Metalworking: Tools, Techniques & Safety for Students

1. Teachers notes Working with metal This section explores working with metal – a versatile and exciting material that offers many opportunities for creativity and innovation. I have intended for the slides to be sharp and simple – with the information supported by visual stills of tools and equipment and making processes; as well as Flash animations of all the making processes. Hopefully whichever option you use, it will capture pupils interest and enable them to follow the screen with ease and make them want to have a go themselves! Slide 1 offers an introduction to the making section outlining the range of processes available to pupils in the making of this project. These could act as lesson objectives at the start of a lesson. Slide 2 introduces the concept of work hardening and then Slide 3 discusses annealing, as a process which to make metal easier to work with. These fundamental principles are explained in an easy to ‘digest’ manner and supported by bold visual examples which pupils seem to like. Slides 3 - 5 introduce the first process involved in making a tea light holder from black mild steel – marking out. I felt that these traditional ‘basics’ needed to be re-emphasised in today’s new curriculum, with time being spent learning the basic marking out tools and equipment, instilling this knowledge ready for GCSE courses. Time is spend looking at each individual tool required and why it is appropriate for its job. A step by step pictorial guide is offered to make marking out easy to understand.

2. Teachers notes Working with metal The next stage we look at is cutting and shaping the black mild steel. On Slide 7 I have included both hand and machine methods of cutting metal, so that this resource can be accessible to a range of school workshops with varying facilities. Flash animation is available for this process as well as simpler step by step animated stills with guide (Slides 8 and 9). This section offers us the opportunity to discuss Health and Safety, of not only when using tools in the workshop but also when making a product that could potentially be sold on the current craft market e.g. no sharp edges and filling off metal ‘bur’s.

3. Teachers notes Working with metal This next section introduces scrollwork – a traditional metalworking skill that I wanted to bring to the attention of today's pupils. It offers quick, visually elegant outcomes; perfect for a high quality KS3 project. Slide 10 looks at the traditional metalworker – the blacksmith. I particularly like to mention to my classes that metalworkers are not all male – and I refer to the stunning metal work of Ann Catrin Evans and Mari Eluned.Slide 11 offers a visual mood board of scrollwork examples. Slides 12 – 14 offer a step by step guide to forming scrolls. Again this resource is available in both animated stills or in Flash animation. pupils tend to respond well to the on screen practical work, plus it saves time and materials rather than undertaking a full demonstration in class. I often bring in the concept and advantages here of virtual modelling to my classes. Slide 15 provides a quirky, alternative format to a re-cap of this process – a visual quiz, 007 style!

4. Teachers notes Working with metal The next section of making focuses on two methods of joining metal together – pop riveting and brazing. These are the two most suitable joining methods to use for a tea light holder project and offer pupils the opportunity to learn many new skills. Once again, this resource is available in both animated stills or in Flash animation for both methods of joining. Slide 16 provides an introduction (supported by close up photographs of tea light holders) of both methods used to join steel. Slides 17 introduces Pop Riveting and gives some general background information on this process. At the bottom of the slide, I have mentioned that an alternative method to pop riveting would be snap-head riveting and this then gives the teacher flexibility (according to resources/facilities) to chose a method most suited to them. I demonstrate both methods and allow pupils to decide which option they prefer on their tea light holders. Slides 18 & 19 provides step by step animated stills with guide. Flash animation is also available for this process if required. Slide 20 offers a re-cap, asking pupils to re-cap on the stages involved in this process.

5. Teachers notes Working with metal Slides 21 introduces Brazing as the alternative way of joining steel and gives some general background information on this process. I am sure that you are aware it is not always easy to demonstrate brazing as a technique to a whole class, therefore a Flash animation is also available to view. I see it as an excellent opportunity to explain this process in depth, with all pupils being able to see the screen. It also allows for pausing so that you can stop at any point to offer further detailed explanation or stop for questioning. If Flash is not available to you, Slides 22 - 24 provide step by step animated stills with a guide of the process.