.3 Oil5.1.4 Caustic Soda
5.2.0 Dry Quenching5.2.1 Air5.2.2 Solids
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 3 Introduction to WeldingChapter 3Introduction to
WeldingTopicsOverviewObjectivesFeatures of this Manual1.0.0 WELDING
PROCESSES1.1.0 Gas Welding1.1.1 OXYFUEL GAS Welding (OFW)
ACETYLENE1.1.2 OXYFUEL GAS Welding (OFW) MAPPGAS
1.2.0 Arc Welding1.2.1 Common Arc Welding Processes1.2.1.1
Shielded Metal Arc Welding (SMAW)1.2.1.2 Gas Shielded Arc
Welding1.2.1.2.1 Gas Tungsten Arc Welding (GTAW)1.2.1.2.2 Gas Metal
Arc Welding (GMAW) 1.2.1.2.3 Flux Core Arc Welding (FCAW) 1.2.1.3
Resistance Spot Welding
2.0.0 WELDING TERMINOLOGY2.1.0 Filler Metals2.2.0 Fluxes2.3.0
Weld Joints2.4.0 Parts of Joints2.5.0 Types of Welds2.6.0 Parts of
Welds
3.0.0 WELDED JOINT DESIGN3.1.0 Butt Joints3.2.0 Corner
Joints3.3.0 Tee Joints3.4.0 Lap Joints3.5.0 Edge Joints
4.0.0 WELDING POSITIONS 5.0.0 EXPANSION and CONTRACTION5.1.0
Controlling Distortion5.1.1 Preparation and Fit-up5.1.2 Heat
Input5.1.3 Preheat5.1.4 Number of Weld Passes5.1.5 Jigs and
Fixtures5.1.6 Allow for Distortion
6.0.0 WELDING PROCEDURES6.1.0 American Welding Society6.2.0
American Society of Mechanical Engineers
7.0.0 DRAWINGS7.1.0 Reading Drawings7.1.1 Lines
7.1.2 Dimensions7.1.3 Notes7.1.4 Views7.1.5 Handling and
Care
7.2.0 Welding Symbol7.2.1 Type of Weld (Weld Symbols)7.2.2
Dimensioning7.2.3 Supplementary7.2.4 Additional Information7.2.5
Multiple-Weld7.2.6 Application of Symbol
8.0.0 SAFETY8.1.0 Eye Protection8.2.0 Welding Helmet8.3.0
Protective Clothing8.4.0 Area Awareness
SummaryReview QuestionsTrade Terms Introduced in this
ChapterCSFE Nonresident Training Course User Update
SW Basic Ch 4 Gas CuttingChapter 4Gas
CuttingTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 OXYGAS CUTTING EQUIPMENT1.1.0 Acetylene1.1.1
Hazards1.1.2 Cylinder Design
1.2.0 MAPP Gas1.2.1 Cylinder Design1.2.2 MAPP
Characteristics1.2.3 Bulk MAPP Gas1.2.4 MAPP Gas Safety
1.3.0 Oxygen1.4.0 Regulators1.4.1 Single-Stage Regulators1.4.2
Double-Stage Regulators1.4.3 Problems and Safety
1.5.0 Hoses1.6.0 Cutting Torches1.6.1 Torch Body1.6.2 Cutting
Torch Tips1.6.2.1 Acetylene Tip Maintenance1.6.2.2 MAPP Tip
Maintenance
2.0.0 OXYGAS CUTTING OPERATIONS2.1.0 Equipment Setup2.1.1
Carburizing Flame2.1.2 Neutral Flame2.1.3 Oxidizing Flame
2.2.0 Cutting Mild-Carbon Steel2.2.1 Cutting Thin Steel2.2.2
Cutting Thick Steel
2.3.0 Cutting Cast Iron2.4.0 Gouging Mild Steel2.5.0 Beveling
Mild Steel2.6.0 Electric Drive Cutting Torch Carriage2.7.0 Cutting
and Beveling Pipe2.8.0 Piercing Holes2.9 0 Cutting Rivets2.10.0
Cutting Wire Rope2.11.0 Cutting on Containers
3.0.0 JUDGING CUTTING QUALITY3.1.0 Drag Lines3.2.0 Side
Smoothness3.3.0 Top Edge Sharpness3.4.0 Slag Conditions
4.0.0 SAFETY PRECAUTIONS4.1.0 Backfire and Flashback4.2.0
Cylinders4.2.1 Identification of Cylinders4.2.1.1 Color
Warnings4.2.1.2 Cylinder Color Bands4.2.1.3 Decals4.2.1.4
Shatterproof Cylinders4.2.1.5 Service Ownership4.2.2 Handling and
Storing Gas Cylinders
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 5 Gas WeldingChapter 5Gas
WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 OXYGAS WELDING EQUIPMENT1.1.0 Welding Torches1.2.0
Filler Rods
2.0.0 OPERATION and MAINTENANCE of OXYGAS EQUIPMENT2.1.0
Operation 2.1.1 Selecting the Welding Torch Tip Size2.1.2 Equipment
Setup2.1.3 Torch Lighting and Flame Adjustment
2.2.0 Maintaining the Equipment2.2.1 Torch Gas Leaks2.2.2
Welding Torch Tips2.2.3 Regulator Leaks
3.0.0 OXYGAS WELDING TECHNIQUES3.1.0 Forehand Welding3.2.0
Backhand Welding3.3.0 Multilayer Welding3.4.0 Joint Edge
Preparation3.5.0 Ferrous Metals3.6.0 Nonferrous Metals3.6.1
Copper3.6.2 Copper-Zinc Alloy (Brasses)3.6.3 Copper-Silicon Alloy
(Silicon Bronze)3.6.4 Copper-Nickel Alloy3.6.5 Nickel and
High-Nickel Alloys3.6.6 Lead3.6.7 Aluminum and Aluminum
Alloys3.6.7.1 Melting Characteristics3.6.7.2 WELDING RODS3.6.7.3
Welding Fluxes3.6.7.4 Welding Preparation3.6.7.5 Welding
Techniques
3.7.0 Welding Pipe
SummaryReview QuestionsTrade Terms Introduced in This
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 6 Soldering, Brazing, Braze Welding,
WearfacingChapter 6Soldering, Brazing, Braze Welding,
WearfacingTopicsOverviewObjectivesFeatures of this Manual1.0.0
SOLDERING1.1.0 Equipment1.1.1 Sources of Heat1.1.1.1 Soldering
Coppers1.1.1.1.1 Filing and Tinning Coppers1.1.1.1.2 Forging
Soldering Coppers1.1.1.2 Electric Soldering Coppers1.1.1.3 Gas
Torches1.1.2 Soft Solder1.1.2.1 Tin-Lead Solder1.1.2.2
Tin-Antimony-Lead Solder 1.1.2.3 Tin-Zinc Solder1.1.2.4
Tin-Antimony Solder1.1.2.5 Tin-Silver Solder1.1.2.6 Lead-Silver
Solder1.1.3 Fluxes1.1.3.1 Noncorrosive Fluxes1.1.3.2 Corrosive
Fluxes
1.2.0 Soldering Techniques1.2.1 Sweat Soldering1.2.2 Seam
Soldering
1.3.0 Soldering Aluminum Alloys
2.0.0 BRAZING2.1.0 Equipment2.1.1 Heating Devices2.1.2 Filler
Metals2.1.3 Fluxes
2.2.0 Joint Design2.2.1 Lap Joints2.2.2 Butt Joints2.2.3 Scarf
Joints
2.3.0 Brazing Procedures2.3.1 Surface Preparation2.3.2 Work
Support2.3.3 Fluxing2.3.4 Brazing2.3.5 Silver Brazing
3.0.0 BRAZE WELDING 3.1.0 EQUIPMENT3.1.1 Filler Metal3.1.2
Flux
3.2.0 Braze Welding Procedures
4.0.0 WEARFACING4.1.0 Wearfacing Materials4.1.1 Iron-Base
Alloys4.1.2 Tungsten Carbide
4.2.0 Wearfacing Procedures4.2.1 Preheating4.2.2 Application
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 7 Plasma Arc Cutting OperationsChapter 7Plasma Arc
Cutting OperationsTopicsOverviewObjectivesPrerequisitesFeatures of
this Manual1.0.0 PLASMA ARC CUTTING PROCESS 1.1.0 Description 1.2.0
Plasma vs. Oxy-Fuel Cutting
2.0.0 EQUIPMENT and CONSUMABLES 2.1.0 Equipment Requirements
2.1.1 Power Source 2.1.2 Rated Cutting Capacity 2.1.3 Cutting
Speed
2.2.0 Consumables 2.2.1 Swirl Ring2.2.2 Electrode2.2.3 Tip 2.2.4
Retaining Cup2.2.5 Shields2.2.6 Consumables Used During Extended
Cutting vs. Drag Cutting 2.2.7 Consumable Tips for Different
Amperages 2.2.8 Replacing Consumables 2.2.9 Cutting Gases
2.3.0 Improving Consumable life
3.0.0 CUTTING and GOUGING OPERATING SEQUENCE 3.1.0 High
Frequency Starts3.2.0 Contact Starts3.3.0 Pilot Arc Control Methods
3.4.0 Starting the Cut
4.0.0 PLASMA ARC GOUGING 5.0.0 QUALITIES of a PLASMA CUT 5.1.0
Kerf 5.2.0 Bevel Angle5.3.0 Drag Line5.4.0 Top Rounding5.5.0
Dross5.6.0 Six Steps to Good Cut Quality
6.0.0 SAFETY PROCEDURESSummaryReview QuestionsTrade Terms
Introduced in this ChapterAdditional Resources and ReferencesCSFE
Nonresident Training Course User Update
SW Basic Ch 8 Shielded Metal Arc WeldingChapter 8Shielded Metal
Arc WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 INTRODUCTION to the PROCESS 1.1.0 Methods of
Application 1.2.0 Advantages and Limitations
2.0.0 PRINCIPLES of OPERATION 2.1.0 Arc Systems 2.2.0 Electrical
Terms2.3.0 Metal Transfer
3.0.0 EQUIPMENT for WELDING 3.1.0 Power Sources 3.1.1 Types of
Current 3.1.2 Power Source Duty Cycle 3.1.3 Types of Power Sources
3.1.3.1 Generator and Alternator Welding Machines 3.1.3.2
Transformer Welding Machines 3.1.3.3 Transformer-Rectifier Welding
Machines 3.1.3.4 Three Phase Rectifier Welding Machines 3.1.3.5
Multiple Operator System 3.1.3.6 Inverter Power Sources 3.1.4
Selecting a Power Source
3.2.0 Controls 3.3.0 Electrode Holder 3.4.0 Welding Cables 3.5.0
Ground Clamps3.6.0 Accessories 3.7.0 Equipment Operation and
Maintenance
4.0.0 COVERED ELECTRODES4.1.0 Classification 4.2.0 Sizing 4.3.0
Selection of Electrode Class 4.3.1 Base Metal Strength
Properties4.3.2 Base Metal Composition4.3.3 Welding Position4.3.4
Welding Current4.3.5 Joint Design and Fit-Up4.3.6 Thickness and
Shape of Base Metal4.3.7 Service Conditions and/or
Specifications4.3.8 Production Efficiency and Job Condition
4.4.0 Selection of Electrode Size 4.5.0 Conformances and
Approvals
5.0.0 WELDING APPLICATIONS5.1.0 Industries 5.1.1 Field Welded
Storage Tanks 5.1.2 Pressure Vessels 5.1.3 Industrial Piping 5.1.4
Transmission Pipelines 5.1.5 Nuclear Power Plants 5.1.6 Structures
5.1.7 Ships 5.1.8 Transportation 5.1.9 Industrial Machinery 5.1.10
Heavy Equipment 5.1.11 Maintenance and Repair
5.2.0 Variations of the Process 5.3.0 Wearfacing5.3.1 Workpiece
Preparation5.3.2 Preheating5.3.3 Techniques5.3.3.1 Bulldozer
Blades5.3.3.2 Shovel teeth
5.4.0 Carbon-Arc Cutting5.4.1 Air Carbon-Arc Cutting5.4.2 Air
Carbon-Arc Gouging5.4.3 Metal Electrode Arc Cutting
6.0.0 WELDING METALLURGY6.1.0 Properties of the Weld 6.1.1
Chemical Properties 6.1.2 Mechanical Properties 6.1.3
Microstructure
6.2.0 Metals Weldable 6.2.1 Steels 6.2.1.1 Mild Steels 6.2.1.2
Low Alloy Steels 6.2.1.3 Heat Treatable Steels 6.2.1.4
Chromium-Molybdenum Steels 6.2.1.5 Stainless & Higher
Chromium-Molybdenum Steels 6.2.1.6 Free Machining Steels 6.2.2 Cast
Irons 6.2.2.1 Gray Cast Iron 6.2.2.2 Nodular and Malleable Cast
Irons 6.2.3 Copper and Copper Alloys 6.2.4 Nickel and Nickel
Alloys
7.0.0 WELD AND JOINT DESIGN7.1.0 Strength 7.2.0 Position 7.3.0
Thickness 7.4.0 Accessibility 7.5.0 Weld Joint Designs7.6.0 Arc
Welding Positions7.6.1 Flat-Position Welding7.6.2
Horizontal-Position Welding7.6.2.1 Electrode Movement7.6.2.2 Joint
Type7.6.3 Vertical-Position Welding7.6.3.1 Current Settings and
Electrode Movement7.6.3.2 Joint Type7.6.3.3 E-7018 Electrode
Welding Technique7.6.4 Overhead-Position Welding7.6.4.1 Current
Settings and Electrode Movement7.6.4.2 Type of Welds7.6.5 Pipe
welding7.6.5.1 Pipe welding positions7.6.5.2 Pipe welding
procedures7.6.5.3 Joint preparation and fit-up7.6.6 Tack
welding7.6.7 Spacers7.6.8 Electrode selection7.6.9 Weather
conditions
8.0.0 WELDING PROCEDURE VARIABLES8.1.0 Fixed Variables 8.1.1
Electrode Type 8.1.2 Electrode Size 8.1.3 Current Type
8.2.0 Primary Variables 8.2.1 Welding Current 8.2.2 Travel Speed
8.2.3 Welding Voltage (Arc Length) 8.2.4 Starting the Arc8.2.4.1
Breaking the Arc8.2.4.2 Reestablishing the Arc8.2.4.3 Peening
8.3.0 Secondary Variables 8.3.1 Angles of the Electrode
9.0.0 WELDING PROCEDURE SCHEDULES10.0.0 PREWELD
PREPARATIONS10.1.0 Preparing the Weld Joint 10.2.0 Fixturing and
Positioning 10.3.0 Preheating
11.0.0 WELDING DEFECTS and PROBLEMS11.1.0 Discontinuities Caused
by Welding Technique 11.1.1 Slag Inclusions11.1.2 Wagon
Tracks11.1.3 Porosity11.1.4 Wormhole Porosity (Piping
Porosity)11.1.5 Undercutting11.1.6 Lack of Fusion11.1.7
Overlapping11.1.8 Burn Through 11.1.9 Arc Strikes 11.1.10 Craters
11.1.11 Excessive Weld Spatter
11.2.0 Cracking 11.3.0 Other Problems 11.3.1 Arc Blow 11.3.2
Improper Moisture Content 11.3.3 Fingernailing
12.0.0 POSTWELD PROCEDURE12.1.0 Cleaning 12.2.0 Inspection and
Testing 12.2.1 Welding Quality Control
12.3.0 Repairing of Welds 12.4.0 Postheating
13.0.0 WELDER TRAINING and QUALIFICATION13.1.0 Welder Training
13.1.1 Basic Shielded Metal Arc Welding 13.1.2 Advanced Shielded
Metal Arc Welding 13.1.3 Shielded Metal Arc Pipe Welding
13.2.0 Welder Qualification
14.0.0 WELDING SAFETY14.1.0 Electrical Shock 14.2.0 Arc
Radiation 14.3.0 Air Contamination 14.4.0 Fires and Explosions
14.5.0 Weld Cleaning and Other Hazards 14.6.0 Summary of Safety
Precautions
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 9 GasTungsten Arc WeldingChapter 9Gas Tungsten Arc
WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 INTRODUCTION to the PROCESS 1.1.0 Methods of
Application 1.2.0 Advantages and Limitations
2.0.0 PRINCIPLES of OPERATION 2.1.0 Arc Systems
3.0.0 EQUIPMENT for WELDING 3.1.0 Power Sources 3.1.1 Power
Source Duty Cycle
3.2.0 Types of Welding Current3.2.1 Direct Current3.2.2 Pulsed
Current3.2.3 Alternating Current3.2.4 High-Frequency Current
3.3.0 Types of Power Sources 3.3.1 Generator and Alternator
Welding Machines 3.3.2 Transformer-Rectifier Welding Machines 3.3.3
Inverter Power Sources 3.3.4 Transformer Welding Machines3.3.5
Square Wave Power Source
3.4.0 Controls 3.5.0 Welding Torches3.6.0 Gas Shielding
System3.7.0 Welding Cables 3.8.0 Other Equipment3.8.1 Filler Wire
Feeders3.8.2 Water Circulators3.8.3 Motion Devices
4.0.0 EQUIPMENT SETUP, ADJUSTMENT, and SHUTDOWN4.1.0 Equipment
Setup4.2.0 Preparing the Electrode Tip4.3.0 Assembling the
Torch4.4.0 Setting Up the Shielding Gas System4.5.0 Setting Up the
Welding Parameters4.6.0 System Shutdown and Clean Up
5.0.0 ELECTRODES, SHIELDING GAS, and FILLER METAL5.1.0
Electrodes5.2.0 Shielding Gases5.2.1 Argon5.2.2 Helium5.2.3
Argon-Helium Mixtures5.2.4 Argon-Hydrogen Mixtures5.2.5
Nitrogen
5.3.0 Filler Metals5.3.1 Classification 5.3.2 Sizing
5.4.0 Selection of Filler Metal 5.5.0 Conformances
6.0.0 WELDING APPLICATIONS6.1.0 Industries 6.1.1 Industrial
Piping 6.1.2 Nuclear Power Facilities 6.1.3 Ships 6.1.4
Aerospace6.1.5 Transportation6.1.6 Pressure Vessels, Boilers, and
Heat Exchangers6.1.7 Maintenance and Repair6.1.8 Miscellaneous
6.2.0 Arc Spot Welding
7.0.0 WELDING METALLURGY7.1.0 Properties of the Weld 7.1.1
Chemical Properties 7.1.2 Mechanical Properties 7.1.3
Microstructure
7.2.0 Weldable Metals7.2.1 Aluminum and Aluminum Alloys7.2.2
Copper and Copper Alloys 7.2.3 Magnesium and Magnesium Alloys7.2.4
Nickel and Nickel Alloys 7.2.5 Steels 7.2.5.1 Plain Carbon and Low
Alloy Steels 7.2.5.2 Cast Iron 7.2.5.3 Free Machining Steels
7.2.5.4 Stainless Steels 7.2.6 Titanium and Titanium Alloys7.2.7
Other Metals
8.0.0 WELD JOINT DESIGN8.1.0 Types of Metal8.2.0 Strength 8.3.0
Position 8.4.0 Thickness 8.5.0 Accessibility 8.6.0 Consumable
Inserts8.7.0 Weld Joint Designs8.8.0 Welding Positions8.8.1
Flat-Position Welding
9.0.0 WELDING PROCEDURE VARIABLES9.1.0 Fixed Variables9.1.1 Type
of Electrode9.1.2 Electrode Size 9.1.3 Type of Welding Current9.1.4
Type of Shielding Gas9.1.5 Electrode Taper Angle
9.2.0 Primary Variables 9.2.1 Welding Current 9.2.2 Travel
Speed9.2.3 Welding Voltage (Arc Length)
9.3.0 Secondary Variables 9.3.1 Angles of the Electrode9.3.2
Electrode Extension
10.0.0 WELDING PROCEDURE SCHEDULES11.0.0 PREWELD
PREPARATIONS11.1.0 Preparing the Weld Joint 11.2.0 Cleaning the
Work Metal11.3.0 Electrode Tip Preparation11.4.0 Fixturing,
Positioning, and Weld Backing 11.5.0 Preheating
12.0.0 WELDING DISCONTINUITIES and PROBLEMS12.1.0
Discontinuities Caused by Welding Technique 12.1.1 Tungsten
Inclusions12.1.2 Oxide Inclusions12.1.3 Porosity12.1.4 Wormhole
Porosity (Piping Porosity)12.1.5 Undercutting12.1.6 Incomplete
Fusion12.1.7 Overlapping12.1.8 Melt-through 12.1.9 Arc Strikes
12.1.10 Craters
12.2.0 Cracking 12.3.0 Other Problems 12.3.1 Arc Blow 12.3.2
Inadequate Shielding12.3.3 Electrode Contamination
13.0.0 POSTWELD PROCEDURE13.1.0 Cleaning 13.2.0 Inspection and
Testing 13.3.0 Repairing of Welds 13.4.0 Postheating
14.0.0 WELDER TRAINING and QUALIFICATION14.1.0 Basic Gas
Tungsten Arc Welding 14.1.1 Mild Steel14.1.2 Stainless Steel14.1.3
Aluminum
14.2.0 Gas Tungsten Arc Pipe Welding 14.2.1 Course Introduction
14.2.2 Small Diameter Piping and Tubing 14.2.3 8-lnch Diameter
Pipe
14.3.0 Welder Qualification
15.0.0 WELDING SAFETY15.1.0 Electrical Shock 15.2.0 Arc
Radiation 15.3.0 Air Contamination 15.4.0 Compressed Gasses15.5.0
Fires and Explosions 15.6.0 Weld Cleaning and Other Hazards 15.7.0
Summary of Safety Precautions
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 10 Gas Metal Arc WeldingChapter 10Gas Metal Arc
WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 INTRODUCTION to the PROCESS 1.1.0 Methods of
Application 1.2.0 Advantages and Limitations
2.0.0 PRINCIPLES of OPERATION 2.1.0 Arc Systems 2.2.0 Metal
Transfer 2.2.1 Short Circuiting Transfer2.2.2 Globular
Transfer2.2.3 Spray Transfer2.2.4 Pulsed Current Transfer
3.0.0 EQUIPMENT for WELDING 3.1.0 Power Sources 3.1.1 Power
Source Duty Cycle 3.1.2 Types of Current 3.1.3 Types of Power
Sources 3.1.3.1 Generator Welding Machines 3.1.3.2
Transformer-Rectifier Welding Machines 3.1.3.3 Inverter Power
Sources
3.2.0 Controls 3.3.0 Wire Feeders 3.4.0 Welding Guns3.4.1
Semiautomatic Guns3.4.2 Machine Welding Guns
3.5.0 Shielding Gas Equipment3.6.0 Welding Cables 3.7.0 Other
Equipment3.7.1 Water Circulators3.7.2 Motion Devices3.7.3
Accessories
4.0.0 INSTALLATION, SETUP, and MAINTENANCE of EQUIPMENT4.1.0
Power Source Connections4.2.0 Gun Cable Assembly4.3.0 Wire
Installation4.4.0 Gas Cylinder Installation4.5.0 Amperage and
Voltage Settings4.6.0 Equipment Shutdown and Clean Up4.7.0 Burn
Back4.8.0 Bird Nests
5.0.0 SHIELDING GAS and ELECTRODES5.1.0 Shielding Gases5.1.1
Argon5.1.2 Helium5.1.3 Carbon Dioxide5.1.4 Argon-Helium
Mixtures5.1.5 Argon-Oxygen Mixtures5.1.6 Argon-Carbon Dioxide
Mixtures5.1.7 Helium-Argon-Carbon Dioxide Mixtures5.1.8
Nitrogen
5.2.0 Shielding Gas Flow Rate5.3.0 Electrodes5.3.1
Classification 5.3.2 Sizing
5.4.0 Electrode Selection 5.5.0 Conformances and Approvals
6.0.0 WELDING APPLICATIONS6.1.0 Industries 6.1.1 Pressure
Vessels 6.1.2 Industrial Piping 6.1.3 Transmission Pipelines 6.1.4
Nuclear Power Facilities 6.1.5 Structures 6.1.6 Ships 6.1.7
Railroads 6.1.8 Automotive 6.1.9 Aerospace6.1.10 Heavy
Equipment
6.2.0 Variations of the Process 6.2.1 Arc Spot Welding6.2.2
Narrow Gap Welding
7.0.0 WELDING METALLURGY7.1.0 Properties of the Weld 7.1.1
Chemical and Physical Properties 7.1.2 Mechanical Properties 7.1.3
Microstructure
7.2.0 Metals Weldable 7.2.1 Aluminum and Aluminum Alloys7.2.2
Copper and Copper Alloys 7.2.3 Magnesium and Magnesium Alloys7.2.4
Nickel and Nickel Alloys 7.2.5 Steels 7.2.5.1 Low Carbon and Mild
Steels 7.2.5.2 Low Alloy Steels 7.2.5.3 Heat Treatable Steels
7.2.5.4 Chromium-Molybdenum Steels 7.2.5.5 Free Machining Steels
7.2.5.6 Stainless Steels 7.2.6 Titanium and Titanium Alloys
8.0.0 WELD and JOINT DESIGN8.1.0 Strength 8.2.0 Position 8.3.0
Thickness 8.4.0 Accessibility 8.4.1 Backing Strips
8.5.0 Types of Metal8.6.0 Weld Joint Designs8.6.1 Welding
Symbols
8.7.0 Welding Positions8.7.1 Flat-Position Welding
9.0.0 WELDING PROCEDURE VARIABLES9.1.0 Fixed Variables9.1.1
Electrode Size 9.1.2 Type of Shielding Gas
9.2.0 Primary Variables 9.2.1 Starting the Arc 9.2.2 Welding
Current 9.2.3 Welding Voltage (Arc Length) 9.2.4 Travel Speed
9.3.0 Secondary Variables 9.3.1 Electrode Extension9.3.2
Electrode Angles
10.0.0 WELDING PROCEDURE SCHEDULES11.0.0 PREWELD
PREPARATIONS11.1.0 Preparing the Weld Joint 11.2.0 Cleaning the
Work Metal11.3.0 Fixturing and Positioning 11.4.0 Preheating
12.0.0 WELDING DISCONTINUITIES and PROBLEMS12.1.0
Discontinuities Caused by Welding Technique 12.1.1 Inclusions12.1.2
Porosity12.1.3 Wormhole Porosity (Piping Porosity)12.1.4
Undercutting12.1.5 Incomplete Fusion12.1.6 Overlapping12.1.7
Melt-through 12.1.8 Whiskers12.1.9 Excessive Weld Spatter 12.1.10
Arc Strikes 12.1.11 Craters
12.2.0 Cracking 12.3.0 Other Problems 12.3.1 Arc Blow 12.3.2
Inadequate Shielding12.3.3 Clogged or Dirty Contact Tube12.3.4 Wire
Feed Stoppages
13.0.0 POSTWELD PROCEDURE13.1.0 Cleaning 13.2.0 Inspection and
Testing 13.3.0 Repairing of Welds 13.4.0 Postheating
14.0.0 WELDER TRAINING and QUALIFICATION14.1.0 Welder Training
14.1.1 Basic Gas Metal Arc Welding 14.1.2 Gas Metal Arc Welding
Steel Pipe
14.2.0 Welder Qualification
15.0.0 WELDING SAFETY15.1.0 Electrical Shock 15.2.0 Arc
Radiation 15.3.0 Air Contamination 15.4.0 Compressed Gasses15.5.0
Fires and Explosions 15.6.0 Weld Cleaning and Other Hazards 15.7.0
Summary of Safety Precautions
SummaryTrade Terms Introduced in this ChapterAdditional
Resources and ReferencesCSFE Nonresident Training Course User
Update
SW Basic Ch 11 Flux Cored Arc WeldingChapter 11Flux Cored Arc
WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 INTRODUCTION to the PROCESS 1.1.0 Methods of
Application 1.2.0 Advantages and Limitations
2.0.0 PRINCIPLES of OPERATION 2.1.0 Arc Systems 2.2.0 Metal
Transfer
3.0.0 EQUIPMENT for WELDING 3.1.0 Power Sources 3.1.1 Power
Source Duty Cycle 3.1.2 Types of Current 3.1.3 Types of Power
Sources 3.1.3.1 Generator and Alternator Welding Machines 3.1.3.2
Transformer Welding Machines
3.2.0 Controls 3.3.0 Wire Feeders 3.3.1 Machine Welding Guns
3.4.0 Fume Extractors3.5.0 Shielding Gas Equipment 3.6.0 Welding
Cables3.7.0 Other Equipment3.7.1 Water Circulators3.7.2 Motion
Devices3.7.3 Accessories
4.0.0 EQUIPMENT SETUP, OPERATION, and SHUT DOWN4.1.0 Protective
Clothing and Tools4.2.0 Obtaining Materials4.3.0 Set Up
Equipment4.4.0 Adjust Equipment4.5.0 Perform the Weld4.6.0 Shut
Down Equipment
5.0.0 SHIELDING GAS and ELECTRODES5.1.0 Shielding Gas5.1.1
Carbon Dioxide5.1.2 Argon-Carbon Dioxide Mixtures5.1.3 Argon-oxygen
mixture
5.2.0 Electrodes5.2.1 Classification 5.2.2 Electrode Selection
5.2.3 Conformance and Approvals
6.0.0 WELDING APPLICATIONS6.1.0 Industries 6.1.1 Structures
6.1.2 Ships 6.1.3 Industrial Piping 6.1.4 Railroads 6.1.5
Automotive Products 6.1.6 Heavy Equipment 6.1.7 Maintenance and
Repair
6.2.0 Flux Cored Arc Spot Welding
7.0.0 WELDING METALLURGY7.1.0 Properties of the Weld 7.2.0
Chemical Properties 7.3.0 Mechanical Properties 7.4.0
Microstructure 7.5.0 Metals Weldable 7.5.1 Steels 7.5.1.1
Low-carbon and Mild Steels 7.5.1.2 Low-alloy Steels 7.5.1.3 Heat
Treatable Steels 7.5.1.4 Chromium-Molybdenum Steels 7.5.1.5 Free
Machining Steels 7.5.1.6 Stainless Steels
8.0.0 WELD and JOINT DESIGN8.1.0 Process Method8.2.0 Type of
Metal8.3.0 Strength 8.4.0 Position 8.5.0 Thickness 8.6.0
Accessibility 8.6.1 Backing Strips
8.7.0 Weld Joint Designs8.8.0 Arc Welding Positions8.8.1
Flat-Position Welding8.8.2 Horizontal-Position Welding8.8.2.1
Electrode Movement8.8.2.2 Joint Type8.8.3 Vertical-Position
Welding8.8.3.1 Current Settings and Electrode Movement8.8.3.2 Joint
Type8.8.4 Overhead-Position Welding8.8.4.1 Current Settings and
Electrode Movement8.8.4.2 Type of Welds8.8.5 Pipe welding8.8.5.1
Pipe welding positions8.8.5.2 Pipe welding procedures8.8.5.3 Joint
preparation and fit-up8.8.6 Tack welding8.8.7 Spacers8.8.8
Electrode selection8.8.9 Weather conditions
9.0.0 WELDING PROCEDURE VARIABLES9.1.0 Fixed Variables 9.1.1
Electrode Type 9.1.2 Electrode Size
9.2.0 Primary Variables 9.2.1 Welding Current 9.2.2 Welding
Voltage (Arc Length) 9.2.3 Travel Speed
9.3.0 Secondary Variables 9.3.1 Electrode Extension9.3.2
Electrode Angles
10.0.0 WELDING PROCEDURE SCHEDULES11.0.0 PREWELD
PREPARATIONS11.1.0 Preparing the Weld Joint 11.2.0 Cleaning the
Work Metal11.3.0 Fixturing and Positioning 11.4.0 Preheating
12.0.0 WELDING DEFECTS and PROBLEMS12.1.0 Discontinuities Caused
by Welding Technique 12.1.1 Slag Inclusions12.1.2 Wagon
Tracks12.1.3 Porosity12.1.4 Wormhole Porosity (Piping
Porosity)12.1.5 Undercutting12.1.6 Lack of Fusion12.1.7
Overlapping12.1.8 Melt-Through 12.1.9 Excessive Weld Spatter
12.1.10 Arc Strikes 12.1.11 Craters
12.2.0 Cracking 12.3.0 Other Problems 12.3.1 Arc Blow 12.3.2
Inadequate Shielding 12.3.3 Clogged or Dirty Contact Tube 12.3.4
Wire Feed Stoppages
13.0.0 POSTWELD PROCEDURE13.1.0 Cleaning 13.2.0 Inspection and
Testing 13.3.0 Repairing of Welds 13.4.0 Postheating
14.0.0 WELDER TRAINING and QUALIFICATION14.1.0 Welder Training
14.1.1 Basic Flux Cored Arc Welding
14.2.0 Welder Qualification
15.0.0 WELDING SAFETY15.1.0 Electrical Shock 15.2.0 Arc
Radiation 15.3.0 Air Contamination 15.4.0 Compressed Gases15.5.0
Fires and Explosions 15.6.0 Weld Cleaning and Other Hazards 15.7.0
Summary of Safety Precautions
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 12 Welding Quality ControlChapter 12Welding Quality
ControlTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 INTRODUCTION 2.0.0 NONDESTRUCTIVE TESTING2.1.0 Visual
Inspection2.2.0 Magnetic Particle Inspection2.3.0 Liquid Penetrant
Inspection2.4.0 Radiographic Inspection2.5.0 Ultrasonic
Inspection2.6.0 Eddy Current Testing
3.0.0 DESTRUCTIVE TESTING3.1.0 Free-Bend Test3.2.0 Guided-Bend
Test3.3.0 Nick-Break Test3.4.0 Impact Test3.5.0 Fillet-Welded Joint
Test3.6.0 Etching Test3.7.0 Tensile Strength Test
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 13 Layout and Fabrication of Sheet-Metal and Fiber
and Glass DuctChapter 13Layout and Fabrication of Sheet Metal and
Fiberglass DuctTopicsOverviewObjectivesPrerequisitesFeatures of
this Manual1.0.0 TOOLS and EQUIPMENT1.1.0 Layout Tools 1.1.1
Scriber1.1.2 Flat Steel Square1.1.3 Combination Square1.1.4
Protractor1.1.5 Prick Punch1.1.6 Dividers 1.1.7 Trammel Points1.1.8
Circumference Ruler
1.2.0 Cutting Tools 1.3.0 Sheet Metal Bending and Forming
Equipment1.3.1 Stakes1.3.2 Other Forming Tools1.3.2.1 Bar
Folder1.3.2.2 Brakes1.3.2.3 Roll Forming Machine1.3.2.4 Combination
Rotary Machine
2.0.0 SHEET METAL DEVELOPMENT 2.1.0 Parallel Line Development
2.2.0 Radial Line Development2.3.0 Triangular Development2.4.0
Fabrication of Edges, Joints, Seams, and Notches 2.4.1 Edges2.4.2
Joints2.4.3 Seams2.4.4 Notches
3.0.0 JOINING and INSTALLING SHEET METAL DUCT 3.1.0 Metal
Screws3.2.0 Rivets3.3.0 Riveted Seams
4.0.0 SHEET METAL DUCT SYSTEMS 4.1.0 Shop Procedures 4.2.0 Shop
Drawings 4.3.0 Duct Material 4.4.0 Reinforcement and Support 4.5.0
Flexible Connections4.6.0 Hanging Duct
5.0.0 FIBERGLASS DUCT SYSTEMS5.1.0 Characteristics5.2.0
Fabrication5.3.0 Installation
6.0.0 SAFETYSummaryReview QuestionsTrade Terms Introduced in
this ChapterAdditional Resources and ReferencesCSFE Nonresident
Training Course User Update
SW Basic Ch 14 Fiber LineChapter 14Fiber
LineTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 FIBER LINE1.1.0 Types of Natural Fiber Line 1.1.1
Manila1.1.2 Sisal1.1.3 Hemp1.1.4 Coir1.1.5 Cotton
1.2.0 Types of Synthetic Fiber Lines 1.3.0 Fabrication of
Line1.3.1 Fibers1.3.2 Yarns1.3.3 Strands1.3.4 Lines
1.4.0 Types of Lays of Line1.4.1 Hawser-Laid1.4.2
Shroud-Laid1.4.3 Cable-Laid
1.5.0 Size Designation1.6.0 Handling and Care of Fiber Line1.6.1
Uncoiling1.6.2 Uncoiling Nylon1.6.3 Making Up1.6.4 Whipping1.6.5
Inspecting1.6.6 Storing
1.7.0 Strength of Fiber Line1.7.1 Breaking Strength 1.7.2 Safe
Working Load1.7.3 Safety Factor1.7.4 Breaking Strength of Nylon
Line
1.8.0 Knots, Bends, and Hitches1.8.1 Line Parts1.8.2 Overhand
Knot1.8.3 Figure-Eight Knot1.8.4 Square Knot1.8.5 Sheepshank1.8.6
Bowline1.8.7 French Bowline1.8.8 Spanish Bowline1.8.9 Running
Bowline1.8.10 Becket Bend1.8.11 Clove Hitch1.8.12 Scaffold
Hitch1.8.13 Barrel Hitch
1.9.0 Splicing Fiber Line1.9.1 Eye Splice1.9.2 Short Splice1.9.3
Long Splice1.9.4 Back Splice
1.10.0 Splicing Nylon Line
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 15 Wire RopeChapter 15Wire
RopeTopicsOverviewObjectivesPrerequisitesFeatures of this
Manual1.0.0 WIRE ROPE1.1.0 Construction 1.1.1 Wires1.1.2
Strands1.1.3 Core
1.2.0 Grades 1.2.1 Mild Plow Steel1.2.2 Plow Steel1.2.3 Improved
Plow Steel
1.3.0 Lays1.4.0 Lay Length1.5.0 Classification1.6.0
Selection1.6.1 Tensile Strength1.6.2 Crushing Strength1.6.3 Fatigue
Resistance1.6.4 Abrasion Resistance1.6.5 Corrosion Resistance
1.7.0 Measuring1.8.0 Safe Working Load1.9.0 Failure1.10.0
Attachments1.11.0 End Fittings1.11.1 Clips1.11.2 Clamps1.11.3
Thimble1.11.4 Wedge Socket1.11.5 Basket Socket1.11.5.1 Dry
Method1.11.5.2 Poured Method1.11.6 Splices
1.12.0 Handling and Care1.12.1 Coiling and Uncoiling1.12.2
Kinks1.12.3 Reverse Bends1.12.4 Sizes of Sheaves1.12.5 Seizing and
Cutting
1.13.0 Inspection1.14.0 Cleaning and Lubricating1.15.0
Storage
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 16 RiggingChapter
16RiggingTopicsOverviewObjectivesPrerequisites1.0.0 BLOCK and
TACKLE1.1.0 Terminology1.2.0 Block Construction1.3.0 Block to Line
Ratio1.4.0 Types of Blocks 1.4.1 Standing1.4.2 Traveling1.4.3
Snatch
1.5.0 Reeving Blocks1.6.0 Types of Tackle1.6.1 Single-whip1.6.2
Runner1.6.3 Gun Tackle1.6.4 Single-luff Tackle1.6.5 Twofold
Purchase1.6.6 Double-Luff1.6.7 Three-fold Purchase1.6.8 Compound
Tackle
1.7.0 Allowance for Friction1.8.0 Block Safety
2.0.0 SLINGS2.1.0 Slings and Rigging Gear Kits2.2.0 Wire Rope
Slings2.3.0 Fiber Line Sling2.3.1 Synthetic Web Slings
2.4.0 Chain Slings2.4.1 Metal Mesh Slings
2.5.0 Using Wire Rope and Fiber Slings2.5.1 Endless2.5.2 Single
Leg2.5.3 Bridle
2.6.0 Sling Inspection2.6.1 Synthetic Web Slings2.6.2 Synthetic
Round Slings2.6.3 Wire Rope Slings2.6.4 Wire Mesh Slings2.6.5 Alloy
Chain Slings
2.7.0 Proof Testing Slings2.8.0 Safe Working Loads of
Slings2.9.0 Sling Angle2.10.0 Storage
3.0.0 CHAINS3.1.0 Inspection3.2.0 Safe Working Loads3.3.0
Handling and Care
4.0.0 ADDITIONAL LIFTING EQUIPMENT4.1.0 Hooks4.1.1 Slip
Hooks4.1.2 Grab Hooks4.1.3 Mousing a Hook4.1.4 Inspection4.1.5 Hook
Strength
4.2.0 Shackles4.2.1 Safe Working Load4.2.2 Mousing a Shackle
4.3.0 Beam Clamps
5.0.0 OTHER LIFTING EQUIPMENT5.1.0 Spreader Bars5.2.0
Pallets5.3.0 Jacks5.4.0 Planks and Rollers5.5.0 Blocking and
Cribbing5.6.0 Scaffolds5.6.1 Planking and Runway Scaffold5.6.2
Swinging Platform Scaffold5.6.3 Needle-Beam Scaffold5.6.4
Boatswains Chair5.6.5 Safety
6.0.0 FIELD-ERECTED HOISTING DEVICES6.1.0 Holdfasts6.1.1 Natural
Types6.1.2 Single-Picket6.1.3 Combination-Picket6.1.4 Combination
Log Picket6.1.5 Deadman6.1.6 Steel Picket
6.2.0 Gin Poles6.3.0 Tripods6.4.0 Shears
7.0.0 SAFE RIGGING OPERATING PROCEDURESSummaryReview
QuestionsTrade Terms Introduced in this ChapterAdditional Resources
and ReferencesCSFE Nonresident Training Course User Update
SW Basic Ch 17 Pre-Engineered StructuresChapter 17Pre-Engineered
StructuresTopicsOverviewObjectivesPrerequisites1.0.0 PRE-ENGINEERED
BUILDINGS1.1.0 Pre-Erection Work1.2.0 Erection Procedures1.2.1
Bolting Rigid Frames1.2.2 Frame Erection1.2.3 Brace Rods1.2.4 Sag
Rods1.2.5 Brace Angles and Base Angles1.2.6 End-Wall
Framing/Doors/Windows1.2.7 Sheeting1.2.8 Building Insulation1.2.9
Multiple buildings Set Side by Side
1.3.0 Disassembly Procedures1.3.1 Marking
2.0.0 K-SPAN BUILDINGS2.1.0 ABM 120 System2.1.1 Operating
Instructions2.1.2 Machinery Placement2.1.3 Foundations2.1.4
Building Erection
2.2.0 ABM 240 System
3.0.0 STEEL TOWERS3.1.0 Assembly and Erection of Sections3.2.0
Dismantling a Tower
4.0.0 ANTENNA TOWERS4.1.0 Guyed Towers4.2.0 Freestanding
Towers4.3.0 Tower Assembly4.4.0 Erection of Guyed Towers4.4.1 Davit
Method4.4.2 Gin Pole Method
4.4.3 Hand Assembly4.5.0 Guying4.5.1 Temporary Guying4.5.2
Permanent Guying4.5.2.1 Single-Guy Layer4.5.2.2 Two-Guy
Layers4.5.2.3 Three-Guy Layers4.5.3 Guy Tension4.5.3.1 Initial
Tension4.5.3.2 Final Tension4.5.4 Guy Anchors4.5.4.1 Screw
Anchor4.5.4.2 Expansion Anchor4.5.4.3 Concrete Anchor
SummaryReview QuestionsTrade Terms Introduced in This
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
SW Basic Ch 18 Introduction to Structural SteelChapter
18Introduction to Structural SteelTopicsOverviewPrerequisites1.0.0
STRUCTURAL STEEL MEMBERS1.1.0 Terminology1.1.1 W-Shape1.1.2 Bearing
Pile 1.1.3 S-Shape 1.1.4 C-Shape 1.1.5 Angle 1.1.6 Plate 1.1.7
Bar
2.0.0 ANCHOR BOLTS 3.0.0 BEARING PLATES 4.0.0 COLUMNS 5.0.0
GIRDERS 6.0.0 BEAMS 7.0.0 BAR JOISTS 8.0.0 TRUSSES 9.0.0 PURLINS,
GIRTS, AND EAVE STRUTS SummaryReview QuestionsTrade Terms
Introduced in this ChapterAdditional Resources and ReferencesCSFE
Nonresident Training Course User Update
SW Basic Ch 19 Introduction to Reinforcing SteelChapter
19Introduction to Reinforcing
SteelTopicsOverviewObjectivesPrerequisites1.0.0 REINFORCED
CONCRETE1.1.0 Concrete Materials1.2.0 Concrete Strength1.3.0
Purposes and Types of Reinforcing Steel1.3.1 Reinforcing Bars1.3.2
Tension in Steel
1.4.0 Additional Types of Reinforcing Steel1.4.1 Expanded
Metal1.4.2 Welded Wire Fabric1.4.3 Sheet-Metal Reinforcement
SummaryReview QuestionsTrade Terms Introduced in this
ChapterAdditional Resources and ReferencesCSFE Nonresident Training
Course User Update
APPENDIX IAPPENDIX IIAPPENDIX IIISW Basic Back Cover
tfP0W101: An adjective used to indicate the presence of iron.
The word is derived from the Latin word ferrum ("iron"). Ferrous
metals include steel and pig iron (with a carbon content of a few
percent) and alloys of iron with other metals (such as stainless
steel).btnFERROUS: tfP0W120: The term used to indicate metals other
than iron and alloys that do not contain an appreciable amount of
iron.btnNONFERROUS: returnTxt1SWB01PG0: Remediation Page, Click
anywhere on this page to return
returnTxt2SWB01PG0: Remediation Page, Click anywhere on this
page to return
dReturnButtonSWB01PG0:
returnTxt1SWB01PG3: Remediation Page, Click anywhere on this
page to return
returnTxt2SWB01PG3: Remediation Page, Click anywhere on this
page to return
dReturnButtonSWB01PG3:
tfP3W463: Subjecting (glass or metal) to a process of heating
and slow cooling in order to toughen and reduce
brittleness.btnANNEALING: tfP3W466: A material, usually metal, that
is cast into a shape suitable for further processing. Ingots
require a second procedure of shaping, such as cold/hot working,
cutting or milling to produce a useful final product.btnINGOT:
tfP3W427: Capable of great deformation without breaking, when
subject to compressive stress.btnMALLEABLE: returnTxt1SWB01PG4:
Remediation Page, Click anywhere on this page to return
returnTxt2SWB01PG4: Remediation Page, Click anywhere on this
page to return
dReturnButtonSWB01PG4:
tfP4W48: Named for Sir Henry Bessemer, an industrial process for
the manufacture of steel from molten pig iron. The principle
involved is that of oxidation of the impurities in the iron by the
oxygen of air that is blown through the molten iron; the heat of
oxidation raises the temperature of the mass and keeps it molten
during operation.btnBESSEMER PROCESS:
returnTxt1SWB01PG5: Remediation Page, Click anywhere on this
page to return
returnTxt2SWB01PG5: Remediation Page, Click anywhere on this
page to return
dReturnButtonSWB01PG5:
tfP5W239: Consisting mainly of austenite, which is a nonmagnetic
solid solution of ferric carbide, or carbon in iron used in making
corrosion-resistant steel.btnAUSTENITIC: tfP5W302: Consisting of
the pure iron constituent of ferrous metals, as distinguished from
the iron carbides.btnFERRITIC: tfP5W341: Consisting of a solid
solution of iron and up to one percent of carbon, the chief
constituent of hardened carbon tool steels.btnMARTENSITIC:
returnTxt1SWB01PG6: Remediation Page, Click anywhere on this page
to return
returnTxt2SWB01PG6: Remediation Page, Click anywhere on this
page to return
dReturnButtonSWB01PG6:
returnTxt1SWB01PG7: Remediation Page, Click anywhere on this
page to returnreturnTxt2SWB01PG7: Remediation Page, Click anywhere
on this page to returndReturnButtonSWB01PG7: returnTxt1SWB01PG8:
Remediation Page, Click anywhere on this page to
returnreturnTxt2SWB01PG8: Remediation Page, Click anywhere on this
page to returndReturnButtonSWB01PG8: returnTxt1SWB01PG13:
Remediation Page, Click anywhere on this page to
returnreturnTxt2SWB01PG13: Remediation Page, Click anywhere on this
page to returndReturnButtonSWB01PG13: returnTxt1SWB01PG14:
Remediation Page, Click anywhere on this page to return
returnTxt2SWB01PG14: Remediation Page, Click anywhere on this
page to return
dReturnButtonSWB01PG14:
returnTxt1SWB01PG16: Remediation Page, Click anywhere on this
page to return
returnTxt2SWB01PG16: Remediation Page, Click anywhere on this
page to return
dReturnButtonSWB01PG16:
dQuestionSWB01PC1a1: dQuestionSWB01PC1a2: dQuestionSWB01PC1a3:
dQuestionSWB01PC1a4: dQuestionSWB01PC2a1: dQuestionSWB01PC2a2:
dQuestionSWB01PC2a3: dQuestionSWB01PC2a4: dQuestionSWB01PC3a1:
dQuestionSWB01PC3a2: dQuestionSWB01PC3a3: dQuestionSWB01PC3a4:
dQuestionSWB01PC4a1: dQuestionSWB01PC4a2: dQuestionSWB01PC4a3:
dQuestionSWB01PC4a4: dQuestionSWB01PC5a1: dQuestionSWB01PC5a2:
dQuestionSWB01PC5a3: dQuestionSWB01PC5a4: dQuestionSWB01PC6a1:
dQuestionSWB01PC6a2: dQuestionSWB01PC6a3: dQuestionSWB01PC6a4:
dQuestionSWB01PC7a1: dQuestionSWB01PC7a2: dQuestionSWB01PC7a3:
dQuestionSWB01PC7a4: dQuestionSWB01PC8a1: dQuestionSWB01PC8a2:
dQuestionSWB01PC8a3: dQuestionSWB01PC8a4: dQuestionSWB01PC10a1:
dQuestionSWB01PC10a2: dQuestionSWB01PC10a3: dQuestionSWB01PC10a4:
dQuestionSWB01PC11a1: dQuestionSWB01PC11a2: dQuestionSWB01PC11a3:
dQuestionSWB01PC11a4: dQuestionSWB01PC12a1: dQuestionSWB01PC12a2:
dQuestionSWB01PC12a3: dQuestionSWB01PC12a4: dQuestionSWB01PC13a1:
dQuestionSWB01PC13a2: dQuestionSWB01PC13a3: dQuestionSWB01PC13a4:
dQuestionSWB01PC9a1: dQuestionSWB01PC9a2: dQuestionSWB01PC9a3:
dQuestionSWB01PC9a4: dQuestionSWB01PC14a1: dQuestionSWB01PC14a2:
dQuestionSWB01PC14a3: dQuestionSWB01PC14a4: dQuestionSWB01PC15a1:
dQuestionSWB01PC15a2: dQuestionSWB01PC15a3: dQuestionSWB01PC15a4:
dQuestionSWB01PC16a1: dQuestionSWB01PC16a3: dQuestionSWB01PC16a4:
dQuestionSWB01PC16a2: dQuestionSWB01PC17a1: dQuestionSWB01PC17a2:
dQuestionSWB01PC17a3: dQuestionSWB01PC17a4: dQuestionSWB01PC18a1:
dQuestionSWB01PC18a2: dQuestionSWB01PC18a3: dQuestionSWB01PC18a4:
dQuestionSWB01PC19a1: dQuestionSWB01PC19a2: dQuestionSWB01PC19a3:
dQuestionSWB01PC19a4: dQuestionSWB01PC20a1: dQuestionSWB01PC20a2:
dQuestionSWB01PC20a3: dQuestionSWB01PC20a4: dQuestionSWB01PC21a1:
dQuestionSWB01PC21a2: dQuestionSWB01PC21a3: dQuestionSWB01PC21a4:
dQuestionSWB01PC22a1: dQuestionSWB01PC22a2: txtRate: txtCourse:
txtDate: txtChapter: txtNumber: txtDescription: txtCorrection:
txtName: