Cleaning metallic castings by blasting
URN: SEMMPF222
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
2020
Overview
| This standard identifies the competences you need to operate machinery to clean castings produced from sand moulds, ceramic moulds or investment shells. The function of the machines will be to remove adhering sand and ceramic material from the surface of the castings. You will be required to select the appropriate equipment to use, based on the type, size, number and alloy of the castings to be cleaned. They will have been produced as either one-offs, or in batches, or by the continuous casting process. Both ferrous and non-ferrous castings are covered in this standard. You will carry out checks of the machine to ensure that it is safe to use and that the substances used during the cleaning operation are available and suitable for the intended purpose. The castings will have been knocked out and de-cored and you will, where appropriate, knock off the runners, risers and any flash, prior to loading them onto tables, benches or other supporting devices before beginning the cleaning. You will be expected to operate the machine to control the cleaning cycle, in accordance with safe working practices and operating procedures. In some cases, you will manually control the flow of abrasive substance onto the casting surfaces. During the cleaning cycle you will, where appropriate, be unloading treated castings from a second table and re-loading with untreated castings. You will be expected to use workholding and lifting devices to manipulate the castings, both for the loading and unloading operations. There could be occasions when larger castings are sited on the floor and you will be expected to manoeuvre these to complete the cleaning. You will monitor the machine's performance, to ensure the consistent treatment of the castings and to check that adequate levels of cleaning substances are maintained within the machine. Metal waste removed from the castings will be segregated, marked up and removed to designated areas. Your responsibilities will require you to comply with organisational policy and procedures for the mechanised cleaning of the castings. You will report any problems with the cleaning activities, tools, machines or substances 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 or written instructions, and to take responsibility for the safe and correct cleaning of the rough castings. 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 mechanical cleaning of various types and size of castings. You will understand the different tools and machines and how to use them for cleaning the various types of casting. You will be familiar with the lifting and moving equipment which is used to handle the different types and size of castings. You will understand the safety precautions required when carrying out the cleaning activities, and when using the associated machines, 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 for cleaning metallic castings by blasting 3. obtain the required materials and check they meet quantity and quality specifications 4. prepare for, and carry out cleaning operations 5. check operations are complete and cleaned castings meet specifications 6. deal promptly and effectively with problems within your control and report those that cannot be solved 7. ensure that work records are completed, stored securely and available to others, as per organisational requirements 8. 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 checks to be made on the machines and equipment to ensure that they are in a safe and usable condition 7. how to set up and use dust extraction equipment and the importance of ensuring that the equipment is operating correctly 8. the effect of incorrect cleaning on casting quality 9. why different methods of cleaning castings are used for different moulding materials 10. the reasons why different types of machine are used to clean ferrous and non-ferrous castings 11. the reasons why different materials are used to clean ferrous and non-ferrous castings 12. the various types of blasting consumables that are used and their suitability to various applications 13. the casting defects which can be directly related to using incorrect methods to remove runners/risers/feeders from castings during cleaning 14. the reasons why runners/risers/feeders need to be identified 15. why some materials can be returned for recycling, why others must be disposed of, and why some need specialist methods of disposal 16. the importance of keeping the equipment clean and free from damage, good housekeeping of tools and equipment and maintaining a clean working area 17. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve 18. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Prepare to clean castings, carrying out all of the following activities: 1. obtain all necessary documents and job instructions for the cleaning operations being performed 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work check that all the machine controls are operating safely and correctly (mechanical parts, circulating pumps, hydro supply, nozzles are clean and undamaged) 3. check that necessary services are connected and operational 4. check that any lifting and handling equipment required is available and in good order 5. ensure that dust extraction and air filtering equipment is functioning correctly 6. ensure that any tracks or carousels are operational 7. check that any consumables, (shot or oil) are at the appropriate levels in the machine 2. Clean castings which have been produced from one of the following materials: 1. ferrous alloys 2. non-ferrous alloys 3. Use one of the following types of blasting unit: 1. twin tabled shot blast 2. cabinet shot blast, manually operated 3. bead blasting 4. single table barrel shot blast 5. cabinet sand blast, manually operated 6. hydro blast 7. continuous shot blast 8. vapour blast 9. other (specify) 4. Clean rough castings using one of the following methods: 1. manual operation of the abrasive/water/vapour stream 2. machine controlled cycle 5. Clean castings, carrying out all of the following: 1. removal of joint line flash and runners/risers/feeders using hand tools 2. loading of rough castings onto or into the blasting unit 3. manual or machine operation of the abrasive/water/vapour stream 4. unloading the castings from the cleaning equipment 6. Monitor the machine performance during the cleaning operation and carry out all of the following checks: 1. consumable material levels 2. supply pressure of services 3. escape of materials from the machine 4. extraction equipment function 5. filtration system function 7. Complete the visual inspection and segregate castings into the following categories: 1. acceptable castings 2. scrap castings 3. castings requiring further cleaning operations 4. castings requiring further inspection by supervision 8. Complete all of the following operations at shut-down 1. close down any machinery or equipment used during cleaning operations (extraction units, power supplies, air supplies, filtering equipment, circulating pumps, hydro supply) 2. check that all systems are failsafe 3. complete the operational log |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
2023
Validity
Current
Status
Original
Originating Organisation
Semta
Original URN
MPF2.22
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; cleaning; metallic; casting; blasting; machining; shot blasting