Inspecting metallic castings visually
URN: SEMMPF225
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
2020
Overview
| This standard identifies the competences you need to visually inspect castings produced from sand or ceramic moulds, dies or investment shells. You will be required to select the appropriate aids and equipment to use, based on the type, size, alloy and inspection requirements of the castings. Both ferrous and non-ferrous castings are covered by this standard. You will carry out checks to the aids and equipment to ensure it is safe to use and is suitable for purpose. The castings may be circular, square or irregular in shape, with projections and internal cavities and curved or tapered profiles. You will carry out visual inspections of external and internal areas of the castings, during any or all of the processes used to finish a casting to meet a company or customer specification. You will use any provided aids to inspect the castings and where appropriate, you will mark the castings to indicate defects/flaws, either obvious or suspected, in accordance with procedures. Where appropriate, you will use workholding devices, benches and lifting equipment to manipulate the castings during the inspection operation. There could be occasions when larger castings are sited on the floor and you will be expected to manoeuvre these to complete the work. Castings that meet specification will be passed to the next operation. Sub-standard castings will be scrapped or segregated for further inspection or testing. You will record, on the appropriate sheets, all your findings on inspected castings and pass these records to named persons. Your responsibilities will require you to comply with organisational policy and procedures for the inspection activities undertaken. You will report any problems with the inspection activities, tools and equipment used 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 inspection 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 inspection of the various types and sizes of casting. You will understand the different methods used and the various aids, machines and materials that are used during the inspection operations. You will be familiar with the lifting and moving equipment that is used to handle the different types and sizes of casting. You will understand the safety precautions required when carrying out the inspection 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 the correct specification for the product or equipment being inspected 3. use the correct equipment to carry out the inspection 4. identify and confirm the inspection checks to be made and acceptance criteria to be used 5. carry out all required inspections as specified 6. identify any defects/flaws in castings or variations from the specification 7. deal promptly and effectively with problems within your control and report those that cannot be solved 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. the emergency procedures to be followed in the event of a malfunction of any of the equipment 7. why different methods of inspecting castings are used for different types of defect/flaw 8. why different methods of inspection are used on castings that have to meet critical criteria (turbine blades) 9. the different equipment that can be used to assist with the visual inspection activities (electronic scanning units, shadowgraph units, magnifying glasses or dye-penetrant equipment) 10. why it is important to inspect castings at all stages of the finishing process 11. why inspection equipment must be calibrated 12. the different types of defects/flaws which can be detected through visual inspection (including sinks, inclusions, mis-runs/cold shuts, shrinkage, surface/sub-surface porosity, cracks, undercuts on runners/risers/feeders, poor ingate or feeder cut-off, swells, cross joints, scabs, mis-placed cores, variable metal section thickness and excessive flash) 13. the importance of keeping the equipment clean and free from damage, good housekeeping of tools and equipment and maintaining a clean working area 14. why costs of need to be considered carefully before any casting is submitted for repair/reclamation operations 15. the types of casting/fettling defect/flaws that can be effectively repaired without loss to the serviceability of the casting 16. why it is important that records of casting inspections are comprehensive and maintained on a regular basis 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. Preparation for the inspection, carrying out all of the following activities: 1. obtain all necessary documents and job instructions for the inspection operations being performed 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. check that all tools and equipment to be used in the inspection activity are in a safe and usable condition 4. comply with work instructions and specifications 2. Inspect castings produced from one of the following materials: 1. ferrous alloys 2. non-ferrous alloys 3. Visually inspect castings at two of the f finishing process stages: 1. mould knock-out and de-core 2. prior to manual cleaning 3. prior to mechanical cleaning 4. after manual cleaning 5. after mechanical cleaning 6. during and after fettling 7. before, during and after repair/reclamation 4. Perform the visual inspection of castings, using two of the following: 1. normal visual scans 2. magnifying glasses 3. electronic scanning units 4. dye-penetrant process equipment 5. shadowgraph units 5. Identify, by visual inspection, four of the following casting defects/flaws: 1. sinks 2. sub-surface porosity 3. shrinkage 4. inclusions 5. undercuts on runners/risers/feeders 6. cracks 7. swells 8. poor ingate or feeder cut off 9. mis-placed cores 10. cross joints 11. broken ingates/runners/risers 12. variable metal section thickness 13. scabs 14. mis-runs/cold shuts 15. excessive flash 16. surface porosity 17. other defects/flaws (specify) 6. Complete the visual inspection, identification marking and segregation of castings, ensuring all of the following meet organisational requirements: 1. meets required specification 2. requiring dimensional checking 3. requiring repair/reclamation work 4. requiring further investigation 5. total scrap |
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
MPF2.25
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; inspecting; metallic; casting; visual; scanning; shadowgraph