Jo Richardson Community School

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Jo Richardson Community School
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Understanding material melting processes
In order for you to understand producing molten
material safely for a given scale of casting or
moulding production you must define and provide
images for the following Single
melt Batch melt Continuous
melt Combined methods
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 1a
Grading Criteria P1 Key Skills Assignment 1
Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
3
Understanding material melting processes
In order for you to understand producing molten
material safely for a given scale of casting or
moulding production you must define and provide
images for the following (continued) Types of
furnace Cupola Induction Rotary Bale
out Lift out crucible Tilting
crucible Direct or indirect arc Air
circulating ovens for thermoplastic melting
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 1a
Grading Criteria P1 Key Skills Assignment 1
Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
4
Understanding material melting processes
In order for you to understand material melting
processes, you must know the material properties
of that you wish to make molten. Define, give
examples and provide images for the
following Ferrous alloys, Non-ferrous
alloys, Thermoplastics Measurement
of temperature e.g. pyrometers
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 1b
Grading Criteria P1 Key Skills Assignment 1
Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
5
Understanding material melting processes
In order for you to understand removing and
finishing molten material safely for a given
scale of casting or moulding production you must
define and provide images for the
following Component removal and finishing
Knocking castings out of moulds Removing
components from the moulding material or
dies De-coring Removing runner/riser/feeder
system Processes used Manual Vibratory
tables/grids Punch-out mechanisms Chemical
leaching
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 1c
Grading Criteria P2 Key Skills Assignment 1
Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
6
Understanding material melting processes
In order for you to understand removing and
finishing molten material safely for a given
scale of casting or moulding production you must
define and provide images for the following
(continued) Tooling used Work-holding devices
(vice, clamps, jigs and fixtures) Disc/angle
grinder Pedestal grinder Slitting saw Band
saw Laser cutter Linisher Pneumatic chipping
hammers Wire brush Scraper Hacksaw File Abrasive
stone Abrasive paper Hammer Blasting
Air Water Sand Plastic trimming knives and
cutters
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 1c
Grading Criteria P2 Key Skills Assignment 1
Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
7
Understanding casting removal processes
When sand casting, you are required to remove
patterns from the sand, before and after the
casting process, and removing the casting surplus
once the cast is cooled. Describe briefly, the
process that you took to remove the pattern
including reference to tools you may have used
before creating the runner and riser system for
pouring Describe briefly, the process that
you took to remove the aluminium cast including
reference to tools you may have used once the
casting process was complete Describe
briefly, the finishing process that you took to
remove the surplus (runner and riser) including
reference to tools you may have used after the
casting process ii) YOU MUST MAKE SURE YOU
GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS
GRADE CRITERIA.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 1di,
ii Grading Criteria P2 Key Skills Assignment
1 Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
8
Hazards and PPE during Casting Processes
When sand casting your scribing block base, it
has been necessary to identify the risks and
hazards that are in the foundry area of the
workshop. On the grid below, create a plan
view for the foundry area showing where there are
assessed risks. Include labels to show how these
risks and hazards are controlled.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
1e Grading Criteria M1 Key Skills Assignment
1 Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
9
Hazards and PPE during Casting Processes
Label and explain the use of the correct PPE on
the man below
Insert a photograph of yourself here to show that
you can demonstrate good use of PPE when using
the foundry area in the workshop
ii) YOU MUST MAKE SURE YOU GET YOUR OBSERVATION
SHEET SIGNED TO ACHIEVE THIS GRADE CRITERIA.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 1fi,
ii Grading Criteria M1 Key Skills Assignment
1 Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
10
Hazards and PPE during Casting Processes
Explain the importance of identifying hazards and
wearing personal protective equipment when
melting metals and removing and finishing
castings
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
1g Grading Criteria M1 Key Skills Assignment
1 Understanding material melting processes and
casting removal
Jo Richardson Community School BTEC First Diploma
in Engineering
11
Understanding Sand Casting
Define and provide images for the
following What are the two parts of the
moulding box called? Describe each of their
purposes. Part a) Part b) What is a
pattern used for? You have created a pattern for
the manufacture of your aluminium cast of the
scribing block base. Include a photograph in
your answer. Explain the function of the
runner and riser in sand casting What is the
type of sand used in sand casting? Why is this
used in the workshop in school?
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 2a
Grading Criteria P3 Key Skills Assignment 2
Understand how casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
12
Understanding Sand Casting
For this task you will be required to provide
evidence to show that you are able to understand
and inform others in how to sand cast a component
that you will be making in the workshop. You
have already created a drawing for your mould.
You must now describe the processes from making
the pattern to manufacturing an aluminium cast in
order to inform your working colleagues the
appropriate steps you have undertaken. Include
Health and Safety considerations you have
made. Create a leaflet or poster that can be
used in the workshop in the foundry area that
offers guidance and important key terms
to others.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 2b
Grading Criteria P3 Key Skills Assignment 2
Understand how casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
13
Understanding Sand Casting

• You have been developing your skills in the
  foundry by producing aluminium casts for your
  scribing block base.
• During this task you will be observed on the
  following
• Following the steps of the sand casting procedure
  explained in task 2b
• Disseminating accurate information to your
  working colleagues
• Working with others in a respectable and
  co-operative manner
• Following appropriate Health and Safety
  considerations
• YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET
  SIGNED TO ACHIEVE THIS GRADE
• CRITERIA.

Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 2c
Grading Criteria P3 Key Skills Assignment 2
Understand how casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
14
Understanding Investment Casting
Briefly describe investment casting? Define
the following terms used in investment casting
processes Wax patterns Single waxes Wax
assemblies Mounting of wax patterns
Handles Bars, Hangers Slurry
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 2d
Grading Criteria P4 Key Skills Assignment 2
Understand how casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
15
Understanding Investment Casting
Define the following terms used in investment
casting processes (continued) Producing
shells/moulds Manually Automatically Combined
manual Semi-automatic Single Multiple curing
shells/moulds natural air forced air gas
activated
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 2d
Grading Criteria P4 Key Skills Assignment 2
Understand how casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
16
Understanding Investment Casting
For this task you will be required to provide
evidence to show that you are able to understand
investment casting. You must watch the
video that has been played to you and take notes
on the stages of manufacture. Use this page to
record your notes. http//www.youtube.com/watch?v
BX8w-GUPz1w Using your notes, create a
simplified version in the form of a flow chart
showing each of the main steps. You must also
include the Health and Safety considerations you
must make during the process as well as the
quality control procedures taken in
industry.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 2e
Grading Criteria P4 Key Skills Assignment 2
Understand how casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
17
Understanding Investment Casting
Using information on the video, justify why
investment casting is used in industry. Give and
explain its advantages and disadvantages.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 2f
Grading Criteria D1 Key Skills Assignment 2
Understand how casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
18
Casting Processes
Justify why you have used Aluminium Sand Casting
to produce the scribing block base.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
2g Grading Criteria D3 Key Skills Assignment
2 Understanding why casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
19
Understanding Gravity Die Casting
Define and provide images for the
following Common die locations Floor
Fixed base Movable base Carousel
Conveyor/roller track
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 3a
Grading Criteria P5 Key Skills Assignment 3
Understand how die casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
20
Understanding Gravity Die Casting
Define and provide images for the following
(continued) Types of die Split die with no
secondary movement, Split die with one
secondary movement, Split die with two or more
secondary movements, Split die with no cores,
Split die with one core, Split die with two
or more cores, Water cooling Use of cores
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
3a Grading Criteria P5 Key Skills Assignment
3 Understand how die casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
21
Understanding Gravity Die Casting
Describe the gravity die casting process when
used safely to produce a component
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
3b Grading Criteria P5 Key Skills Assignment
3 Understand how die casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
22
Understanding Pressure Die Casting
Define and provide images for the
following Types of pressure Die Casting
processes High pressure hot chamber High
pressure cold chamber Squeeze process water
cooling use of cores
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
3c Grading Criteria P6 Key Skills Assignment
3 Understand how die casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
23
Understanding Pressure Die Casting
Define and provide images for the following
(continued) Types of die Split die with no
secondary movement, Split die with one
secondary movement, Split die with two or more
secondary movements, Split die with no cores,
Split die with one core, Split die with two
or more cores, Core assembly with external
cores, Core assembly with internal cores,
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
3c Grading Criteria P6 Key Skills Assignment
3 Understand how die casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
24
Understanding Pressure Die Casting
Describe the pressure die casting process when
used safely to produce a component
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
3d Grading Criteria P6 Key Skills Assignment
3 Understand how die casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
25
Understanding Die Casting
Often it is necessary as a manufacture to weigh
up the advantages and disadvantages of different
manufacturing processes. Explain when die
casting would be used in preference to sand
casting. Note the advantages and disadvantages
of each and conclude. http//www.castingstechnolo
gy.com/public/services/technologies/TECGravityDieC
asting.asp
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
3e Grading Criteria M2 Key Skills Assignment
3 Understand how die casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
26
Understanding Die Casting
Justify why it is sometimes necessary to make the
use of a pressure die casting process for
components. List the advantages of Pressure Die
Casting.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
3f Grading Criteria D2 Key Skills Assignment
3 Understand how die casting processes are used
Jo Richardson Community School BTEC First Diploma
in Engineering
27
Understanding Injection Moulding
Label the parts of the diagram and briefly
describe the four main stages of the process.
Use images to support your understanding.
(http//technologystudent.com/equip1/inject1.htm)
Name two types of plastic
that can be used in this process
1 2 3 4
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 4a
Grading Criteria P7 Key Skills Assignment 4
Understand how plastic moulding processes are
used
Jo Richardson Community School BTEC First Diploma
in Engineering
28
Understanding Vacuum Forming

• You need to produce a casing for your electronic
  circuit so that it is secure. Create an
  informative guide that can
• be used to assist a Year 8 Design and Technology
  student through the process of Vacuum Forming.
• http//technologystudent.com/equip1/vacform1.htm
• Make notes below to show the 6 main stages of the
  process.

Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
4b Grading Criteria P8 Key Skills Assignment
4 Understand how plastic moulding processes are
used
Jo Richardson Community School BTEC First Diploma
in Engineering
29
Understanding Vacuum Forming
You need to produce a casing for your electronic
circuit so that it is secure. You will be
observed operating the Vacuum Former safely.
Show using a photograph that you can demonstrate
this well and the Health and Safety
considerations you have made.
YOU MUST MAKE SURE YOU GET YOUR OBSERVATION
SHEET SIGNED TO ACHIEVE THIS GRADE CRITERIA.
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task 4c I,
ii Grading Criteria P8 Key Skills Assignment
4 Understand how plastic moulding processes are
used
Jo Richardson Community School BTEC First Diploma
in Engineering
30
Understanding Wet Lay-up Composite Moulding
Briefly describe the Wet Lay-Up
technique Explain when a wet lay-up
technique would be used in preference to
injection moulding or vacuum forming
Name Candidate No Unit 22 Casting and
Moulding Engineering components Task
4d Grading Criteria M3 Key Skills Assignment
4 Understand how plastic moulding processes are
used
Jo Richardson Community School BTEC First Diploma
in Engineering