Producing castings using pressure die processes

URN: SEMMPF324
Business Sectors (Suites): Materials Processing and Finishing Suite 3
Developed by: Enginuity
Approved on: 2020

Overview

This standard identifies the competencies you need to produce castings using high and low pressure die casting processes, in accordance with approved procedures. It covers high pressure (hot or cold chamber), squeeze and low-pressure die-casting. Dies/moulds will be mounted on the platens in the machines, using recognised and approved techniques.

You will be expected to check that the correct die/mould is in place, that there is no damage to the die/mould or non-conformance that could impair the quality of the castings produced, that the machine conditions are set and that molten metal is available for production to begin.

The molten metal will either be drawn into the die automatically (hot chamber) or collected from a furnace close to, or integrated into, the die/mould-casting machine (cold chamber or squeeze). In all cases, you will be expected to check the temperature of the metal prior to production of the castings. You will cast the die/mould in a safe manner, as appropriate, to 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/mould and will visually inspect the product for compliance with the specification. Acceptable castings will be placed in the required locations prior to 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/mould-casting activities undertaken. You will report any problems with the 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 with a minimum of supervision and to take personal responsibility for the quality and accuracy of the castings 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 pressure die/mould castings. Your knowledge will enable you to identify when there are faults in the produced castings and why these faults have occurred. You will know which defects/flaws are caused by your own actions, and which are outside of your control.

You will understand the safety precautions required when carrying out the pressure die/mould casting activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to 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
  3. prepare equipment and confirm that it is set up correctly and ready for the casting activities
  4. maintain an adequate supply of base materials
  5. manipulate the machine controls safely and correctly in line with operational procedures
  6. produce cast components to the required specification, using pressure die processes
  7. carry out quality sampling checks at suitable intervals and check the castings produced meet specifications
  8. deal promptly and effectively with problems within your control and report those that cannot be solved
  9. ensure that work records are completed, stored securely and available to others, as per organisational requirements
  10. 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 the information
  6. the basic parts and functions of a pressure die/mould casting machine (to include dies, die location points, secondary die locations and core locations, die heating arrangements, die coolant supply, connection and operation of die spray system, furnace type, machine controls, hydraulic, pneumatic and electricity supplies, metal transfer systems, guards and other safety devices)
  7. the importance of carrying out pre-production checks on the dies/moulds
  8. the different types of pressure die/mould casting
  9. the different methods used to locate dies/moulds and associated parts
  10. the  different types of core used in the pressure die/mould casting process
  11. the benefits and limitations of the high pressure hot chamber process, high pressure cold chamber process, low pressure and squeeze process
  12. the different metals used in producing pressure die/mould 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/mould
  15. why dies need to have release agent applied prior to casting
  16. why some dies need to have coolant circulating through them
  17. how to identify casting defects/flaws (such as mis-runs, broken sections, blows, distorted sections, sinks, die-dressing runs, short runs, shrinkage, cracks, inclusions and flash)
  18. the organisational quality control checks to be carried out on the prepared pressure die/mould (to include cleanliness, complete and freedom from foreign bodies and defects/flaws)
  19. the importance of keeping the pressure die/moulds and equipment clean and free from damage, good housekeeping of metal handling tools and equipment and maintaining 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
  21. how to access, use and maintain information to comply with organisational requirements and legislation

Scope/range


Scope Performance

  1. Prepare the machine 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. ensure that all molten metal handling/transfer equipment, such as spoons and ladles, is available and in good order
    4. check that all services are connected and that all connections are in good order (such as power supply, hydraulics, water cooling)

    5. check that all machine controls are operational

    6. check that die coolant and die spray systems are operational         
  2. Prepare for the pressure die/mould casting operations, to include carrying out all of the following:

    1. checking that the correct die/mould is located in the machine and is complete, clean and free from damage
    2. ensuring that die/mould location points are clean
    3. checking that secondary die/mould and core locations are clean, free from damage and free to move
    4. heating the die/mould to the correct operating temperature applying die release agents (where appropriate)
    5. ensuring the furnace contains sufficient molten metal of the correct specification and is at the correct temperature
    6. preheating metal transfer tools where appropriate (to include single bale-out or double shanks/crucibles)
  3. Produce pressure die/mould castings, using one of the following methods:

    1. high pressure hot chamber
    2. high pressure cold chamber
    3. squeeze process
    4. other specific process
  4. Produce castings using two of the following types of pressure die/mould:

    1. split die with no secondary die movement      
    2. split dies with one core
    3. split die with one secondary die movement
    4. split dies with two or more cores
    5. split die with two or more secondary die movements  
    6. core assembly with external cores
    7. split die with no cores                  
    8. core assembly with internal cores
  5. Produce castings by mechanical or manual methods, to include all of the following:

    1. insertion of cores into die/mould cavity (where appropriate)
    2. collection of molten metal from specified location
    3. disposal of surplus metal according to company procedures
    4. removal of casting from the die/mould
  6. Complete quality sampling checks on molten metal, to include all of the following:

    1. molten metal temperature (such as by immersion pyrometer, furnace readout, visually or technician approved)
    2. cast sample test bars
    3. cast samples for chemical analysis
  7. Produce pressure die/mould cast components made from one of the following materials:

    1. zinc                      
    2. copper base  
    3. iron
    4. aluminium       
    5. lead     
    6. precious metal
    7. magnesium      
    8. other specific material
  8. Complete visual inspection and segregation of castings, according to organisational procedures, to include all of the following:

    1. acceptable castings
    2. scrap castings

    3. castings requiring further inspection by supervisor


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

SEMMPF324

Relevant Occupations

Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives

SOC Code

8115

Keywords

Engineering; manufacturing; processing; machining; pressure die casting; casting; high pressure; low pressure; squeeze; moulding