Metal Fabricating Specialist

720 Pages·2007·16.47 MB·English

DOCUMENT RESUME
ED 272 713
CE 044 812
TITLE
Metal Fabricating Specialist (AFSC 55252).
INSTITUTION
Air Univ., Gunter AFS, Ala. Extension Course Inst.
PUB DATE
82
NOTE
730p.
PUB TYPE
Guides - Classroom Use - Materials (For Learner)
(051)
EDRS PRICE
MF04/PC30 Plus Postage.
DESCRIPTORS
Assembly (Manufacturing); Behavioral Objectives:
Correspondence Study; Equipment Utilization;
Finishing; Hand Tools; Hygiene; Learning Activities;
Machine Tools; Mathematics Skills; *Metals; *Metal
Working; Military Personnel; *Military Training;
Postsecondary Education; Safety; Sanitation; *Sheet
Metal Work; *Trade and Industrial Zducation;
*Welding
IDENTIFIERS
Air Force; Military Curriculum Materials
ABSTRACT
This seven-volume student text is designed for use by
Air Force personnel enrolled in a self-study extension course for
metal fabricating specialists. Covered in the individual volumes are
general subjects (career progression, management of activities and
resources, shop mathematics, and characteristics of metals); sheet
metal tools and equipment (cutting tools and equipment; drilling,
punching, and fastening; folding, forming, and seaming equipment and
spot welding, lead soldering, and sealing); installed equipment and
doors (fixed utility equipment, awnings and canopies, metal roof
parts, and doors and gates); layout and duct systems (drawings and
layout, seams and joint connections, characteristics and contlol of
airflow, duct systems, and stacks and ventilators); oxyacetylene
welding (equipment, welding and brazing castings, oxyacetylene
cutting, forging, and carbon steel and heat- and corrosion-resistant
ferrous alloys); electric welding and metallic arc equipment
(preparation; metallic arc welding and applications; and
gas-shielded, tungsten-inert-gas, and pipe welding); and general
contingency responsibilities (first aid, field hygiene and
sanitation, work party security, and convoy techniques). Each volume
in the set contains a series of lessons, exercises at the end of each
lesson, a bibliography, and answers to the exercises. Volume review
exercises and a change supplement for the package are also included.
(MN)
***********************************************************************
Reproductions supplied by EDRS are the best that can be made
from the original document.
***********************************************************************
METAL FABRICATING SPECIALIST
(AFSC 55252)
BES-i COPY AVAIL/Wu_
U.S. DEPARTMENT OF EDUCATION
,,,ernent
Sce of EducaSonal Research and irnt
INFORMATION
JUCATIONAL RESOURCES
CENTER IERICI
reprOduced as
This document ha5 been
organtzatton
rorn the pe,son or
received
o,iginating
to anpro,e
Minor changes have been rnade
reproduction duality
in this doCu
Pomts 0 vtew or opinions slated
represent official
mem do not necesSarily
on or pohCy
nERI
Extension Course Institute
Air University
ECI COURSE MATERIALS SHIPPING LIST
EFFECTIVE DATE
COURSE NUMBER
COURSE TITLE
METAL FABRICATING SPECIALIST
55252
(AFSC 55252)
16 Jul 86
reeded to oonspiete this course. Check this list immediately upon receiving your course package, and
The
following mania/mare
INSTRUCTIONS:
to include
if any materials are missing or incorrect (numbers don7 match ), notify EC1 immediately. Use the ECI Form 17 for fhis purpose, and be Burf
Your identification number, address, course and volume number, and VRE form designation (If a VRE Is involued). Send all correspondence separately
from your answer sheet.1
VRE ANSWER
INVENTORY CONTROL
ITEm
TYPE
DESIGNATION OR TITLE
SHEET
NUMBER
IDENTIFICATION
VOL
3
VOL 1, General Subjects
55252
8302
01
VRE
VOLUME REVIEW EXERCISE (VOL 1)
4
55252
55252
22
01
01
22
VOL
VOL 2, Sheet Metal Tools and Equipment
5
55252
8302
02
VRE
6
VOLUME REVIEW EXERCISE (VOL 2)
55252
55252
22
02
22
02
VOL
7
VOL 3, Layout and Duct Systems
55252
8301
03
VRE
8
VOLUME REVIEW EXERCISE (VOL 3)
55252
03
22
55252
03
22
VOL
9
VOL 4, Installed Equipment and Doors
8301
55252
04
VRE
10
VOLUME REVIEW EXERCISE (OOL 4)
55252
04
55252
22
04
22
VOL
11
VOL 5, Oxyacetylene Welding
55252
8301
05
VRE
12
VOLUME REVIEW EXERCTSE IN", 5)
55252
05
55252
22
22
05
VOL
13
%11
VOL 6, Electric Welding, Metallic Arc
55252
06
Equipment
VRE
14
VOLUME REVIEW EXERCISE (VOL 6)
55252
06
55252
22
06
22
VOL
15
VOL 7, General Contingency Responsibilities
55252
8211
07
VRE
16
VOLUME REVIEW EXERCISE (VOL 7)
55252
22
55252
07
22
07
SUPP
17
CBANGE SUPPLEMENT (VCCs 1,2,4,5 & 6)
501
55252
8408
00
NOM: DIRECT ANY QUESTICNS OR COMMENTS
RELATING TO ACCURACY OR CURRENCY OF TEXTUAL
MATERIALS TO AUTOVCN 736-2072.
IISEE REVERSE SIDE FOR ADDITIONAL INSTRUCTIONS.
ECI "Rm 25
PREVIOUS EDITION WILL, SE USED.
JUN 114
Page 1 of 3
L 1ST OF CHANGES
tounsrNummER
CAREER FIELDS, POLICIES, PROCEDURES AND EQUIPMENT CHANGE.
ALSO,
55252
ERRORS OCCASIONALLY GET INTO PRINT. THE FOLLOWING ITEMS UPDATE AND
EFFECTIVE DATE OF
SHIPPING LIST
CORRECT YOUR COURSE MATER/ALS. PLEASE MAKE THE INDICATED CHANGES.
16 jul 86
NOTE:
PLEASE MAKE THE CORRECTIONS INDICATED BELOW.
THESE CORRECTIONS MAY OMIT SOME ERRORS,
SUCH AS TYPOS, THAT DO NOT AFFECT
THE MEANING OF THE MATERIAL.
1.
CHANGES FOR THE SUPPLEMENT:
55252 00 SO1 8408
Supplement page 12, replacement
P
page 80, answer 032-c:
Change "5 2/3" to "5 2/13."
b.
Supplement page 13, replacement page 81,
answer 034-3.b:
Change "9584.24" to
"1583.37."
Pl,t 5.a:
Pa
Change "3531.4" to "4484.9."
Answer 034-5.b:
Change "130.79" to
"166.11."
Answ
Change "137,455" to "530.145."
)7, -4:
2.
CHANGES FOR THE TEXT:
VOLUME 2
a.
Page 11, col 2, line 20:
After "Porta-Band" add "04" and after "1-13" add "(Fig
1-13 has been reproduced courtesy *the
Porter-Cable Power
ools, Jackson, Tennessee 38301) ."
Line 28:
After 'Porta-Band" add
b.
Page 12, col 2, line 5:
After "1-14" add "(Fig 1-14 has been reproduced
courtesy of
Kyser Machine Tools Division,
Stongville, Ohio 44136) ."
Page 41, col 2, line 6:
c.
After "2-35" add "(Figs 2-35 thru 2-38 have been reproduced
Dourtesy of Ramset Fastening Systems, East Alton,
Add "0" after "Ramset" each
IL 62024) ."
time it appears in the remainder of this
exercise.
d.
Page 59, col 2, line 15:
After "4-4" add "(Fig 4-4 has been reproduced courtesy of
3oodheart-Wilcox Co., Inc., S. Holland IL, 60473)."
CHANGE FOR THE TEXT:
3.
VOLUME 5
Page 51, col 1, line 11:
After "thoroughly" add "steam."
Line 12:
Change "as
5oon
. as pcssible" ) "within 30 minutes after steam cleaning."
.
.
CHANGES FOR ME 7EXT.
4.
VOLUME 6
Page 36, col 1, line 15:
a.
Change "titanium bearinc, rods in" to "rods containing
titanium for."
Line 27:
Change "ordinary" to "carbon."
Line 29:
Chang
"common" to
'carbon."
b.
Page 54, col 1, lines 19-last-
Delete "6-3.
Titanium and
. speed and pressure."
.
.
Pages 55-59:
c.
Delete pages in their entirety.
d.
Page 75, answers A29-1 through A31-5:
Delete.
CHANGE FOR THE VOLUME REVIEW EXERCISE:
5.
VOLUME 1
Question 19 is no longer scored and need not be answereoL
CHANGE FOR THE VOLUME REVIEW EXERCISE:
5.
VOLUME 2
The following questions are
no longer scored and need not be answered:
l5. 19, 29, 31, 39, 63, 73 and 74.
4
:ontinuation Sheet for ECI Form 25
Page 2 of 3
L 1ST OF CHANGES
ALSO,
CAREER FIELDS, POLICIES, PROCEDURES AND EQUIPMENT CHANGE.
55252
ERRORS OCCASIONALLY GET INTO PRINT. THE FOLLOWING ITEMS UPDATE AND
:FFECTIVE laitTE OF
LT
CORRECT YOUR COURSE MATERIALS. PLEASE MAKE THE INDICATED CHANGES.
iT",'Itit
CHANGE FOR THE VOLUME REVIEW ENERCMSE:
VOLUME 3
7.
The following questions are no longer scored and need not be answered:
5, 38, 48, 58 and 69.
AANGE FOR THE VOLUME REVIEW EXERCISE:
VOLUME 4
B.
Question 38 is no longer scored and need not be answered.
CHANGE FOR THE VOLUME REVIEW EXERCISE:
VOLUME 5
9.
The following questions are no longer scored and need not be answered:
1, 2, 35, 47, 48, 94, 95 and 96.
10., CHANGEF FOR ME VOLUME REVIEW EXERCISE:
VOLUME 6
Page 6, question 50:
Change "(A26)" to "(A27) ."
a.
The following questions are no longer scored and need not be answered:
b.
25, and 53 thru 58 inclusive.
VOLUME 7
11. CHANGE FOR THE VOLUME REVIEW EXERCISE:
The following questions are no longer scored and need not be answered:
46, 57 and 76.
Page 3 of 3
Continuation Sheet for ECI Form 25
55252 00 SO1 8408
CHANGE SUPPLEMENT
CDC 55252
METAL FABRICATING SPECIALIST
(AFSC 55252)
IMPORTANT: Make the correction, in this supplement before beginning study of
Volumes I. 2, 4, 5, and 6. This supplement contains both "pen-and-ink" changes and
replacement pages. It is perforated and three-hole-punched so that you can tear out the
replacement pages and insert them into your volumes.
MA1111,11111ASSIA111111111111111SIAVIAVVIANNININIMASIMAVVVIA %%%%%% 1,11111,11111
Extension Course Institute
Air University
6
CHANGES FOR THE TEXT: VOLUME 1
Pen-and-Ink Changes:
Pa t:c-Col
.Sribret r
irrerNI
Correetion
38R
After
add "11/18
13 fr bOt
1
1- and "35- add "11/18.-
11 fr bot
After
After "I'' add "5/8."
7 fr bot
1- and "196" add "5/8.-
5 fr bot
After
39L
Chanae "12 1/4" to "11 3/4."
5
After "1** add "3/32..
1
add "1/8."
After "1
3
after "6" acid "7/16.-
4
After "3" add "5/8."
6
Change "d' to exercise "8.-
15
55R
3 fr bot
Change
--=-C* to "XC."
57R
Change "furnace" to "air."
2 fr bot
59
Figs. 4-4
Reverse the Iegendc -
and 4-5
Page Changes:
Remove Pages
Insert Pages
17-18
17-18
78a-78 b
79-82
79-82
3
Preface
THIS VOLUME of CDC 55252. Metal Fabricating Specialist, contains information about
career progression.
engineering organization.
civil
base
subjects:
following
the
publications, activities management, resources management. shop mathematics, and
characteristics of metals. The other volumes in the course include: Volume 2, Sheet Metal
Tools and Equipment: Volume 3. Layout and Duct Systems Volume 4, Installed
Equipment. Doors, and Hoists: Volume 5, Oxyacetylene Welding: Volume 6, Electric
Welding: and Volume 7, General Contingency Responsibilities.
When you successfully complete the seven volumes of this course, you will have the
knowledge you need to perform your duties as a metal fabricating specialist. By
performing the exercises before you look at the answers, you learn to master the contents
of the course. Then when you combine the knowledge gained with the practical
experience you get on the job, you earn success, prestige, and promotions that are
awaiting you.
Code numbers appearing on figures are for use by preparing agency only.
The inclusion of names of any specific commercial product, commodity, or service in
this publication is for information purposes only and does not imply indorsement by the
Air Force.
Call the author between 0800 and 1600 CT, Monday through Friday, to get an
immediate response to subject matter questions which come up while you are studying
this course. Or you may write the author 3770 TCHTGITTGIC, ATTN: MSgt Thomas P.
Kelley, Jr., Sheppard AFB TX, 76311. Sending subject matter questions to ECI only
slows the response time. You should also tell the author about subject matter and
technical errors (except minor printing errors) that you find in the text, the volume review
exercises, or the course examination. This will help the author to keep up with changes
that must be made when the course is revised.
Consult your education officer, training officer, or NCO if you have questions on
course enrollment or administration, Your Key to a Successful Course, and irregularities
(possible scoring errors, printing errors, etc.) on the volume review exercises and course
examination. Send questions these people can't answer to ECI, Gunter AFS AL 36118,
: fln /1.^
on ECI Form 17, Student Request for Assistance
.V07
ye
corr"rtions for prirP;
Progrc
.)r
i
olunic is ...titled at 24 hours (8 points).
-ial in this volume is technically accurate, adequate, and current as of January
1984.
5
Contents
Page
Preface
iii
Chapter
BCE Organization. Career Progression.
and Publications
Management of Activities and Resourcs
2
17
Shop Mathematics
3
37
Characteristics of Metals
4
57
Answers for Exercises
79
9
6
iv
CHAPTER 2
Management of Activities and
Resources
of the
THE MANAGEMENT philosophy
Air Force
identified work. He uses one of the 85-series manuals to do
includes getting maximum efficiency for each dollar spent
These manuals contain Engineered Performance
this.
while reaching planned objectives. This means that human
Standards for the various jobs in civil engineering. These
resources, material resources, and financial resources must
standards have been compiled over a number of years by
be used in the most effective way to meet the goals of the
engineers who have studied the results of numerous time
organization. As you supervise people working on your
and motion studies. These studies break down each job into
base, you should ask and answer these two questions. "Are
different tasks and assign a specific time to it. This time is
the jobs being done well'? and "Is there a better way to do
how long it should take a skilled craftsman to complete that
them?"
task. The planner then totals the time of these tasks to get
the total labor hours for the job. When this survey is
The key to improving jobs is not necessarily an attempt to
one of the inputs provided to
speed up work by prodding people. Substandard work may
completed
Civil
it
is
be brought up to standard by planning projects better,
Engineering to develop its work plan.
In addition to the facility survey, shop foremen are
improving
eliminating
material
support,
delays,
and
coordinating with other people. Plan your projects well
responsible for two inputs to the work plan. One of them is
that is, with activities and resources management in mind.
for recurring labor-hours, and the other is for equipment
maintenance labor-hours. The recurring labor-hours are for
2-1. Activities Management
work done on a periodic basis within a particular year. An
example of this work is to inspect and repair drainage
As we stated
the Air Force owns a
in Chapter
1,
the hours required
Another example
facilities.
for
is
tremendous amount of property which must be operated,
removing snow and ice from paved surfaces. There are
maintained, and managed properly. To manage these
other inputs used to formulate the civil engineer's work plan
activities effectively and efficiently, the Air Force uses a
which do not concern you. They are also used to preicLity
program concept which has been planned by "planners" in
work requirements.
advance. The program includes allocating labor hours and
After all the work inputs are sent to Resources and
materials for work and services performed by CE troops.
Requirements, they are gathered together and then assigned
Various Air Force forms are initiated by CE personnel and
labor-hours on a document called the In-Service Work Plan.
processed through a computer. Data printouts from the
Each month, work items from this plan are sent to the
computer include data which assist CE managers to make
production control section for assignment to CE units.
good management decisions.
These
work
items
are
known
on
work
forms
as
authorization documents. As the words indicate, these
Very briefly state how the
engineering
civil
015.
documents are the authority from Civil Engineering to
management system works.
perform the work stated on the forms.
Performance evaluation. Civil Engineering also has a
CE Management System. As a worker in
management plan. In this plan there are provisions for
Civil
Engineering, you may ask the question, "Who originates
evaluating the performance of CE units. By knowing types
all the work that CE personnel have to do?" The greatest
of work which have been done in the past with a cert,n
majority of the work in
Engineering has been
Civil
amount of labor-hours, the industrial engineering sects
identified and planned ahead of its actual start date. The
through the use of a computer, can predict what work can
planning and controlling of this work could not be done
be done in the future with various amounts of labor-hours.
without a sound management plan. The plan we are talking
Units who fall behind the labor-hours expected by using
about is called the In-Service Work Plan. Like all other
more hour, titan predicted must answer for the deviations.
plans, it is only as good as the information used to develop
,;ineer Automated Management System. In
Base
it and the effort put forth to adhere to its principles and
Civil Engineering an enormous amount of records are
objectives.
required to be kept. These records include the amount and
Planning. Do you recall an office called Resources and
cost of roads on base; amount and cost of runways; amount
unit known as
Requirements? Under this
office
is
of sewage disposed; labor-hours required to operate plants;
a
Planning. Each year the planners visit each facility on base
and the size, shape, condition, and cost of each facility.
and thoroughly inspect it for any work that needs to be
Many other records are required by law to be kept. Even
done. The inspection is called a Facility Survey.
your name and emç'myee number are part of the records.
After compiling the information from these surveys, the
When information of this sort is needed, Civil Engineering
planner determines the labor hours needed to do the
merely asks the computer in symbols it understands to
17
7
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