Vous êtes sur la page 1sur 25

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

1
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

2
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 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 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.
pattern making 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
• 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 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 pattern workshop
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
5-8 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
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 • Shrinkage (contraction)
a. Mould joints • Considerations and and fillets provisions
b. Slip joint emphasis on the relevance of • Appropriate Formulae
c. Core prints a-i in 3.1 from Texts for
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
9-12 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

5
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

6
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

7
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
i. Shell
2
casting
ii. Lost
wax
casting
iii. Frozen
mercury
casting
e. Centrifugal casting
f. Plaster casting

8
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)

9
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 Learning Resources

4.1 Explain the effects of cooling stages on • Ask students to: • Text, lesson notes
the casting of different metals • Differentiate between rate of • Gain Refiners
4.2 Know the effects of grain refiners such cooling on different metals i.e. slow • Special gating
as 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
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
6-7
a) Chills minimize shrinkage in castings • Drawing materials
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

10
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

5.1 Recognise sand mould defects • 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
10-12
o. Orange peel • Emphasize the limitation of each • Relevant tools and
p. Drooped cod of three inspection methods equipment as listed in
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
5.2 Recognise defects emanating from: • 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.

11
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

12
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.

13
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

1.1 Recognise different types of furnaces • 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
1.2 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
Furnace linings and repairs
Term 1.4 Operate Furnaces, make up charges, use • Ask students to charge and
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.

14
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

2.1 Outline the composition and properties of the • Ask students to state the • Alloying materials
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
6-8 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
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

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
9 - 12 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
for defective castings procedures for defective
castings
• Emphasize on
• Burning on
• Welding
• Pressure impregnation

16
PROGRAMME: ADVANCE NATIONAL TECHNICAL CERTIFICATE IN FOUNDRY

MODULE: MOULDING AND CASTING MODULE CODE: CFD 23 CONTACT


PROCESSES 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 CONTACT


PROCESSES 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 • Phase Diagram
metals and alloys, nucleation and growth solidification processes of metal and • 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
5-9
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,
in molten metals by degassing methods Hydropress,
e.g. • Ask students to perform the Grinding and
a) Vacuum • Micro analysis polishing machines
b) Lancing • Macro analysis and Re-agents
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
methods 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)
10 - 6.2 Use the following factors to choose the most • Emphasis on cost analysis
12 suitable casting method:
a) Plant cost
b) Material cost
c) Reclaiming system
d) Production rate
e) Dimensional tolerance
f) Quality required

19
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 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
1
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 devices • Spectrometer, Carbon-
diagrams • 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 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 prickling treatment
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
4.6
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
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 • Electricity
c) Nitriding operations
d) Flame hardening • Emphasize on the effects of
e) Induction hardening the different processes
Etc.

General Objective 5.0: Carry out inspection and quality control of finished products.

Week Special Learning Outcome Teachers/Student Activities Learning Resources

5.1 Carry out routine inspection by: • Ask students to perform • Relevant testing
a. Visual routine inspection on castings equipment
8-9
b. Jigs and Gauges using different methods.
c. Pressure testing

5.2 Carry out a destructive testing • Ask students to perform • Relevant testing
(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 • Relevant testing
a) Use of penetrants the various non-destructive equipment.
b) Magnetic particle tests.
c) Ultrasonic testing
d) Radiographic testing
e) Spectrometric testing

5.4 Carry out quality control for sand • Ask students to perform • Testing instrument
mixtures, routine sand testing, compact tests • Various sand routine tests appropriate for the
on finished moulds, high temperature tests, • Various molten metal tests. 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

6.1 Carry out • 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
6.2 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