Melting metal for casting
URN: SEMMPF213
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
30 Mar 2020
Overview
| This standard identifies the competences you need to prepare and process the materials and metal used in the production of molten metal to cast moulds and shells. Manual and mechanised methods will be used, in accordance with approved procedures. You will be required to select the appropriate equipment to use, based on the type and amount of molten metal needed. Single, batch and continuous production methods for the metal are included in this standard, which also covers both ferrous and/or non-ferrous alloys. You will maintain an adequate amount of the base metal and necessary materials and will notify supervision when stocks reach re-ordering levels. For single and batch production you will, in conjunction with others and where appropriate, prepare the base metal for insertion into the melting furnace. You will light/start up the furnace and charge the base metal plus any other specified materials/additions into the melting vessel at the specified time. You will also adjust the furnace operating conditions to suit the molten metal requirements. You will be expected to discharge the molten metal into receiving vessels or to other holding furnaces, as appropriate. Your activities will include the operating of any mechanical, electrical or electronic equipment used during the melting of the metal. Your responsibilities will require you to comply with organisational policy and procedures for the preparation and control of the melting activities undertaken. You will report any problems with base metal, materials and equipment in use that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to verbal and written instructions, with minimal supervision, taking personal responsibility for your actions and for the quality of the molten metal produced. Your underpinning knowledge will be sufficient to provide a sound basis for your work and will enable you to adopt an informed approach to the preparation and control of the molten metal you produce and any additional materials used during the melting process. You will understand the different types of metals in use and the associated furnaces used to melt these metals. You will understand the different methods of melting metal (single, batch or continuous) and the tests that are used to confirm that the process is under control. You will understand the safety precautions required when carrying out the metal melting operations and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout. You will also understand your responsibilities for safety and the importance of taking the necessary safeguards to protect yourself and others in the workplace. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines 2. follow relevant job instructions and specifications for melting metal for casting 3. set up the operating conditions of the melting furnace making any necessary adjustments to maintain satisfactory operating conditions 4. obtain the required charge materials and check they are in a suitable condition to use 5. start up the furnace using approved procedures and add the materials at the appropriate time 6. test the molten metal at suitable intervals and check the completed work meets specification for casting 7. deal promptly and effectively with problems within your control and report those that you cannot solve 8. ensure that work records are completed, stored securely and available to others, as per organisational requirements 9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. how to obtain the job instructions and how to interpret their information 6. to the importance of checking the amounts of metal and other materials, prior to melting operations 7. what actions are needed when base metal and materials are found to be below the required amounts 8. how problems with materials can affect the melting operating and molten metal (if the base product has passed its `use by' date, differs from the organisational requirement/specification, or if the melt is incorrect) 9. the different types of furnace that are used to melt metals (to include cupola, induction, rotary, bale out, crucible (lift out or tilting) and direct or indirect arc) 10. the different fuels used in melting metal 11. the reasons why furnace start-up procedures are performed and why these must always be adhered to 12. the additions are made to the metals/alloys used on a regular basis 13. the actions to take if the molten metal is outside of the specified temperature range 14. the methods of checking the metal temperature and the types of equipment used 15. the company quality control checks required on the molten metal 16. to the importance of keeping the furnace and melting equipment clean and free from damage, good housekeeping of tools and equipment and maintaining a clean and unobstructed working area 17. the extent of your own authority and whom you should report to if you have problems that you cannot resolve when preparing the molten materials 18. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Prepare the furnace for operation, carrying out all of the following activities: 1. ensure that services/power supplies are connected and operational and start-up procedures are initiated 2. check that guards/screens are in position and operational 3. check that emergency stop controls are operational 4. check that visual display panels are operational 5. refer to and action any notes/reports from the previous shift 6. ensure that supply and discharge outlets are clear and operational 7. adhere to health and safety regulations, systems and procedures to realise a safe system of work 8. comply with job instructions and melting specifications 9. check furnace linings and equipment 10. shut down the furnace to a safe condition on completion of the melting activities 2. Prepare the materials used in the casting process, ensuring that they are to the required specification, checking all of the following: 1. selection and preparation of metallic charge materials (scrap, ingots, returns) 2. selection and preparation of any additives and additions (fluxes, inhibitors, de-oxidisers) 3. selection and preparation of any fuel charge materials 4. taking appropriate action when stocks of raw materials are low 3. Produce the molten material, using one of the following methods: 1. single melt 2. batch melt 3. continuous melt 4. combined methods 4. Produce molten metal, using one of the following types of furnace: 1. cupola 2. bale out 3. direct or indirect arc 4. induction (high or low frequency) 5. lift out crucible 6. rotary 7. tilting crucible 8. other melting furnaces (specify) 5. Produce molten material from one of the following: 1. ferrous alloys 2. non-ferrous alloys 6. Monitor the melting process, to include all of the following: 1. measuring the melt temperature (visually, immersion pyrometer, visual display units, electronic means) 2. adjusting the operating conditions of the melting furnace (melting rate by changing the power or fuel input) 3. making necessary additions to the melt 4. where applicable, informing appropriate people of non-conformance of the molten metal 5. confirming that the melt is ready for casting (verbally, visual display, e-mail) 7. Discharge the molten metal from the furnace into one of the following: 1. holding furnace 2. prepared pouring ladle 3. prepared treatment ladle 4. other holding/casting vessel/pig |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
31 Mar 2023
Validity
Current
Status
Original
Originating Organisation
Semta
Original URN
MPF2.13
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; melting; metal; furnace; casting; monitor melt; discharge