Controlling and treating molten metal in readiness for casting

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This standard identifies the competences you need to control the temperature of, and treat, molten metal used to make castings. You will be required to use approved procedures techniques, methods and equipment. You will be required to select the appropriate equipment to use, based on the type and amount of molten metal being controlled and treated. You will use single, batch and continuous production methods for the metal, and both ferrous and non-ferrous alloys.

You will maintain an adequate amount of the materials needed to treat the molten metal and will notify supervisors when stocks reach re-ordering levels. You will provide information and materials, where appropriate, to others who will add the specified materials/additions into the melting furnace at the specified time.

You will be required to monitor and record the temperature of the molten metal on a regular basis. You will plan, supervise or perform simple tests on samples taken from the molten metal, in accordance with the company control procedures. The tests could be performed manually, or by using in-built continuous monitoring equipment that provides information visually or by printouts. You will be expected to prepare samples for testing, interpret test results and plan any corrective actions required to the molten metal. For the manually performed tests, you will be expected to record the results obtained on control charts. From information obtained from the test results, or from other sources, you will, if necessary, be expected to add materials/metal to correct any deficiencies. You will treat the molten metal to remove/contain impurities and to modify the cast metal to meet the casting specification.

Your responsibilities will require you to comply with organisational policy and procedures for the control and treatment of the molten metal. You will report any problems with the materials and equipment 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 quality and accuracy of the treated molten metal.

Your underpinning knowledge will be sufficient to provide a sound approach to your work and will provide an informed approach to the control and treatment of the molten metal. You will understand the different types of metals in use and the associated furnaces used to melt these metals. You will understand the different methods of melting metal, such as single melt, batch or continuous
processes and the tests and treatments that are used to confirm that the process is under control.

You will understand the safety precautions required when carrying out the testing and treatment of the molten metal. 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 and towards the environment.

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1. work safely at all times, complying with health and safety legislation,  regulations, directives and other relevant guidelines
2. check and monitor the operating conditions of the melting furnace making any necessary adjustments to maintain satisfactory operating conditions
3. carry out temperature tests of the molten metal at the appropriate intervals
4. plan and prepare charge materials for melting to meet required specifications
5. plan and prepare control tests to ensure molten metal for casting meets material specification
6. apply appropriate treatments to the melt in order to achieve material specification
7. take samples of the molten metal and carry out appropriate tests to determine quality
8. make any necessary adjustments/additions to the melt to ensure it achieves the required characteristics and meets the final material specification
9. deal promptly and effectively with problems within your control and report those that you cannot solve
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

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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 job instructions and specifications and how to interpret their information
6. why it is necessary to check the amounts of materials prior to starting the treatment operations
7. what actions are needed when materials are found to be below the required amounts
8. why quality checks should be made on the materials to be used
9. the effects on the molten metal if the treatment materials are past the `use by' date, are different in content from the company requirement/specification, are added to the furnace/metal at the wrong time or at the wrong temperature, or if too little or too much is added to the furnace/molten metal
10. the different types of furnace and fuels used in melting metal
11. the types of furnace used to melt ferrous and non-ferrous alloys
12. the materials/gases you use on a regular basis when treating metal, during melting or when molten
13. why it is important to keep records of test results
14. why sampling of molten metal should be performed
15. the types of test which you perform on the molten metal
16. why molten metal, which is outside of specification after testing, has to be disposed of
17. the actions you need to take if the molten metal is outside of specification
18. the consequences to casting quality that can result from using metal that is out of specification or which has been incorrectly treated
19. the company quality control checks required for the molten metal
20. the importance of  keeping the furnace and treatment equipment clean and free from damage, practising good housekeeping of tools and testing equipment and maintaining a clean and unobstructed working area
21. the defects/flaws in castings which can be directly related to the use of molten metal which is outside of the specified temperature range, is untreated, or incorrectly treated or is treated but when the casting of the moulds, is delayed, or to the use of un-skimmed metal
22. the extent of your own responsibilities and whom you should report to if you have problems that you cannot resolve

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1. Control and treat molten metal ready for casting, carrying out all of the following during the molten metal treatment activities:

   1. obtain the correct amounts of consumables to treat the molten material (fluxes, deoxidizers, oxidising agents, inhibitors, grain refiners, inoculating materials)
   2. adhere to health and safety regulations, systems and   procedures to realise a safe system of work
   3. check the quality/specification of the materials that you use, and ensure that the materials specification complies with melt documentation
   4. use appropriate personal protective equipment (PPE) and check that it is in good order
   5. follow the defined testing and sampling procedures and apply safe working practices and procedures at all times
   6. ensure that the completed melt meets the required specification

2. Check and prepare the molten metal, to include carrying out both of the following:

   1. determining the temperature of the molten metal (immersion    pyrometer, visual display units, visually, or by electronic methods)
   2. adjusting the operating conditions of the melting furnace

3. Carry out treatment of the melting/molten metal, to include two of the following:

   1. adding deoxidising agents to charge material
   2. adding cover fluxes to charge material
   3. adding oxidising agents to charge material  
   4. degassing molten metal
   5. deoxidising molten metal               
   6. grain refining of molten metal
   7. modification or other metallurgical treatment of molten metal         
   8. removal of slag/oxide skins
   9. other specific treatment

4. Take samples of the molten metal, for one of the following types of test:

   1. carbon equivalent measurement       
   2. spark emission spectrometry
   3. chemical analysis                      
   4. wedge tests
      X-Ray Fluorescence Spectrometry (XRF)
   5. mechanical testing
   6. other specific test

5. Take action to adjust the molten metal, as required, by one of the following methods:

   1. manual/mechanical addition of further metal/materials
   2. treatment of the metal by mechanical/manual means
   3. adjusting the power or fuel input to furnace

6. Complete preparation work for the molten materials, to include carrying out all of the following:

   1. recording of test results according to company specifications
   2. confirming that the prepared melt is ready for use and complies with required specification
   3. discharging molten metal according to company procedures

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2

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2023

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Current

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Original

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Semta

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MPF3-066

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

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3113

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Engineering; manufacturing; processing; controlling; treating; molten metals; casting; techniques; equipment

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