Producing metallic castings using the gravity die process
URN: SEMMPF218
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 produce castings using the gravity die casting process, in accordance with approved procedures. You will be expected obtain the correct dies and to inspect them for any damage or non- conformance that could impair the quality of the castings produced. Dies will be assembled, and any cores required will be inserted, using recognised techniques. The dies will be secured and positioned ready for casting. You will ensure that the molten metal is available for use, to enable production to begin. It is expected that you will collect your own metal from specified points and that you will check its temperature. You will then produce the castings, in a safe manner and in accordance with specified company procedures. Any surplus metal not required will be returned to the collection point or disposed of safely. After allowing a suitable time for the molten metal to solidify, you will remove the casting from the die and visually inspect the product for compliance with the specification. Acceptable castings will be placed in the required locations, ready for their next operation. Any sub-standard castings will be held for investigation, or returned to the furnace area for re-melting. Your responsibilities will require you to comply with organisational policy and procedures for the die-casting activities undertaken. You will report any problems with the die casting operations which have been identified during your production run that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to verbal or written instructions and to take responsibility for the quality and accuracy of the castings that you produce. 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 production of gravity die-castings. Your knowledge will enable you to identify when there are faults in the castings produced, and why these faults have occurred. You will know which defects are caused by your own actions, and which ones are outside of your control. You will understand the safety precautions required when carrying out the die casting activities, 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 work instructions and specifications fpr producing metallic castings 3. ensure that the moulds are correctly prepared, sited and positioned ready for the casting process 4. ensure that the molten material is at the required casting temperature 5. collect and transport the molten material safely and correctly from the furnace 6. use the appropriate technique to pour the molten material into the moulds 7. produce castings to the required specification 8. dispose of surplus material safely and correctly 9. deal promptly and effectively with problems within your control and report those that cannot be solved 10. ensure that work records are completed, stored securely and available to others, as per organisational requirements 11. 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. the basic parts and functions of a gravity die (to include die location points, secondary die locations, core locations, die heating arrangements, die coolant supply, connection and operation of the die spray system, furnace type, guards and other safety devices) 7. why pre-production checks are carried out on the dies 8. the different types of gravity die casting 9. different methods used to locate dies and associated parts 10. different types of core used in the gravity die casting process 11. the benefits and limitations of the gravity die casting process 12. the different metals used in gravity die castings 13. the pouring temperature range of the metal alloy being cast 14. why castings need time to solidify before removing them from the die 15. why dies need to have release agent applied prior to casting 16. why some dies need to have coolant circulating through the die 17. how to identify casting defects (mis-runs, broken sections, blows, distorted sections, sinks, die-dressing runs, short runs, shrinkage, cracks, inclusions and flash) 18. the organsiational quality control checks required to the prepared gravity die (to include cleanliness, completion and freedom from foreign bodies and defects) 19. why it is important to keep the gravity dies and equipment clean and free from damage, to practice good housekeeping of metal handling tools and equipment, and to maintain a clean and unobstructed working area 20. the extent of your own responsibilities and to whom you should report if you have problems that you cannot resolve when making gravity die castings 21. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Prepare the dies for the casting operations, carrying out all of the following: 1. obtain all necessary documents and job instructions for the casting operations being performed 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. check that all molten metal handling/transfer equipment required is available and in good order (spoons and ladles) 4. check that all services are connected and that all connections are in good order (power supply, hydraulics, water cooling) 5. ensure that die coolant and die spray systems are operational 2. Assemble the dies and site them in two of the following locations, ready for casting: 1. floor 2. fixed base 3. movable base 4. carousel 5. conveyor/roller track 3. Prepare for the die casting operations, carrying out all of the following activities: 1. checking that the correct die is located in the machine, and that it is complete, clean and free from damage 2. ensuring that die location points are clean 3. checking that secondary die and core locations are clean, free from damage and free to move 4. heating the die to the correct operating temperature 5. applying appropriate die release agents 6. ensuring that the furnace contains sufficient molten metal of the correct specification, and at the correct temperature 7. pre-heating metal transfer tools (to include single bale-out or double shanks/crucibles) 4. Produce castings, carrying out all of the following: 1. insertion of cores into the die cavity 2. collection of molten metal 3. removal of the casting from the die 4. disposal of surplus metal according to company procedures (return to holding furnace, return to ladle, pour into prepared ingot moulds) 5. Produce castings using three of the following types of gravity die: 1. split die with no secondary die movement 2. split die with no cores 3. split die with one secondary die movement 4. split dies with one core 5. split die with two or more secondary die movements 6. split dies with two or more cores 6. Complete quality checks on the molten metal, carrying out two of the following: 1. molten metal temperature (such as immersion pyrometer, furnace readout, visually or technician approved) 2. cast sample test bars 3. cast samples for chemical analysis 7. Produce diecast components made from one of the following materials: 1. zinc 2. copper based 3. aluminium 4. lead 5. iron 6. precious metal 7. other specific material 8. Complete the visual inspection and segregation of castings, according to organisational procedures for all of the following: 1. acceptable castings 2. scrap castings 3. castings requiring further inspection by supervision 9. Complete all of the following operations at shut-down: 1. check that all systems are failsafe 2. complete the operational log, where appropriate 3. hand over to supervision ** ** |
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
MPF2.18
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; metallic; casting; gravity die process; techniques; equipment