Repairing and reclaiming metallic castings
URN: SEMMPF224
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
2020
Overview
| This standard identifies the competences you need to repair and reclaim castings produced from sand or ceramic moulds, dies or investment shells. The decision to repair or reclaim the castings will be made by others. You will be required to select the appropriate equipment to use, based on the type, size and alloy of the casting to be repaired or reclaimed. Both ferrous and non-ferrous castings are covered by this standard. You will carry out checks to the equipment to ensure it is in a safe and usable condition and is capable of completing the repair or reclamation. The castings to be repaired or reclaimed may be circular, square or irregular in shape and have projections and internal cavities. The profiles could be curved and tapered. You will prepare the areas of the castings that require repair, prior to adding new metal by welding or burning-on. Where appropriate for reclamation work, you will remove excessive metal and re-shape the casting profile to meet the specification. You will operate fixed and portable machines to remove the surface protrusions and where appropriate, polish the castings in accordance with procedures. You will use workholding devices, benches and lifting equipment to manipulate the castings during the repair/reclamation operation. There could be occasions when larger castings are sited on/in the floor and you will be expected to manoeuvre these to complete the work. Repaired and reclaimed castings will be placed in specified areas to be inspected and/or tested prior to returning them to the production line. You will record all repairs and reclamation work carried out to the castings. Your responsibilities will require you to comply with organisational policy and procedures for the repair or reclamation of the castings. You will report any problems with the repair/reclamation activities, tools, machines or materials 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 repair or reclamation of the 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 repair and reclamation of various types and sizes of casting. You will understand the different tools and machines used and how to use them for repairing or reclaiming the various types of casting. You will be familiar with the lifting and moving equipment which is used to handle the different types and sizes of casting. You will understand the safety precautions required when carrying out the repair and reclamation 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 the relevant specifications for the component to be repaired 3. prepare the component for repair 4. carry out the repairs within agreed timescale using appropriate materials, components, methods and procedures 5. check that the repaired component meets the operating conditions and 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. why different methods of repairing/reclaiming castings are used for different types of defects and alloys (welding, burning-on with molten metal, impregnation or brazing) 9. the importance of ensuring that a defective area has been totally exposed during the preparation work and how this can affect a welded repair to a casting 10. the different types of equipment that may be used to repair/reclaim ferrous and non-ferrous castings (including manually, mechanically or electronically operated thermal cutting and welding equipment, hand-held or pneumatic chisels and chipping hammers, chemical cleaning, disc/angle grinder, straight grinder, angle pencil grinder) 11. the types of fuel used when operating cutting and gouging equipment 12. why costs of repair/reclamation need to be considered carefully before any work is started on the defective casting 13. the types of casting/fettling defect that can be effectively repaired without loss to the serviceability of the casting (sinks, inclusions, mis-run/cold shuts, shrinkage, sub-surface/surface porosity, cracks, undercuts on runners/risers/feeders, poor ingate or feeder cut-off, swells, broken ingates/runners/risers, cross joints) 14. the importance of keeping the equipment clean and free from damage, good housekeeping of tools and equipment and maintaining a clean working area 15. the extent of your responsibility and to whom you should report if you have problems that you cannot resolve 16. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Repair and/or reclaim castings carrying out all of the following in activities: 1. obtain all necessary documents and job instructions for the repair or reclamation operations being performed 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. check that all 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 2. Repair and/or reclaim castings produced from one of the following materials: 1. ferrous alloys 2. non-ferrous alloys 3. Prepare the castings for repair and/or reclamation, using two of the following methods: 1. pre-heating 2. digging out affected areas using portable power tools (disc/angle grinders, pencil grinder) 3. gouging out affected areas using thermal cutting equipment (manual, mechanically or electronically operated) 4. setting up the casting to receive molten metal 5. removing parent metal using hammer and chisel or pneumatic chisels 6. chemical cleaning 4. Repair and/or reclaim prepared sub-standard areas of the castings, using one of the following processes: 1. burning on with molten metal 2. welding 3. brazing 4. impregnation 5. other processes (specify) 5. Repair and/or reclaim all of the following shaped castings: 1. irregular 2. curved or tapered profiles 3. projections or internal cavities 6. Repair defects in castings, to include three of the following: 1. sinks 2. broken ingates/runners/risers 3. mis-run/cold shuts 4. shrinkage 5. inclusions 6. cracks 7. undercuts on runner/riser/feeders 8. sub-surface porosity 9. cross joints 10. poor ingate or feeder cut-off 11. swells 12. surface porosity 13. other defects (specify) 7. Complete all of the following operations at shut down: 1. close down the machines/tools after use 2. check that all systems are failsafe 3. record details of repairs/reclamation carried out according to organisational procedures |
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
MPF2.24
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
3113
Keywords
Engineering; manufacturing; processing; repairing; reclaiming; metallic; casting; adding metal; re-shape