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Mechanics
Student workbook
2
Contents
Unit 1 Page 1
Unit 2 2
Unit 3 3
Unit 4 4
Unit 5 5
Unit 6 6
Unit 7 7
Unit 8 8
Unit 9 9
Unit 10 10
Unit 11 11
Unit 12 12
Unit 13 13
Unit 14 14
Unit 15 15
Unit 16 16
Unit 17 17
Unit 18 18
Answer Key 19
ii Metal Mechanics
1
1 Complete the text with the words listed below.
power electrode power source arc base material
2 Match the protective equipment (1–5) with the words listed below.
mitten face shield goggles
5 1
hand shield gauntlet
1
2
3
3 2
4
5
3 Complete the sentences about health and safety with the words listed below.
contact goggles cables helmet
1 Always wear an appropriate welding , and clothing that covers arms and legs.
2 Wear when chipping slag or wire-brushing welds.
3 Keep all electrical in good condition.
4 Make sure cannot be made with hot items.
4 Look at the table to find a metal for each of the properties listed below.
More than one answer is possible.
1 ductile
2 malleable
3 corrosion resistant
4 good conductor
Metal Mechanics 1
2
1 Match the beginnings to the words (1–8) with the endings(a–h) to form nouns.
A B
1 compress- a -ee
2 corro- b -ian
3 equip- c -ics
4 fric- d -sion
5 logist- e -ment
6 supervis- f -or
7 technic- g -or
8 train- h -tion
1
2
2
3
4
4
5
6
3
2 Metal Mechanics
3
1 Match to the processes listed below to the descriptions (1–6).
2 Complete the text about fume with the words listed below.
vaporizes particulate gases oxides metal fume
Welding 1
metals, and anything which is resting on the surface. This gives rise to
2
, which is condensed fine 3
material. The fume is mostly 4
3 Label the Arc Welding diagram with the terms listed below.
nozzle filler rod gas shielding
arc weld pool
5
1
2 4
3 1
3
4
5
2
Metal Mechanics 3
4
1 Label the typical MIG torch diagram with the terms listed below.
1 2
trigger torch body gas supply tube
armoured torch cable nozzle 8
2 6
5
3 7 6
4 8
2 Complete the text about bonding processes with the words listed below.
join welding resistance heat binding processes
4 Read the text and mark the statements as true (T) or false (F).
Die casting is a versatile process for producing engineered metal parts by forcing molten metal under high
pressure into reusable steel moulds. These moulds, called dies, can be designed to produce complex shapes
with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured
surfaces, and are suitable for a wide variety of attractive and serviceable finishes.
4 Metal Mechanics
5
1 Study the diagram showing how th
eng
the properties of carbon vary sile str
Ten
with the percentage of carbon
in carbon steels and answer ess
Hardn
the questions.
Duct
ility
3 What are the adjectives from these nouns? Complete the table.
Noun Adjective
1 width
2 height
3 length
4 depth
5 weight
Metal Mechanics 5
6
1 Read the statements and mark each as a hazard (H) or risk (R).
1 Using noisy equipment without ear protectors.
2 Working without a harness.
3 Damaging eyesight.
4 Falling.
5 Welding without goggles.
6 Damaging hearing.
a b c
6 Metal Mechanics
7
1 Rearrange the letters to make names of the portable power tools.
4 Match the functions below with a power tool or tools in the workshop picture.
3 lathe
Lathe
4 bench grinder
5 drill press Table saw
Compressor
4 Label the oxyacetylene welding equipment diagram with the words listed below.
welding torch bottle cart oxygen cylinder
1
acetylene cylinder pressure regulator
1
2
2
3 5
3
4
5
4
8 Metal Mechanics
9
1 Write these abbreviations next to the correct words.
cm g kg km m mm t
1 grams
2 kilos
3 tonnes
4 millimetres
5 centimetres
6 metres
7 kilometres
4 Look at the picture. Match the parts (1–5) with the names (a–e).
a gas cylinder
b valve
c regulator
d cylinder cap
e cart
Metal Mechanics 9
10
1 Complete the sentences with much or many.
1 There isn’t ethanol in the tank.
2 How gas cylinders are there?
3 Is there smoke in the workshop?
4 Do you get shocks when you use the arc welder?
5 I don’t have information about the new project.
6 How welders work on your crew?
f sparks
6 5
10 Metal Mechanics
11
1 Match the words (1–6) with the definitions (a–f).
1 slag a restricted area, difficult to work in
2 weld b pool of molten metal
3 overhead c vitreous bi-product of welding
4 confined d same shape as the tip of a pencil
5 pointed e connect two alloys or metals
6 puddle f welding position with arms raised
10
1
2 5
3 9
4
5 8
6
7 6
8 6
9 7
10
Metal Mechanics 11
12
1 Complete the instructions using the words listed below.
torch tungsten foot pedal plug AC regulator clamp connect
A: … OK Pedro. This is your first time with this equipment. What are we going to do?
B: Shall we 1
the torch?
A: That’s right – good. Where do we 2
it in?
B: Into the front of the machine. Here. We should also connect the gas hose and 3
.
A: Good. Two more things to connect first. First the 4
so you can control the equipment….
B: … and finally the 5
. Shall I attach here to the work table?
A: That’s fine. Now we must check current. What do we need for aluminium?
B: 6
.
A: Excellent. Now check the tungsten. That looks good. Well pointed. Let’s assemble the 7
.
Put the 8
in the collet here. That’s fine.
B: Are we ready?
A: Let’s connect power and start.
12 Metal Mechanics
13
1 Read the text and answer the questions.
What is corrosion?
Corrosion is a general term which refers to the undesired oxidation of metals to oxides and other
compounds. When the metal is iron, the corrosion process is called rusting. While iron is structurally
strong, the iron oxides formed as the products of rusting are not. Other metals such as copper and silver
become tarnished from surface oxidation of the metal. Billions of dollars must be spent annually to
replace materials that have corroded. The greatest damage is from the rusting of iron and steel. It has been
estimated that 25% of the annual steel production in the USA goes towards the repair and replacement of
metals lost by corrosion.
Metal Mechanics 13
14
1 Complete the text about shielding gases with the words listed below.
welding gases oxygen defects problem atmospheric
Shielding 1
are necessary for gas metal arc welding to protect the 2
area
from 3
gases such as nitrogen and , which can cause fusion
4 5
,
porosity, and weld metal embrittlement if they come in contact with the electrode, the arc, or the welding
metal. This 6
is common to all arc welding processes.
1 length =
2 outside diameter =
3 pipe wall thickness =
655 mm 550 mm
4 outside circumference =
5 inside diameter (bore) =
6 inside radius =
2800 mm
3 Write sentences using the Past Continuous and the Past Simple.
1 (learn) to weld when I (burn my hand).
2 When I (fall), I (climb) a ladder.
3 They (weld) when the fire (start).
4 (you use) the computer when the power (go off)?
5 He (not use) the safety guard when he (cut) his finger.
6 When we (eat) lunch, the oxygen bottle (explode).
14 Metal Mechanics
15
1 Label the arc welding equipment diagram with the words listed below.
ground clamp electrode lead
arc welding machine 6
1
electrode holder electrode 7
1
4
2
3
4
5 3 2
6
7
3 I don’t know how to use the equipment you sent. I need a more information.
Metal Mechanics 15
16
1 Read the text and answer the questions.
Tool and die makers
Tool and die makers are among the most highly skilled workers in manufacturing. These workers
produce and repair tools, dies, and special guiding and holding devices that enable machines to produce
a variety of products we use daily – from clothing and furniture to heavy equipment and parts for
aircraft. They may work in manufacturing plants that produce tools in house, or in machine shops that
only produce specialized machine tools for other manufacturers.
Toolmakers craft precision tools and machines that are used to cut, shape, and form metal and other
materials. They also produce jigs and fixtures – devices that hold metal while it is bored, stamped, or
drilled – and gauges and other measuring devices.
2 Match the beginning of each sentence (1–8) with the correct ending (a–h).
1 Routine maintenance a damaged.
2 Heat and dust can b inspected every day.
3 The generator should be c replaced it.
4 The hose was split so we d follow the maintenance schedule.
5 We removed the pump after it e repair it.
6 We replaced the compressor f stopped working.
because we couldn’t g damage a machine.
7 The gasket was h reduces accidents and injuries.
8 It’s very important to
16 Metal Mechanics
17
1 Complete the text with the words listed below.
torch pressure hoses apparatus trolley oxygen
The 1
used in gas welding consists basically of an 2
source and a fuel gas source
(usually cylinders), two 3
regulators and two flexible 4
(one of each for each
cylinder), and a 5
. This sort of torch can also be used for soldering and brazing. The cylinders
are often carried in a special wheeled 6
.
4 Label the diagram of an angle grinder with the words listed below.
power cord wheel guard
2
switch spindle lock button
1
grinding wheel side handle
1 6
2
3
4
5 3
6
5 4
Metal Mechanics 17
18
1 Label the diagram of a soldering gun with the words in the list.
solder cord sleeve tip housing 8
heating element pistol grip handle 1
6
1 2
2
3
5
4
3
5
4
6
7
8
18 Metal Mechanics
Answer Key
Unit 1 Unit 4
1 1 power source 4 base material 1 1 torch body
2 electrode 5 power 2 armoured torch cable
3 arc 3 gas supply tube
4 torch liner guiding filler wire
2 1 face shield 4 goggles
5 trigger
2 mitten 5 hand shield
6 contact tip with nozzle
3 gauntlet
7 nozzle
3 1 helmet 4 contact 8 insulated neck
2 goggles 5 ventilation
2 1 processes 4 heat
3 cables
2 join 5 resistance
4 1 aluminium, copper, mild steel 3 welding 6 binding
2 copper, mild steel
3 aluminium, copper, brass 3 s t
4 aluminium, copper, brass o l i
l w e l d i n g
Unit 2 d a n
1 1 g 2 d 3 e 4 h 5 c 6 f 7 b 8 a e d i
2 1 I’m sorry but what did you say? b r a z i n g n
2 Excuse me can you repeat the number for me? i n g
3 Could you spell that please? n g
g
3 w c u t t i n g
m e t a l c
r l d o 4 1 T 2 F 3 F 4 F 5 T
u d u r
s i r o n c r Unit 5
t e n s i l e t o 1 1 0.83%
i g i s 2 It decreases.
3 Increased carbon increases hardness.
n l i
4 Tensile strength is reduced when the % of
g e o
carbon increases beyond 0.84%.
s t e e l n 5 It decreases to its lowest point.
2 1 c 2 h 3 b 4 e 5 g 6 d 7 f 8 a
4 1 eye safety shield
2 fire-resistant gauntlet gloves 3 1 wide 4 deep
3 safety shoes 2 high 5 heavy
4 clean fire-resistant clothing 3 long
5 hand-held helmet with filter lens 4 1 a 2 c 3 b
6 flame-proof skull cap
Unit 6
Unit 3 1 1 H 2 H 3 R 4 R 5 H 6 R
1 1 Soldering 4 Brazing
2 Tinning 5 Welding 2 1 b 2 a 3 e 4 c 5 d
3 Leading 6 Cutting 3 1 fall behind 4 chase up
2 1 vaporizes 4 oxides 2 carry out 5 catch up
2 fume 5 gases 3 hold up 6 get on with
3 particulate 6 metal 4 1 b 2 c 3 a
3 1 filler rod 4 gas shielding
2 weld pool 5 nozzle
3 arc
4 1 A 2 A 3 D 4 D 5 A 6 A
Metal Mechanics 19
Answer Key
Unit 7 Unit 10
1 1 grinder 1 1 much 4 many
2 drill 2 many 5 much
3 saw 3 much 6 many
2 1 Have you finished welding? 2 a 3 b 4 c 1 d 2 e 6 f 5
2 We’ve done the grinding.
3 1 e 2 a 3 d 4 c 5 b
3 Have you and Ahmed painted it?
4 We haven’t painted it. 4 1 equipment 5 clothes
5 Have they built the base? 2 hazards 6 Smoke
6 They haven’t finished the base. 3 cylinders 7 the material
4 the spark 8 skin
3 1 a leaking discharge hose
2 check the valve discharge hose Unit 11
3 three hours
1 1 c 2 e 3 f 4 a 5 d 6 b
4 1 welding and cutting
2 1 c 2 b 3 c 4 c
2 cutting
3 turning and shaping 3 1 regulator 6 torch
4 grinding 2 gas valve 7 clamp
5 drilling 3 power source 8 remote control
6 designing 4 coolant system 9 shielding gas
7 welding and cutting 5 adaptor block
8 welding
4 1 gas valve 4 clamp
2 Shielding gas 5 torch
Unit 8
3 Remote control 6 power source
1 a four hundred and ninety
b 5,000 Unit 12
c six thousand three hundred and forty-four
1 1 connect 5 clamp
d 10,000
2 plug 6 AC
e thirteen thousand four hundred and fifty
3 regulator 7 torch
f 300,000
4 foot pedal 8 tungsten
g four hundred and sixty-five thousand
h 7,000,000 2 1 c 2 a 3 e 4 f 5 d 6 b
i seventy-five million
3 a r
2 1 Can I come in?
l p i p e e
2 Can you pass me that hammer?
3 Can you help me carry this pipe? s l a g g
4 Can I take off my hard hat? o u
y l
3 1 b 2 c 3 d 4 a 5 e
t o r c h a
4 1 bottle cart p o w e r t
2 pressure regulator g o
3 acetylene cylinder a r
4 welding torch
t u n g s t e n
5 oxygen cylinder
4 1 longest
Unit 9 2 heavier
1 1 g 2 kg 3 t 4 mm 5 cm 6 m 7 km 3 less
2 1 safe 4 most
2 Italian 5 better
3 calculator 6 worse
4 hazards 7 worst
5 employer
3 1 e 2 a 3 c 4 b 5 d 6 f
4 a 3 b 2 c 1 d 5 e 4
20 Metal Mechanics
Answer Key
Unit 13 Unit 16
1 1 undesired oxidation of metals to oxides and 1 1 produce and repair tools, dies, and other
other compounds devices
2 rusting 2 manufacturing plants or in machine shops
3 copper and silver 3 precision tools and machines
4 25%
2 1 h 2 g 3 b 4 c 5 f 6 e 7 a 8 d
2 1 metal inert gas (MIG) or metal active gas
3 1 If 4 in case
welding (MAG)
2 in case 5 When
2 constant voltage, direct current power source
3 When
3 globular, short-circuiting, spray and
pulsed-spray 4 1 but 3 but
4 to weld aluminium and other non-ferrous 2 and 4 because
materials
5 it allowed for lower welding time Unit 17
6 the cost of inert gas limited its use in steels 1 1 apparatus 4 hoses
2 oxygen 5 torch
Unit 14 3 pressure 6 trolley
1 1 gases 4 oxygen
2 1 b 2 c 3 e 4 a 5 d
2 welding 5 defects
3 atmospheric 6 problem 3 1 many
2 much
2 1 2,800 mm 4 2,058 mm
3 many
2 655 mm 5 550 mm
4 much
3 105 mm 6 275 mm
4 1 power cord
3 1 I was learning to weld when I burned my hand.
2 switch
2 When I fell, I was climbing a ladder.
3 side handle
3 They were welding when the fire started.
4 wheel guard
4 Were you using the computer when the
5 grinding wheel
power went off?
6 spindle lock button
5 He wasn’t using the safety guard when he
cut his finger. Unit 18
6 When we were eating lunch, the oxygen
1 1 housing
bottle exploded.
2 pistol grip handle
4 1 the building of metal structures by cutting, 3 solder
bending, and assembling 4 soldering iron
2 sawing, shearing, chiseling, torching, CNC 5 cord sleeve
cutting 6 on/ off switch
3 bending 7 heating element
4 structural steel and sheet metal 8 tip
Metal Mechanics 21
acknowledgements
The publisher would like to thank the following for their kind permission to reproduce
photographs and other copyright.
Illustrations by: Mark Duffin p10; Oxford Designers and Illustrators pp1, 2, 3, 4,
5 (graph), 8, 9, 11, 15, 17, 18; Peter Bull Art Studio p7; Stefan Chabluk p14.
Photographs: Alamy Images pp5 (grinding/Riedmiller/Caro), (CAD screen/Dough
Stanley), 6 (wood mill/Chrise Cheadle), (copmputer design/RightImage),
17 (Terence Hobgen); OUP pp5 (welding/Glowimages), 6 (drilling/Fotosearch),
10 (Glowimages).
Cover image by: OUP (Welder/Photodisc)
3 A001182
www.oup.com