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METALWORK

PREAMBLE

The examination is designed to test candidate’s skill in basic design, practical work and
entrepreneurship. It will also assess their knowledge of tools, equipment and materials and
understanding of those areas of creative thinking which can be expressed and developed through
planning and working primarily on metals as part of general education. The test will also assess
candidate’s competency in the fundamentals of manufacturing to pursue higher education in
science and technology.

AIM

The aim of the syllabus is to test candidate’s acquisition of the requisite knowledge andskills
needed to pursue further education and self development in science and technology.

OBJECTIVES

Candidates will be expected to

(1) observe safe working practices in the workshop;

(2) demonstrate knowledge and understanding of tools, material and equipment;
(3) apply basic processes for the care and maintenance of hand and machine tools;
(4) have ability in identifying, analysing and evaluating a problem;
(5) apply their knowledge of processes and materials to the solution of problems;
(6) demonstrate basic skills of good craftsmanship;
(7) apply knowledge of career opportunities in metalwork;
(8) have ability to translate an idea into a project design.

SCHEME OF EXAMINATION

The examination shall consist of three papers, Papers 1, 2 and 3, all of which must be taken.
Papers 1 and 2 will be a composite paper to be taken at one sitting.

Paper 1: Will consist of forty compulsory multiple choice objective questions. Candidates will
be allowed 1 hour to answer the questions. The paper will carry 40 marks.

Paper 2: Will consist of five questions out of which candidates will be expected to answer four
in 1½ hours. The paper will carry 60 marks. All questions will carry equal marks.

Paper 3: Will be a practical test of 3 hours. 10 minutes shall be given prior to the
commencement of the examination for the study of the drawings. The paper will consist
of two questions out of which candidates will be expected to answer one. They will be
required to make a test piece for which the appropriate drawings will be supplied. The
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paper will carry 100 marks. Schools will be required to supply materials that will be
needed for the practical test.

DETAILED SYLLABUS

TOPIC THEORY PRACTICALS

1. General safety in 1.1 Potential sources of accidents.

the workshop. Measures to avoid accidents.

1.2 Personal safety. Safety clothings: goggles

apron, gloves, bootswith hard toe caps,
helmet.
1.3 Safety rules and precautions in a metal
workshop.

2. Metals. 2.1 Description of metals: physical and 2.1.1 Identification:

mechanical properties. - file test.
2.2 Types of Metals: - spark test.
-Ferrous metals: pig iron, wrought iron, cast
iron and steels.
- Non Ferrous Metals: aluminium, zinc,
copper, tin and lead.
- Non-ferrous alloys: brass, bronze,
solders and duralumin.
- Constituents and properties.
2.3 Uses of Metals: Construction of auto
bodies, frames,structural members of
building and bridges.
- Selection of suitable metals for specific
jobs.

2.4 Production of Metals

- Types of metals and their ores:
copper-pyrite, aluminium –
bauxite, iron – hematite, zinc –
calamine, lead – gelina,tin – tin ore
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(cassiterite) .
- Methods of extraction: open pit and
underground.
- Processes of smelting and refining:
Blast furnace, Bessemer converter,
open hearth, crucible, cupola electric
arc and high frequency induction
furnace and reverberating furnace.
- Forms of metal supply: billets, blooms
and slabs.

3. Hand Tools and 3.1 Hand tools. 3.1.1 Practical exercises

Bench Work. - Hand tools: care and maintenance. involving the uses of
handTools.
- Measuring tools: linear and angular.
- Steel rule, angle plate and scriber, etc.
- Bench vice, hand vice, G-clamp, chuck,
etc.
- Cold chisels, hacksaw, files, taps and
dies.
- Engineers’ hammers, mallets.
- Screwdrivers, spanners, drifts, etc.

3.2 Benchwork
- Filing, chiselling, threading and sawing.

3.3 Care and maintenance of tools 3.3.1 Practical exercises

- Need for maintenance. involving care and
Maintenance
– oiling, cleaning,
greasing of
hand tools.

4. Heat treatment
of metals. 4.1 Importance of heat treatment of metals.

4.2 Heat Treatment processes. 4.2.1 Heat treatment of

- Annealing hand tools.
- Case hardening
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- Hardening
- Tempering
- Normalizing

4.3 Materials and Equipment for heat treatment

of metals.
- Materials used as cooling media for
heat treatment of metals:coal, brine, water,
air, oil and ash.
- Equipment: furnaces, pyrometer, oven
quenching tanks, blacksmith forge, oxy-
acetylene flame.

4.4 Tempering colours and temperature 4.4.1 Use of colour charts.

ranges.
4.5 Safety precautions.

5. Hand forging. 5.1 Principles of forging

- Definition of forging
- Importance of forging
- Types of forging: cold, hot and drop
forging.
5.2 Forging tools and Equipment.
- anvil, hammer, top and bottom
swages, hardies, fullers, tongs and
heart forge.

5.3 Forging operations 5.3.1 Forging of chisels,

– fullering, upsetting, bending, drawing centre punch,
down, punching, flattening, cutting, scriber, door
twisting and swaging. bolts, hinges, hoes,
pokers, etc.
5.4 Safety precautions.
6. Foundry Work. 6.1 Principles of Casting:
- Definition and importance of casting.
- Method of casting: sand casting.
6.2 Materials and equipment for sand casting.
6.3 Processes: pattern making (single piece,
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split and flat back), moulding, melting and 6.3.1 Mould making and
pouring, dismantling and fettling. metal pouring.

6.3.2 Simple pattern

making.

6.4 Core making (box, sand).

6.5 Casting defects (types and causes)
6.6 Safety precautions.

7. Metal Joining 7.1 Types: temporary and permanent.

- Temporary metal joining processes.
- Explanation, identification and uses of
common fasteners: Bolts, Nuts, Pins and
Screws.
7.2.1 Design and make an
7.2 Soft Soldering artifact involving soft
- Tools and equipment. Types of joints soldering.
and processes.

7.3 Hard soldering

- Tools and equipment .Types of joints
and processes. Procedure for making
hard soldered joints.
7.4 Gas and Electric Arc Welding.
- Welding equipment, welding operation,
welding flames. Welding techniques and
safety.
7.5 Riveting
- Tools and equipment, types of rivets and
joints.
7.6 Safety precautions.
8. Sheet 8.1 Selection of materials,
Metalwork. - Low carbon sheet, galvanised sheet,
tin plate, copper,aluminium and
brass sheet.
- Standard gauges.
8.2 Tools and Equipment:
- Stakes, Hammers, Mallets, Snips,
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Hand lever, Shears, Folding bar,

Sand bag and Slip roll.
8.3 Pattern development and cutting .
- Methods of Pattern development: types,
layout, and cutting out of patterns.

8.4 Basic Fabrication processes: Bending, 8.4.1 Production of

Raising, Hallowing,Sinking, Expanding and simple articles e.g.
Contracting. cans, funnelsand
bowls.
8.5 Joints and joining
- Types of joints: lap, grooves, seams.
- Methods of joining:
- Self – tapping screw.
- Soft soldering.
- Seaming

8.6 Safety precautions.

9. Machine Tools 9.1 Drilling, Drilling machines and reaming 9.1.1 Exercises on
and processes. - Description, types of tools and setting drilling machine:
up. drilling, reaming,
- Types of drilling machines: sensitive, countersinking
pillar and radial. and counterboring.
- Drilling faults & remedies
9.2.1 Grinding of single
9.2 Grinding, Description of grinding operations. point tools, e.g.
scribers, chisels
- Types of grinding wheels and setting up and lathe tool bits.
of grinding operation.
9.3 Power sawing: 9.3.1 Using the power
- Description, types of tools and machines. saws to cut
- Setting up of machinefor power sawing. materials for
projects.
9.4 Lathe and lathe turning operations.
- Parts and functions of the centre lathe: 9.4.1 Operation
the bed, headstock, tailstock, carriage sequence,
feed and thread cutting mechanism. exercises
- Operations on the centre lathe: involving step
parting off, knurling and taper - turning. turning, drilling,
- Work holding devices: 3 and 4 – jaw boring, taper
chucks, collets, face plates, catch
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plates and mandrels. turning, knurling,

other accessories, steadies and vee thread-
centres. cutting and
parting off.
9.5 Shaping Machines
- Types of shapers: swivel, tilting and
universal table
- Parts of a shaping machine and their
functions
Pedestal, ram, saddle, table and
driving mechanism.
- Cutting tools materials and holders.

9.6 Cutting lubricants and coolants (soluble

oil, straightcutting oil, soda solution).

9.7 Care, maintenance and safety

precautions.

10. Finishes and 10.1 Types of finishes and decorative 10.1.1 Application of
decorative processes finishes on projects.
processes. – polishing and buffing, spot facing,
planishing, colouring, plating, etching,
lacquering, pickling and enamelling

11. Design. 11.1 Identifying the Problem

- Problem areas: market, classroom, lorry
park,workshop.
- Problem definition:benefits to be derived
from finding solution(s) to the problem
identified.

11.2 Generating possible solutions 11.2.1 Produce a folio and

- Investigation procedures and possible realise the artifact.
solutions: interviews, observation, visits,
reading journals, books, photographs,
sketches of solution alternatives.
- Generation of possible solution.
Selecting the best solution by: simplicity/
complexity, availability of materials and
cost.
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- Freehand sketching, working drawings,

prototype, testing and production.

LIST OF MATERIALS AND EQUIPMENT FOR METAL WORK WORKSHOP

Recommended workshop size:

Purpose-bulk 14m length x 8m width x 4m height, well ventilated and illuminated.

Safety Equipment and Materials;

Fire extinguishers, first aid box, buckets of sand, CO2 wall charts etc.

1. Workshop Tools

(a) Cutting tools: Hacksaw, drills, chisels, snips, files, stock and die, scrappers,
reamers, turning tools, milling machine, shaping tools.
(b) Measuring tools: Steel rules, inside and outside callipers, combination square,
micrometer screw gauges,verniergauges, vernier protractors, spirit level, dial
gauges.
(c) Marking out tools: Surface gauge, surface plate, try square, vee-block, dividers,
odd leg callipers, trammels, straight edge, scriber, angle plates, centre punches.
(d) Driving tools; pin punches, screwdrivers, hammers, drifts.
(e) Work holding devices: clamps, vices, pliers, mole grips, self gripping wrenches.
(f) Forging tools: hardies, fullers, tongs, swages, anvils, anvil stands, letter stamps
and stakes, sand bag.

2. Workshop Equipment

Work benches, marking out table, blacksmith’s hearth, foundry furnace, sets of tool
boxes, oil cans, computer hard ware and soft ware.

3. Machine Tools

Centre lathe(with accessories), sensitive and pillar drilling machines, pedestal grinder,
power hacksaw, folding machine, shears, rolling machine, milling, shaping machine, etc

Welding Equipment

Standard arc welding machine accessories, electrodes, shields, aprons, chipping

hammers, welding boots, standard oxygen and acetylene cylinders, filler rods, spark
lighters, regulators, nozzles, etc.

Materials
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Mild steel round bars (03mm – 050mm), Flat bars (of different sizes), Square bars,
Hexagonal bars, Mild steel sheets and plates, Galvanized and tinned sheets. Projects may
be constructed with non-ferrous metal e.g. Copper, Aluminium and Brass.

RECOMMENDED TEXT BOOKS

1. Workshop Technology (parts 1 and 2) - W.A.T. Chapman

2. Metalwork Technology - G. H. Thomas
3. Metal Technology - C. E. S. A. C.
4. Introductory Technology - C. E. S. A. C.
5. Welding Technology - Gourd
6. Mechanical Engineering practice - A. Green and W.H. Howe
7. Crafts Theory and Related Studies - R.T. Pritchard Vol. 1 & 2
8. Mechanical Engineering - R.I. Timings
9. Metalwork Theory, Books 1, 2, 3, & 4
(Metric Edition) - P.F. Lye – Harrap, Lon
10. Design Technology in Metal and Plastics
(Metric Edition) - G.H. Thomas-John Murray
11. Jab Metalwork Projects for African Schools
and Colleges - R. Edward – Cassel Lon
12. Basic Engineering Processes - S. Crawford
13. Metalwork - R. Sandham
& F.R. Willmers
14. Workshop Processes and Materials - J. V. Courtney
15. Metalwork Projects and Theory (S.I. Units) - K. Parkinson
16. The Theory and Practice of Metalwork
(3rd Edition) - G. Love
17. Metalwork for Schools and Colleges - J. N. Green
18. Metal Cutting Machine tools - Adejuyigbe, S. B.
19. Metalwork Technology - J.K.N. Sackey
S. K. Amoakohene.
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