View Unit : Producing Sand Moulds using Plated Patterns

Unit

Unit Reference Number

R/502/9196

Qualification Framework

QCF

Title

Producing Sand Moulds using Plated Patterns

Unit Level

Level 3

Unit Sub Level

None

Guided Learning Hours

109

Unit Credit Value

Date of Withdrawal

SSAs

4.1 Engineering

Unit Grading Structure

Pass

Assessment Guidance

This unit must be assessed in a work environment and must be assessed in accordance with the ‘Common Requirements for National Vocational Qualifications (NVQ) in the QCF’ which can be downloaded from Semta’s website: http://www.semta.org.uk/training_providers__awarding/national_occupational_standard/qca_assessment_requirements.aspx

Additional assessment requirements have been published by Semta. These additional assessment requirements are set down in Semta’s Engineering assessment strategy which can be downloaded from Semta’s website: http://www.semta.org.uk/training_providers__awarding/national_occupational_standard/qca_assessment_requirements.aspx

View Unit's Qualifications

Learning Outcomes and Assessment Criteria

Learning Outcome - The learner will:		Assessment Criterion - The learner can:
1	Produce Sand Moulds using Plated Patterns	1.1	Work safely at all times, complying with health and safety and other relevant regulations and guidelines
		1.2	Carry out all of the following during the sand moulding activities: confirm that all the required materials and equipment are available and in a safe and usable condition use appropriate personal protective equipment comply with job instructions, moulding specifications, relevant COSHH sheets and risk assessment documentation use the correct tools and equipment for the moulding activity follow the defined moulding procedures and apply safe working practices and procedures at all times ensure that the moulds produced meet the required specification for quality and accuracy leave the work area in a safe condition on completion of the moulding activities
		1.3	Follow the correct component drawing or any other related specifications for the component to be produced
		1.4	Determine what has to be done and how this will be achieved
		1.5	Obtain and prepare the appropriate tools, equipment and materials
		1.6	Prepare the pattern equipment for use, including both of the following: visually inspecting the pattern for damage applying release agents to the pattern (as applicable)
		1.7	Carry out the moulding or laying-up activities using the correct methods and techniques
		1.8	Produce half moulds from plated patterns, with and without cores, to include all of the following: plated - flat back (with a surface area of at least 0.5 square metre) plated - split type (with a surface area of at least 0.5 square metre) plated - cope parts (with a surface area of at least 0.5 square metre)
		1.9	Produce moulds using one of the following techniques: manually combined manual and ribbon flow combined manual and mixer/slinger combined manual and vibratory table other (specify)
		1.10	Produce moulds from patterns, with at least three cores, where core locations must cover all of the following positions: horizontal vertical interconnecting
		1.11	Incorporate reinforcements in the mould, to include one of the following: boxes with bars loose strengthening provision
		1.12	Incorporate mould locating devices, to include one of the following: pins rebates bobbins (diabolos) cores
		1.13	Carry out moulding techniques, to include one of the following: chill insertion densener insertion use of chill sand
		1.14	Produce moulds using one of the following types of sand: combined (eg, chemically bonded gas activated with green backing) chemically bonded gas activated ester silicate bonded chemically bonded resin/catalyst
		1.15	Complete the moulding operation, to include carrying out all of the following: forming runner, riser and feeder systems using fixed formers forming runner riser and feeder systems on the mould using loose formers finishing/repairing the moulds using adhesives
		1.16	Apply mould coatings/dressings to the moulds, using two of the following methods: spray flood flood brush dry
		1.17	Produce sand moulds which meet all of the following quality and accuracy standards: moulds are complete and free from obvious defects (cracks, broken or damaged mould surfaces) the mould meets the required specification (shape, dimensional accuracy) the mould is free from soft spots
		1.18	Sort the finished moulds, to include carrying out both of the following: placing acceptable moulds into designated areas disposing of sub-standard moulds into designated areas
		1.19	Check that all the required operations have been completed to specification
		1.20	Deal promptly and effectively with problems within their control and report those that cannot be solved
2	Know how to Produce Sand Moulds using Plated Patterns	2.1	Explain the specific safety precautions to be taken when producing sand moulds manually
		2.2	Describe the hazards associated with producing sand moulds by manual means, and how they can be minimised
		2.3	Explain the COSHH regulations that apply when dealing with chemically bonded sands, surface coatings, release agents, surface dressings
		2.4	Describe where to obtain information on COSHH regulations
		2.5	Explain the provision and Use of Work Equipment Regulations (PUWER)
		2.6	Describe the manual lifting techniques and EU requirements on acceptable weights to be handled
		2.7	Describe what personal protective equipment (PPE) should be used, and how to obtain it
		2.8	Explain how to obtain the necessary job instructions and interpret their information
		2.9	Describe the different types of pattern plate used in the moulding process
		2.10	Describe the different types of mould location devices (such as pins, rebates, bobbins and cores)
		2.11	Describe the different types of core print used to locate and secure cores including drag and cope prints and interconnecting types
		2.12	Describe the different types of mould reinforcements (such as fixed and loose bars, grids, sprigs and lifters/gaggers/soldiers)
		2.13	Explain why chills/denseners are used
		2.14	Describe the different sand moulding processes used (such as combined, chemically bonded sand gas activated, resin/catalyst and ester silicates)
		2.15	Describe the various additions and additives that are used when mixing sands, and how these affect the moulding process (such as chemicals, resins, catalyst, breakdown agents, inhibitors, refractory materials)
		2.16	Describe the effects, on the produced casting, of using incorrect amounts of additions or additives in the moulding sand
		2.17	Explain why different types of sand mixes used for producing moulds have limited or unlimited life
		2.18	Explain how the pattern type and configuration can determine the moulding process and the sand used
		2.19	Explain the application and use of release agents and mould coatings
		2.20	Explain the reasons why different release agents are used with different sand and pattern types
		2.21	Explain the type and application of mould coating/dressing for different metal alloys
		2.22	Describe how to identify mould defects (such as soft spots, broken/damaged mould surfaces, clagging/sticking, distorted sections, misplaced/displaced chills, ineffective or inadequate mould support and reinforcement, friable surfaces)
		2.23	Explain the company quality control procedures for producing and inspecting moulds (such as checks for completeness, cleanliness, freedom from foreign bodies, freedom from defects; correct type, application, coverage and thickness of mould coatings/dressings; checking mould section thickness; mould hardness testing)
		2.24	Explain why it is important to keep the pattern equipment clean and free from damage, practice good housekeeping of moulding tools and equipment, and maintain a clean working area
		2.25	Describe the extent of their own authority and whom they should report to if they have problems that they cannot resolve when making the moulds

Equivalent Units

There are no equivalences to display.