Foundry Procedures

Foundry - National Technical Certificate (NTC) and Advanced National Technical Certificate (ANTC)

Advanced Courses

Pattern Making ........................................................................................................................................... 2 Moulding and Core-making......................................................................................................................... 6 Melting and Casting Processes ................................................................................................................ 13 Finishing and Quality Control.................................................................................................................... 20

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Pattern Making ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY CRAFT PRACTICES PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: CFE 21 PATTERN MAKING DURATION: 144 HOURS (12 HOURS PER WEEK) PRE-REQUISITE: CME 11, 12 AND CMW 10 GOAL: This module is intended to provide the trainee with advanced knowledge and skill to read and interpret engineering drawing of casting and translate blueprints into patterns. GENERAL OBJECTIVES: On completion of this module the trainee will demonstrate the following practical competencies to a standard expected in industry. 1. Understand trade science of pattern making 2. Acquire special skills in pattern making 3. Carry out simple engineering drawings for pattern making STUDENT OUTCOME: On completion of this module the student will demonstrate the following competencies. 1. Making working drawings and interpret engineering drawings of patterns 2. Select correct materials for pattern construction. 3. Produce patterns using appropriate tools and equipment 4. Carry out various finishing operations on patterns 5. Make expendable pattern using appropriate materials 6. Carry out casting with appropriate calculations from a given drawing and pattern equipment

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: PATTERN MAKING

COURSE CODE: CFD 21

CONTACT HOURS: 12 HRS/WK PER WEEK: T4, P8

Course Specification: Theoretical and Practical Contents General Objective 1.0 Understand the Art of Pattern Making Week Special Learning Outcome

1-4

Teachers Activities

Resources

1.1 Design patten from blue-print

• Guide student to design

• Drawing materials and

1.2 Carry out cost analysis of a given job

pattern from Blue-print

instruments

1.3 Select common and special materials

• Emphasis on importance of

• Casting Design

for pattern making

cost analysis of a given job

• Writing materials,

a. Wood

• Ask students to:

calculator

b. Wax

• Distinguish and identify the

• Pattern making

c. Plaster of Paris (P.O.P)

various pattern making

materials

d. Plastics

materials.

• Quality control tools and

e. Metals

• State the advantages and

devices

f. etc.

• Disadvantages of various

• Tape Ruler, Venier

1.4 Explain inspection and quality control

pattern making materials

Calipers

operations involved in pattern making

• Ask students to carry out

• Micrometer screw

1.5 Carry out various finishing operations in inspection and quality control

gauge etc.

through

• Sand papers, paint

a. Sand papering

• Measurement

• Vanisher dowels, lifting

b. Vanishing

• Gauging

strips etc.

c. Painting and colour

• Sampling

coding

• etc.

d. Pattern fixtures

• Emphasis on the need for

e. etc.

good finish

pattern making

• Perform finishing operations

3

PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: PATTERN MAKING

COURSE CODE: CFD 21

CONTACT HOURS: 12 HRS/WK PER WEEK: T4, P8

Course Specification: Theoretical and Practical Contents General Objective: 2.0 Acquire special skill in pattern making Week Special Learning Outcome

5-8

Teachers Activities

Resources

2.1 Carry out simple carving and tooling

• Ask students to carry out

• Carving tools

operations

simple carving operations in

• Machines and Tools as

2.2 Carry out wood milling and turning

pattern shapes

listed in objective 2.2

operations using common and special

• Guide students to operate

• Availability of

machines and tools, example:

both the common and special expendable materials.

a. Woodturning lathe

machines in pattern production • Relevant standard

b. Wood milling machine

• Ask students to distinguish

c. Bobbling sander

the differences between the

d. Thicknessing machine

various expendable materials

e. Circular saw machine

• State the advantages over

f. Band saw machine

the wooed and metal patterns

g. etc.

• Emphasis on good pattern

2.3 Make expendable pattern using

workshop layout

materials such as: a. Wax b. Plaster of Paris c. Polystyrene 2.4 Explain the general layout of a pattern shop example: a. Arrangement of machines and equipment b. Tools storage c. Gangways

4

pattern workshop

PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: PATTERN MAKING

COURSE CODE: CFD 21

CONTACT HOURS: 12 HRS/WK PER WEEK: T4, P8

Course Specification: Theoretical and Practical Contents General Object: 3.0 Carry out simple Engineering drawing for pattern making Week Special Learning Outcome

Teachers Activities

Resources

3.1 Make working drawings isometric,

• Ask student to produce

• Drawing materials and

autographic (oblique and sectioning) for

working drawings for pattern

instruments

pattern production; Consider the following: - production

9-12

• Shrinkage (contraction) and fillets provisions

a. Mould joints

• Considerations and

b. Slip joint

emphasis on the relevance of • Appropriate Formulae

c. Core prints

a-i in 3.1

d. Loose pieces

• Emphasis on the importance calculations of volumes

e. Running and feeding

of allowances and provisions

and weights

systems

to be made on patterns e.g.

• Samples of already

f. Mould and core

• Shrinkage

made patterns

reinforcements

• Taper

g. Draw backs

• Machining

h. False (self cores)

• Core prints

i. Cover cores and Core

• Fillets etc.

assemblies

• Ask students to carry out

3.2 Interpret engineering drawing of

casting weight calculations

patterns

using

3.3 Estimate casting weights from given

• Drawings

drawing and prepared

• Prepared pattern

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from Texts for

Moulding and Core-making PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: CFD 22 MOULDING AND CORE-MAKING DURATION: 180 HOURS (15 HOURS PER WEEK) GOAL: The module is intended to provide the trainee with further knowledge in moulding, core-making and to make good cores and moulds. GENERAL OBJECTIVES: On completion of this module the trainee will demonstrate the following practical competencies to a standard expected in industry. 1. Understand the properties of materials used in moulding processes. 2. Understand sand casting process and other special mould castings 3. Understand the basic approach to solidification of metals and alloys 4. Understand the methods used to minimize shrinkage and inclusions in castings 5. Understand the causes of faulty castings, and their preventive measures Student outcome: On completion of this module the student will demonstrate the following competencies. 1. Carry out sand routine tests 2. Carry out calculations on gating system i.e. gating ratio’s 3. Use correct gating system 4. Prepare sand moulds 5. Melt and remove slag and dross in molten metal 6. Carry out fluidity tests using spiral testing device. 7. Measure casting temperature 8. Pour the molten metal with correct pouring technique 9. Knock-out casting and carry out salvaging of defective castings as the need arises 10. Carry out inspection control on finished casting Produce castings using other special casting processes. 1. Centrifugal casting 2. Investment casting 3. Gravity or permanent mould casting 4. Pressure die casting 5. Plaster casting

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CORE-MAKING

COURSE NO CFD 22

CONTACT HOURS: 15 HRS/WK PER WEEK: T6, P9

COURSE SPECIFICATION: THEORETICAL AND PRACTICAL CONTENTS General Objective: Understand the properties of materials in moulding processes Week Special Learning Outcome

Teachers/Student Activities

Learning Resources

1.1 Identify and describe the properties of

• Ask students to identify and

• Sand samples

materials used in moulding and core-

describe the properties of various

making:

types of foundry sands. a. Green compressive

• Emphasis on different types of

strength

sand materials and their

b. Refractoriness

composition, viz;

c. Dry strength

• Natural sand

d. Hot strength

• Silicate sand • Zircon sand • Chromite sand • Olivine sand • Ask students to list the advantages and disadvantages of the use of the sands in 2 above

1.2 State the simple properties of metallic

• Emphasis on the use of

• Samples of metallic

materials used in moulding and core

appropriate metallic material for

material for mould

making practice

specific job.

making e.g. Mild

a. Strength

• Ask student to use the properties Steel, Aluminum etc.

b. Ductility

in selecting metallic materials

c. Hardness d. Corrosion e. Malleability f. Roughness g. Brittleness h. Annealing and Normalizing

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CORE-MAKING

COURSE NO CFD 22

CONTACT HOURS: 15 HRS/WK PER WEEK: T6, P9

COURSE SPECIFICATION: THEORETICAL AND PRACTICAL CONTENTS General Objective 2.0: Understand Different Casting Processes Week Special Learning Outcome

Teachers/Student Activities

Learning Resources

2.1 Carry out the following casting

• Ask student to differentiate

• Casting Equipment

processes:

between sand casting and other

and special materials

a. gravity or permanent

casting processes

mould casting

• Ask student to make related

b. sand casting

sketches

c. Low and high pressure die casting d. Investment casting 2

i. Shell casting ii. Lost wax casting iii. Frozen mercury casting e. Centrifugal casting f. Plaster casting

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CORE-MAKING

COURSE NO CFD 22

CONTACT HOURS: 15 HRS/WK PER WEEK: T6, P9

COURSE SPECIFICATION: THEORETICAL AND PRACTICAL CONTENTS General Objective 3.0: Understand the basic approach to solidification of metals and alloys Week Special Learning Outcome

Teachers/Student Activities

Learning Resources

3.1 Explain solidification and its influence

• Understand the basic approach

• Texts, slides,

on solid/liquid interface

to solidification of metals and

microscope Reagents

3.2 Explain shrinkage and its effect.

alloys

• Phase diagram

3.3 State the implications of shrinkage in

• Ask students to describe

• Shrinkage Rule

the provision of sound casting

solidification rate as it affects

• Spiral testing device

3.4 Explain fluidity of metals, its necessity, structure of cast metals, with influencing factors and assessment tests

particular emphasis on grain size and dendrites etc. • Ask students to explain volume

3-5

changes as it relates to: • Liquid contraction • Solidification contraction • Solid contraction • Emphasis on shrinkage allowances with reference to • Pattern maker allowance • Feeding provision (feeders) • Ask students to perform fluidity test (assessment tests)

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CORE-MAKING

COURSE NO CFD 22

CONTACT HOURS: 15 HRS/WK PER WEEK: T6, P9

COURSE SPECIFICATION: THEORETICAL AND PRACTICAL CONTENTS General Objective 4.0: Understand the methods used to minimize shrinkages and inclusions in castings Week Special Learning Outcome

Teachers/Student Activities

4.1 Explain the effects of cooling stages on • Ask students to: the casting of different metals

• Differentiate between rate of

Learning Resources • Text, lesson notes • Gain Refiners

4.2 Know the effects of grain refiners such cooling on different metals i.e. slow • Special gating and rapid

samples in prepared

a. Silicon

• Explain effect of cooling rate on

mould or sketches as

b. Aluminum

grain structure on different metals listed in 4-3

c. Copper

• Ask students to explain the effect • Materials and

as

6-7

4.3 Employ special gating methods such

of additions of grain refiners on

Devices in 4.4

as

casting structures.

• Slagging device

a. Pencil runner

• Emphasis on the correct

• Gating Ratio

b. Whirl gate

additions (percentage)

Formula from Texts

c. Strainer runner

• Ask studenst to apply the use of

• Relevant Text

4.4 Employ the use of

the gating methods in a-c in 4.3 to • Prepared sketches

a) Chills

minimize shrinkage in castings

b) Insulators

• Ask students to explain the use of

c) Exothermic compound

different method of minimizing

d) Tie bars

shrinkage in castings following the

e) Ribs

list in 4.4

f) Knock off feeders

• Ask students to identify and

4.5 Remove slag and dross such as non-

remove non-metallic inclusions in

metallic inclusions

melts by the use of slagging bars

4.6 Carry out elementary calculations on

• Ask studens to perform

gating systems

calculations of gating systems with

4.7 Make simple sketches of gating

particular emphasis on gating

systems

ratios for: • Pressurized gating system

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• Drawing materials

PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CORE-MAKING

COURSE NO CFD 22

CONTACT HOURS: 15 HRS/WK PER WEEK: T6, P9

COURSE SPECIFICATION: THEORETICAL AND PRACTICAL CONTENTS General Objective 5.0: Understand the causes and of faulty casting and their preventive measures Week Special Learning Outcome

Teachers/Student Activities

Learning Resources

• Understand the causes of faulty

• Relevant Texts

a. Blow holes

castings and their preventive

• Sketches of the

b. Slag or non-metalli

measures

sand mould defects

c inclusionsc. Shrinkage

• Ask students to describe and

• Samples of the sand

cavity and mismatch

recognise the various sand mould mould defects in cast

d. Swelling

defects.

components

e. Scabbing

• Ask students to describe the

• Temperature

f. Pin holes

casting defects emanating from a- measuring instrument

g. Porosity

g in 5-2

and devices

h. Fins and flashes

• Emphasis on casting

• Casting designs

i. Misrun and Cold shot

temperatures and pouring

• Mould designs &

j. Hot tearing

techniques

Assembly

k. Cracking

• Guide students to perform

• Core designs

l. Distortion

inspection

• Relevant tools and

m. Segregation

• Ask students to distinguish the

equipment as listed in

n. Poor surface finish

three inspection methods

5.3

o. Orange peel

• Emphasize the limitation of each • Relevant tools and

p. Drooped cod

of three inspection methods

q. Incorrect section

• Ask students to reclaim defective 5.4

thickness

casting using any of the three

• Sand Testing

r. Warping

methods mentioned in 5.4 (a-c)

equipment as listed in

5.1 Recognise sand mould defects

10-12

5.2 Recognise defects emanating from:

equipment as listed in

• Ask students to perform the sand 5.5

a. Casting design

routine test using the appropriate

b. Melting and Moulding

sand testing equipment.

equipment c. Molten metal d. Pouring systems e. Gating systems f. Mould and Cores g. Metal mould reaction and incorrect mould assembly and handling.

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CORE-MAKING

COURSE NO CFD 22

CONTACT HOURS: 15 HRS/WK PER WEEK: T6, P9

General Objective 5.0: Understand the causes and of faulty casting and their preventive measures COURSE SPECIFICATION: THEORETICAL AND PRACTICAL CONTENTS 5.3 Carry out sand routine tests such as: a. Moisture content b. Silica and Clay content c. Permeability d. Shatter index e. Green and Dry compressive strength f. Sieve analysis for the sand grain sizes

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Melting and Casting Processes PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: CFD 23: MELTING AND CASTING PROCESSES DURATION: 180 HOURS (TERM 2, 5HRS/WK AND TERM 3, 10HRS/WK) GOAL: The Module is intended to provide the trainee with the knowledge and skill to melt various metals using all types of furnaces. General Objective: On Completion of this module, the trainee should be able to: 1. Maintain and operate common foundry melting furnaces 2. Understand the structure, properties and uses of special metals. 3. Understand the casting processes including quality control of raw and finished products. 4. Design and make suitable pouring, gating and feeding systems to prevent common pouring defects. 5. Relate metallurgical aspects of metal solidification characteristics to the objectives of casting and pouring, gating and feeding systems designs. 6. Produce sound casting using any of the modern processes Student Outcome On completion of this module, the student will demonstrate the following competencies: 1. Use and maintain common foundry melting furnaces 2. Explain the structure, properties and use of special metal 3. Explain all casting processes including quality control of raw and finished products 4. Produce suitable pouring, gating and feeding systems to prevent common pouring defects. 5. Explain the relationship of metallurgical aspect of metal solidification characteristic to the objectives of casting and pouring, gating and feeding systems designs.

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PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CASTING PROCESSES

MODULE CODE: CFD 23

CONTACT HOURS: 15 HRS/WK PER WEEK: T2, P3 (TERM 2)

MODULE SPECIFICATION: THEORY AND PRACTICAL CONTENT General Objective: Maintain and operate common foundry melting facilities Week Specific Learning Outcome

Teacher/Student Activities

Learning Resources

• Ask students to recognize

• Any of the melting

a. Cupola furnace

different types of furnaces

furnaces

b. Crucible furnace

• Emphasis on the choice

• Furnace lining

c. Reverbatory furnace

furnace considering the

materials

d. Rotary furnace

factors used in selecting the • Charge make up

e. Electric arc furnace

types of melting units

• Texts and

f. Induction furnace

• Ask students to state the

literature

g. Resistance furnace

uses and limitations of each

1.1 Recognise different types of furnaces

1.2 Explain the uses and limitations of the

of the furnaces.

Furnaces in 1.1 above

• Students should be guided

1.3 Construct Furnace linings and repair damaged to carry out furnace lining and repairs

Furnace linings

• Ask students to charge and

Term 1.4 Operate Furnaces, make up charges, use 2

fluxes and covers.

operate furnaces

1- 5

1.5 Distinguish between melting losses and gain

• Ask students to perform

and be able to compensate them during charge

charge calculations to avoid

preparation.

losses of elements during

1.6 Carry out tapping operations

melting • Emphasis on correct metal temperature required for tapping • Ask students to follow tapping procedures before tapping • Students to operate appropriate tapping devices observing safety precautions.

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PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CASTING PROCESSES

MODULE CODE: CFD 23

CONTACT HOURS: 15 HRS/WK PER WEEK: T2, P3 (TERM 2)

MODULE SPECIFICATION: THEORY AND PRACTICAL CONTENT General Objective 2.0: Understand the structure, properties and uses of special metals Week Specific Learning Outcome

Teacher/Student Activities

Learning Resources

6-8

2.1 Outline the composition and properties of the

• Ask students to state the

following:

composition and properties

a. Special and alloy cast iron

of metals and their alloys

b. Alloy steel and non-ferrous

• Emphasis to be made on

metals

the treatment given to

c. Inoculated and Spherodial

special alloys e.g. Spheroidal

Graphite cast irons

Graphite Iron

d. Heat, Wear and Corrosion

• Ask students to identify and

resistance alloys

explain the

e. Non-ferrous alloys

• Uses of alloys

i) Brasses ii) Aluminum iii) Bronze iv) Magnesium alloys etc. 2.2 Describe the application of the alloys listed in 2.1 above

15

• Alloying materials

PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CASTING PROCESSES

MODULE CODE: CFD 23

CONTACT HOURS: 15 HRS/WK PER WEEK: T2, P3 (TERM 2)

MODULE SPECIFICATION: THEORY AND PRACTICAL CONTENT General Objective 3.0: Understand all casting processes including quality control of raw and finished products Week Specific Learning Outcome

Teacher/Student Activities

Learning Resources

9 - 12

3.1 Recognise the effect of raw materials, casting

• Ask students to recognise

• Relevant Texts

processes, quality of material and design factors

and explain the effects of:

• Test Equipment

on production procedure.

• Raw material

3.2 Carry out the following quality control test on

• Casting processes

molten metal

• Quality of materials

a. Fluidity

• Design factors on

b. Gas content

production procedures

c. Temperature

• Ask students to perform the

d. Spectrometer (metal analysis)

various test on molten metal

e. Wedge test

• Ask students to perform

3.3 Carry out investigation and remedial procedure investigation, and remedial procedures for defective

for defective castings

castings • Emphasize on • Burning on • Welding • Pressure impregnation

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PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CASTING

MODULE CODE: CFD 23

PROCESSES

CONTACT HOURS: 15 HRS/WK PER WEEK: T2, P3 (TERM 2)

MODULE SPECIFICATION: THEORY AND PRACTICAL CONTENT General Objective 4.0: Design and make suitable pouring, gating and feeding systems to prevent common pouring defects Week Specific Learning Outcome

Teacher/Student Activities

Learning Resources

4.1 Design and make suitable gates to

• Guide students in designing

• Chills and

prevent:

suitable gating systems

Denseners

a) Aspiration

• Emphasize on correct methods of

b) Turbulence

casting procedures and providing

Term

c) Sand erosion

the right aid.

3

d) Oxide formation

• Emphasize on the importance of

1- 4

e) Slag and Dross from

directional solidification by the use

molten metal

of chills and denseners

4.2 Use feeding aids, chills and denseners to assist directional solidification and freezing rate. 4.3 List the effects of the properties of

• Ask student to list the

• Mould coat, Boric

metals and moulds on directional

• Effects of properties of metals on

Acid and refractory

solidification and freezing rate

directional solidification and

chills.

4.4 Use mould facing and dressings to

freezing rate

• Etc.

prevent sand erosion, metal mould reaction • Effects of properties of moulds on and promote chilling and refractoriness

directional solidification and freezing rate • Ask students to list materials used in mould facing and dressings • Emphasize on the effect of the use of mould coat such as: • Inhibitors • Tellurium paints • Refractory paints • On mould erosion, metal mould reaction and chilling.

17

PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CASTING

MODULE CODE: CFD 23

PROCESSES

CONTACT HOURS: 15 HRS/WK PER WEEK: T2, P3 (TERM 2)

MODULE SPECIFICATION: THEORY AND PRACTICAL CONTENT General Objective 5.0: Relate the metallurgical aspect of metal solidification characteristics to the objectives of casting and pouring gating and feeding systems design. Week Specific Learning Outcome

Teacher/Student Activities

Learning Resources

5.1 Explain all aspect of solidification of

• Ask students to describe

metals and alloys, nucleation and growth solidification processes of metal and

5-9

• Phase Diagram • Microscope

Mechanism, equiaxed and chilled

alloys at all stages using phase

• Microscope

equiaxed, grain structure, dendritic

diagram and appropriate sketches.

• Relevant text

growth, degree of contraction in the

• Ask students to explain the use of

• Phase diagram

various phases

phase diagram for different alloys.

• Slider

5.2 Interpret phase diagram for various

• Ask students to state the effect of

• Microscope

alloys

casting temperature on microstructure. • Relevant text a) Iron carbon

• Ask student to describe

• Phase diagram

b) Copper alloys

• Hot tears

• Slides

c) Aluminum alloys

• Residual stress

• Microscope

5.3 Explain the influence of casting

• Cold crack

• Relevant text

temperatures on the microstructure

• Shrinkage cavity

• Ditto

5.4 Explain the influence of cooling rate

• Porosity causes and prevention

• Text

on microstructure

• Ask students to differentiate between • Pattern samples

5.5 Identity hot tear, residual stress, cold the various effects on solidification.

• Cast samples

cracking and shrinkage cavity, porosity

• Ask students to identify and explain

• Degassing

and their causes

the use of various degassers

Devices and agents

5.6 List the effects of contraction

A Chlorine tablets

as in teacher’s

hindrance, casting design and alloy

B Cuprex degassers

activities of 5.7

composition on solidification

C Aluminum degasser

• Metallurgical

5.7 Prevent and/or remove gas solubility

D Nitrogen etc.

microscope, Hydropress,

in molten metals by degassing methods • Ask students to perform the

Grinding and

a) Vacuum

• Micro analysis

polishing machines

b) Lancing

• Macro analysis

and Re-agents

e.g.

c) Plunging d) Others

18

PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: MOULDING AND CASTING PROCESSES

MODULE CODE: CFD 23

CONTACT HOURS: 15 HRS/WK PER WEEK: T2, P3 (TERM 2)

MODULE SPECIFICATION: THEORY AND PRACTICAL CONTENT General Objective 5.0: Relate the metallurgical aspect of metal solidification characteristics to the objectives of casting and pouring gating and feeding systems design. 5.8 Examine casts by micro and macro techniques for grain size, cell and nodularity counts, shrinkage, porosity, slag and sand inclusions General Objective 6.0: Produce sound casting using any of the modern processes Week Specific Learning Outcome

Teacher/Student Activities

Learning Resources

6.1 Produce sound casting by any of the following • Ask studenst to produce

• Casting

sound casting using any of

Equipment

a) Sand casting

the method

• Relevant Text

b) Die-casting

• State the advantages of the

c) Centrifugal casting

use of each method

d) Investment casting etc.

(process)

methods

10 -

6.2 Use the following factors to choose the most

12

suitable casting method: a) Plant cost b) Material cost c) Reclaiming system d) Production rate e) Dimensional tolerance f) Quality required

19

• Emphasis on cost analysis

Finishing and Quality Control PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: CFD 24: FINISHING AND QUALITY CONTROL DURATION: 120 HOURS (10 HOURS PER WEEK) GOAL: The module is intended to equip the student with the knowledge and skill to carry out post casting operations. GENERAL OBJECTIVES On completion of this module the trainee should be to: 1. Understand the use of all equipment in the finishing shop. 2. Understand the basic principles of some metallurgical applications 3. Understand and apply the principles of post casting knock-out including cleaning and fettling 4. Carry out all post-casting treatment to a finished product conditions. 5. Carry out inspection and quality control of finished products 6. Carry out preliminary processing of casting Student outcomes: On completion of this module the student will demonstrate the following competencies. • Carry out knock-out operations on castings • Use appropriate tools and equipment to fettle and clean castings • Carry out necessary quality control tests on castings • Carry out metallographic examinations of casting • Apply appropriate device in conveying completed castings from one section to another • Salvage defective castings if required • Keep inspection records • Carry out necessary preliminary processing of castings

20

PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: FINISHING AND QUALITY CONTROL MODE CODE: CFD 24

CONTACT HOURS: 10 HOURS PER WEEK T6: P4

Module Specification: Theory and Practical content General Objective 1.0: Understand the use of all Equipment in the finishing shop Week Special Learning Outcome

1

Teachers/Student Activities

Learning Resources

1.1 Apply all safety requirements for

• Ask students to apply safety

machines usage

precautions and use of safety • Safety wears

1.2 Carry out dust and noise control

wears

• Respirators

1.3 Take precaution against X-ray and

• Emphasis on the use of

• Dust extractors

general material handling such as chemical

Respirators, Dust extractors

• Ear plugs

usage

and

• Safety wear and

Ear plug

Devices

• Emphasis on danger

• First Aid Box

associated with X-rays and chemicals General Objective 2.0: Understand the basis principles of some metallurgical applications Week Special Learning Outcome

Teachers/Student Activities

Learning Resources

2.1 Carry out metallographic examinations

• Ask students to perform

• Metallurgical

on metals

• Micro analysis

Microscope

2.2 Carry out tests with ultrasonic

• Macro analysis

• Hydropress,

radiography and micro-hardness testing

• Produce micrograph

• Grinding & Polishing

equipment

• Ask students to differentiate machines and Etchants

2.3 Use thermocouple types of furnaces,

between these non-destructive • Ultrasonic Radiograph

time temperature recorders for drying of

method

• Hardness equipment.

moulds and cores

• Ask students to apply the

• Temperature

2.4 Analyse metals and alloys

use of temperature measuring measurement Devices

2 - 3 2.5 Explain the importance of phase diagrams

devices

• Spectrometer, Carbon-

• Guide students to analyse

Silicon analyser and

metal and alloys using

chemical reagent and

• Spectrometer

apparatus

• Wet analysis

• Phase Diagram

• Carbon-Silicon analysis • Ask studens to draw and interpret simple phase diagram e.g. Iron-Carbon phase diagram

21

PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: FINISHING AND QUALITY CONTROL MODE CODE: CFD 24

CONTACT HOURS: 10 HOURS PER WEEK T6: P4

Module Specification: Theory and Practical content General Objective 3. 0: Understand and apply the principles of post casting including cleaning and fettling. Week Special Learning Outcome

4.6

Teachers/Student Activities

Learning Resources

3.1 Carry out knock-out operations using

• Ask student to perform the

• knockout equipment

manual and mechanical means

knock out operations using

and devices

3.2 Recognise and avoid the dangers of

• Manual means

• Cleaning equipments

premature knock out that will lead to:

• Mechanical means

listed in 3.3

a) Damage of casting

• Emphasis on the use of

• Tools and equipment

b) Hot tears

intermittent and vibrating grits fettling

c) Warpage and distortion

• Emphasis on the effect of

• Conveying Devices

d) Fast cooling etc.

premature knock-out

• Safety wears

3.3 Use tumble barrels, shot blast chamber

• Ask student to distinguish the • Bath and chemicals for

and hydroblasts

use of different cleaning

3.4 Remove gates, feeder, risers and fins

equipment

from ferrous and non ferrous castings

• Tumble barrel

3.5 Employ cranes, hoists, skips, palettes,

• Shot blast chamber

fork-lifts and conveyor for conveying finished • hydroblast products.

• Ask student to perform

3.6 Observe all safety measures involved in fettling operations such as knock-outs, cleaning and fettling operations

• Knocking/flogging

3.7 Carry out cleaning operation involving

• Cutting

chemical treatment of castings

• Chipping • Grinding • etc. • Ask students to use the various conveying devices • Emphasize on safety rules and regulations • Emphasize on the use of prickling bath in cleaning operation

22

prickling treatment

PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: FINISHING AND QUALITY CONTROL MODE CODE: CFD 24

CONTACT HOURS: 10 HOURS PER WEEK T6: P4

Module Specification: Theory and Practical content General Objective 4.0: Carry out all post casting treatment to a finished product condition. Week Special Learning Outcome

Teachers/Student Activities

Learning Resources

4.1 Salvage defective castings by welding

• Ask students to perform the

• Welding equipment

4.2 Carry out the following heat treatment:

reclaiming of defective casting • Heat-treatment

a) Stress relieving

by:

furnaces

b) Annealing

• Arc welding

• Materials for solution

c) Normalizing

• Chermit welding

treatment

d) Quenching

• Oxy-acetylene etc.

• Electricity

e) Tempering

• Impregnation

• Heat treatment

f) Solution treatment

• Ask students to perform the

furnaces

g) Aging

heat treatment operations as

• Treatment materials

Etc.

itemized in 4. 2

e.g. Carbon, Nitrogen

4.3 Carry out the following case-hardening

• Emphasize on the effects of

and Cyanide

operations

the different processes

• Flame (for construction

a) Carbonizing

• Ask students to describe and components)

b) Cyaniding

perform the case hardening

c) Nitriding

operations

d) Flame hardening

• Emphasize on the effects of

e) Induction hardening

the different processes

• Electricity

Etc. General Objective 5.0: Carry out inspection and quality control of finished products. Week Special Learning Outcome 5.1 Carry out routine inspection by: 8-9

Teachers/Student Activities

Learning Resources

• Ask students to perform

• Relevant testing

a. Visual

routine inspection on castings equipment

b. Jigs and Gauges

using different methods.

c. Pressure testing • Relevant testing

5.2 Carry out a destructive testing

• Ask students to perform

(mechanical) of casting, example:

mechanical testing on castings equipment.

a. Hardness

using different methods.

b. Tensile strength

• Emphasize on Rockwell,

c. Impact test

Brinell and Vickers hardness

d. Transverse test

testers.

Etc.

23

PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY MODULE: FINISHING AND QUALITY CONTROL MODE CODE: CFD 24

CONTACT HOURS: 10 HOURS PER WEEK T6: P4

Module Specification: Theory and Practical content 5..3 Carry out non-destructive tests example: • Guide students to perform a) Use of penetrants

the various non-destructive

b) Magnetic particle

tests.

• Relevant testing equipment.

c) Ultrasonic testing d) Radiographic testing e) Spectrometric testing 5.4 Carry out quality control for sand

• Ask students to perform

mixtures, routine sand testing, compact tests • Various sand routine tests on finished moulds, high temperature tests,

• Various molten metal tests.

• Testing instrument appropriate for the specified tests.

and fluidity tests on molten metals. 5.5 Keep inspection records and give

• Ask students to keep proper • Record book.

information or feedback on daily basis.

and accurate quality control records of inspections.

General Objective 6.0: Carry out preliminary processing of casting Week Special Learning Outcome

Teachers/Student Activities

Learning Resources

• Ask students to perform the

• Machines and Tools

a) Machining of castings

various operation

appropriate for each

b) Setting up of tools and

• Emphasize on

operation

jobs

• Correct use of tools and

• Safety wears

c) Turning operation

equipment

• Relevant Texts

d) Milling operations

• Safety measures

• Cast samples

e) Shaping operations

• Ask students to state the

• Working drawing

f) Drilling operations

relevance of (a -i) on

• Boring tools

Etc.

machinable castings

• Coring equipment

6.1 Carry out

6.2 Explain the relevance of the following to

• Emphasize the specific areas • Machining tools jigs

machinable castings:

to be machined from working

and Fixtures

a) Feed rates

drawing

• Grinding and Cutting

b) Cutting action

• Guide students in making

Machines, examples;

c) Hard spots

cores to dimension

• Hand Grinder

d) Location point

• Emphasize the minimum

• Table Grinder

e) Influence of casting

hole diameter to be cored or

• Power Saw

features

bored

• Guillotine

f) Joints

• Ask students to perform

• Etc.

24

g) Gate location

batch, slow and transfer

• Safety wears and

h) Taper

machining operations

safety measures.

i) Chip formation

• Emphasize the use of jigs

Etc.

and fixtures for machining

6.3 Identify machining allowance form

• Ask student to differentiate

working drawing

between the different types of

6.4 Use core or boring for holes

wheel grinding and cutting

6.5 Carry out batch, slow and transfer

machines

machining operations

• Emphasis on the following

6.6 Identify types of wheel-grinding and

points: -

cutting machine

• Speed

6.7 Apply all safety requirement for

• Dressing

machining and grinding

• Balancing • Maintaining of the wheels • Emphasize on the safety requirement for performing machining and grinding operations.

25