Preface | p. ix |
Acknowledgements of figures and tables | p. xi |
Health and safety | p. 1 |
Health, safety and the law | p. 2 |
Employers' responsibilities | p. 4 |
Employees' responsibilities | p. 5 |
Electrical hazards | p. 6 |
Fire fighting | p. 7 |
Fire precautions and prevention | p. 10 |
Accidents | p. 11 |
First aid | p. 14 |
Personal protection | p. 16 |
Hazards in the workplace | p. 19 |
Manual lifting | p. 23 |
Mechanical lifting equipment | p. 26 |
Use of lifting equipment | p. 31 |
Accessories for lifting gear | p. 32 |
Useful knots for fibre ropes | p. 35 |
Inspection (lifting equipment) | p. 37 |
Oxy-acetylene welding | p. 37 |
Arc-welding equipment (mains operated) | p. 43 |
Working on site | p. 50 |
Exercises | p. 53 |
Personal development | p. 57 |
Basic relationships | p. 58 |
Relationship with managers, supervisors and instructors | p. 59 |
Attitude and behaviour | p. 61 |
Implementing company policy | p. 62 |
Creating and maintaining effective working relationships with other people | p. 64 |
Exercises | p. 66 |
Engineering materials and heat treatment | p. 69 |
States of matter | p. 70 |
Properties of materials | p. 70 |
Classification of materials | p. 77 |
Ferrous metals (plain carbon steels) | p. 77 |
Ferrous metals (alloy steels) | p. 80 |
Ferrous metals (cast irons) | p. 81 |
Abbreviations | p. 81 |
Non-ferrous metals and alloys | p. 81 |
The identification of metals | p. 86 |
Non-metals (natural) | p. 86 |
Non-metals (synthetic) | p. 86 |
Forms of supply | p. 88 |
Heat treatment processes (introduction) | p. 91 |
Heat treatment processes (safety) | p. 92 |
The heat treatment of plain carbon steels | p. 93 |
The heat treatment of non-ferrous metals and alloys | p. 100 |
Heat-treatment furnaces | p. 102 |
Temperature measurement | p. 105 |
Atmosphere control | p. 108 |
Exercises | p. 109 |
Using and communicating technical information | p. 111 |
Selection of information sources | p. 112 |
Interpretation of information (graphical) | p. 112 |
Interpretation of information (tables, charts and schedules) | p. 116 |
Evaluating engineering information | p. 118 |
Recording and processing engineering information | p. 119 |
Methods of record keeping | p. 121 |
Communications (miscellaneous) | p. 121 |
Engineering drawing (introduction) | p. 124 |
First angle orthographic drawing | p. 125 |
Third angle orthographic drawing | p. 127 |
Conventions | p. 129 |
Redundant views | p. 132 |
Dimensioning | p. 132 |
Welding symbols | p. 136 |
The development of surfaces | p. 137 |
Interpenetration | p. 151 |
Pictorial views | p. 153 |
Exercises | p. 155 |
Measuring and marking out | p. 161 |
Introduction | p. 162 |
Linear measurement | p. 162 |
Angular measurement | p. 169 |
Correct use of measuring equipment | p. 171 |
Marking out equipment (tools for making lines) | p. 172 |
Marking out equipment (tools for providing guidance) | p. 177 |
Marking out equipment (tools for providing support) | p. 181 |
Techniques for marking out | p. 183 |
The need for templates | p. 192 |
The manufacture of templates | p. 192 |
The use of templates | p. 195 |
Condition and care of equipment | p. 206 |
Exercises | p. 208 |
Material removal | p. 211 |
Cutting tool principles | p. 212 |
The application of basic cutting tool angles to hand tools | p. 214 |
Drilling, drilling machines and routing | p. 226 |
Shearing sheet metal | p. 239 |
Portable power tools | p. 249 |
Blanking (stamping and piercing) | p. 259 |
Flame cutting | p. 263 |
Exercises | p. 275 |
Sheet and plate metalwork | p. 277 |
Sheet and plate metalwork (introduction) | p. 278 |
Roll-bending sheet metal and plate | p. 296 |
Flow forming sheet metal | p. 301 |
The principles of metal spinning | p. 318 |
Swaging sheet metal | p. 324 |
Basic fabrication procedures | p. 330 |
Exercises | p. 345 |
Structural steelwork and pipework | p. 347 |
Rolled steel sections | p. 348 |
Typical structural steel connections and assemblies | p. 348 |
Trusses and lattice frames | p. 353 |
Web stiffeners | p. 356 |
Fabricated lightweight beams | p. 359 |
Castellated beams | p. 359 |
Pipework (setting out bends) | p. 362 |
Pipe bending | p. 366 |
Pipe fitting | p. 373 |
Exercises | p. 382 |
Joining processes (mechanical connections) | p. 385 |
Mechanical connections (threaded) | p. 386 |
Hand reamers and reaming | p. 404 |
Riveted joints | p. 405 |
Pop Diveting | p. 411 |
Self secured joints | p. 418 |
Folding and jointing allowance | p. 421 |
The Pittsburgh lock | p. 425 |
Exercises | p. 428 |
Joining processes (soldering, brazing and braze-welding) | p. 429 |
Soft soldering | p. 430 |
Soft-soldered joints using lead-free solders | p. 445 |
Hard soldering (brazing) | p. 447 |
Aluminium brazing | p. 457 |
Types of brazed joints | p. 460 |
Braze-welding | p. 460 |
Exercises | p. 466 |
Joining processes (welding) | p. 467 |
Fusion welding | p. 468 |
Oxy-acetylene welding | p. 468 |
Manual metal-arc welding | p. 490 |
Workshop testing of welds | p. 504 |
Miscellaneous fusion welding processes | p. 506 |
Workholding devices for fusion welding | p. 509 |
Resistance welding | p. 515 |
Further welding processes | p. 518 |
Exercises | p. 519 |
Composite fabrication processes and adhesive bonding | p. 521 |
Introduction | p. 522 |
Lamination | p. 522 |
Fibre reinforcement | p. 525 |
Particle reinforcement | p. 531 |
The manipulation and fabrication of polymers (plastics) | p. 533 |
Adhesive bonding | p. 540 |
Adhesive bonding of metals | p. 545 |
Exercises | p. 554 |
Appendix A | p. 555 |
Index | p. 557 |
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