© the Design and Technology Association Health and Safety Training Standards in Design and Technology S3HS CASTING NON-FERROUS METALS Specialist Extension Level Standards:

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Preparing a sand mould, to demonstrate: The names of all equipment and their functions Use of oil-bonded sand (if possible) Use of quality manufactures moulding boxes. PRACTICAL SKILLS

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Preparing a sand mould, to demonstrate: Use and placing of pattern(s), parting powder, runners, riser sprues, gates, vents and pouring basin Lifting procedures for moulding boxes Use of clamps or weights to prevent moulding boxes lifting apart Correct positioning of the moulding boxes close to the pouring spout of the crucible

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Lighting and melting procedures, pouring the metal, breaking the mould and reclaiming the casting, to demonstrate: The names of all equipment and their functions Appropriate use of PPE Use of LEV, e.g. checking that the flexible extraction arm is in place

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Lighting and melting procedures, pouring the metal, breaking the mould and reclaiming the casting, to demonstrate: The use of a crucible pot that is clean and free from damage or cracks Use of the manufacturer’s instructions for lighting the crucible furnace, e.g. use of a low flame to gently warm and dry the crucible before turning up to full heat Correct preparation of tools, i.e. all tools that may come into contact with the molten metal should be wire brushed and if possible coated with refractory limestone wash then warmed to dry

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Lighting and melting procedures, pouring the metal, breaking the mould and reclaiming the casting, to demonstrate: Use of appropriate amount of aluminium or zinc based alloys to fill the crucible no more three quarters full Use of tongs to place ingots to pre- heat Use of tongs to remove the refractory cover and carefully place the warm ingots into the red hot crucible When the melt reaches a ‘paste’ consistency, use of coverall flux with a long handled spatula or skimmer, avoiding the rising air

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Lighting and melting procedures, pouring the metal, breaking the mould and reclaiming the casting, to demonstrate: Use of a pyrometer to check the melt temperature Use of a degassing plunger to push the degassing tablet to the bottom of the crucible and stir into the melt

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Lighting and melting procedures, pouring the metal, breaking the mould and reclaiming the casting, to demonstrate: Use of a skimming ladle/dross lifter to remove the dross and place into a steel receptacle within the sand tray Switching off the crucible furnace and adjusting the LEV arm above the mould to remove fumes

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Lighting and melting procedures, pouring the metal, breaking the mould and reclaiming the casting, to demonstrate: Pouring the melt, using either ‘tilt and pour’ or ‘lift and pour’ technique, latter carried out with a second person, using suitable lifting attachments or tongs Pouring the melt into the mould in a smooth, steady stream (NB Staff should usually carry out the pouring process – Local Authority/employer guidelines may permit student assistance after training and risk assessment)

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Lighting and melting procedures, pouring the metal, breaking the mould and reclaiming the casting, to demonstrate: Emptying the crucible and scraping out any slag or dross while it is red hot Allowing casting and the furnace to cool slowly, use of a ‘Caution HOT’ notice before moving away from the area

© the Design and Technology Association Specialist Extension Level S3HS: CASTING NON-FERROUS METALS Lighting and melting procedures, pouring the metal, breaking the mould and reclaiming the casting, to demonstrate: Checking with a poker that the molten metal has solidified, breaking open and safely recovering the hot casting with tongs Placing to cool Disposal of the layer of burnt sand next to the molten metal