FOUNDRY MOLDING NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR FOUNDRY MOLDING NC III

The TESDA Course for FOUNDRY MOLDING NC III consists of competencies that a person must achieve to be able to prepare sand mixture and produce all types of molds manually to cast heavy casting (500 kgs. or more net weight) individually or as a team. It also include competency in pouring molten metal to heavy castings. The heavy casting are usually cast to make press die parts such as forming, blanking die and trimming dies, base plates for molding machine.

This Qualification is packaged from the competency map of the Automotive Industry (Manufacturing sub-sector)

A student who has achieved this TESDA Course in FOUNDRY MOLDING NC III is competent to be:

• Jobbing Foundry Molder

FOUNDRY MOLDING NC III – TRAINING AND REGULATION MODULE

Course Title: FOUNDRY MOULDING
Level: NC III
Nominal Training Duration : 112 Hours

This course is designed to equip individual with competency to to prepare sand mixture and produce all types of molds manually to cast heavy casting ( 500 kgs or more net weight) individually or as a team. It also include competency in pouring molten metal to heavy castings. The heavy casting are usually cast to make press die parts such as forming, blanking die and trimming dies, base plates for molding machine.

Basic competencies such as: Lead workplace communication; Lead small teams; Develop and practice negotiation skills; Solve problems related to work activities; Use mathematical concepts and techniques and Use relevant technologies are included.

It also includes common competencies such as: Read, Interpret and Apply Engineering Drawings; Perform Mensuration and Calculation Read; Interpret and Apply Specifications and Manuals and; Perform Shop Maintenance.

TRAINEE ENTRY REQUIREMENTS

This section specifies the qualifications of trainees and educational experience. Other requirements like health and physical requirements are also stated. Passing entry written examinations may also be indicated if necessary.

• With background in basic machining
• Ability to communicate both oral and written; and
• Physically and mentally fit
• Must possess the Foundry Molding National Certificate (NC) II

COMPETENCIES REQUIRED IN FOUNDRY MOLDING NC III

This units of competency comprising this qualification include Basic, Common, Elective and Core Competencies.

To obtain this TESDA Course in FOUNDRY MOLDING NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (72 hours)
ALT812312	Prepare Sand Mixture for Heavy Casting
ALT812313	Perform Hand Molding To Produce Heavy Castings
ALT812314	Pour Molten Metal to Heavy Castings
UNIT CODE	COMMON COMPETENCIES (20 hours)
ALT742201	Read & Interpret Engineering Drawings
ALT311202	Perform Mensuration and Calculation
ALT723203	Read, Interpret and Apply Specifications and Manuals
ALT723205	Perform Shop Maintenance
UNIT CODE	BASIC COMPETENCIES (20 hours)
500311109	Lead Workplace Communication
500311110	Lead Small Teams
500311111	Develop and Practice Negotiation skills
500311112	Solve Problems Related to Work Activities
500311113	Use Mathematical Concepts and Techniques
500311114	Use Relevant Technologies

CORE COMPETENCIES

This section gives the details of the contents of the core units of competency required in FOUNDRY MOLDING NC III

UNIT OF COMPETENCY : PREPARE SAND MIXTURE FOR HEAVY CASTING
UNIT CODE : ALT812312

This unit covers the preparation of a sand mixture for molding / core making of heavy casting (500 kgs. or more net weight). The mixture will be applied for facing, backing and core sand. The heavy castings are usually cast to make press die parts such as forming, blanking die and trimming dies, base plates for molding machine.

1. Determine job requirement
   • Italicized terms are elaborated in the Range of Variables
   • Determine job requirement
   • Job requirement are determined from job sheet and instruction sheet.
   • Type of sand mixture is selected in accordance with job requirements
   • Volume of sand mixture is prepared according to job requirements.
2. Select materials
   • Materials for sand mixture are calculated as per job requirements.
   • Requisition of materials is completed as per standard operating procedure.
3. Select mixer
   • Mixer selected applying knowledge of facing, backing, core sand mixer capacities.
   • Pre-operational equipment inspection is conducted as per standard operating procedures.
4. Mixing of sand mixture
   • Sand mixer / muller is operated according to manufacturing instruction
   • Loading sequence of sand, binder, additives is accomplished according to standard operating procedures.
   • Cycle time per loading / mixing is determined per volume of mixture.
   • Moldability of sand mixture is manually tested according to job requirements.
5. Discharge / store sand
   • Sand discharged to sand bin as per standard operating procedures.
   • Mixer / muller shut down as per standard operating procedures.
   • Conditioned sand transfer to molding / core making line according to procedure.
6. Perform house keeping
   • Mixer/Muller cleaned according to standard operating procedure.
   • Excess sand and other debris are disposed of according to occupational health and safety (OH & S) requirements.
   • Housekeeping around the work area is performed as per company procedure.

UNIT OF COMPETENCY : PREPARE HAND MOLDING TO PRODUCE HEAVY CASTING
UNIT CODE : ALT812313

This unit covers the production of mold manually to cast heavy casting (500 kgs. or more net weight) individually or as a team. Examples of application are castings used for stamping, forming, blanking and trimming dies, welding fixtures, skid rails.

1. Determine job requirements
   • Job requirement are determined from job sheet, instruction manual, and shop brainstorming meeting.
   • Pattern size (length, width and height) inspected and measured according to product drawing.
   • Method of molding and rigging are determined and selected according to job requirements.
   • Type of sand mixture to be used is determined according to job requirements.
2. Prepare pattern and accessories
   • Pattern / corebox is cleaned and inspected according to standard operating procedures.
   • Molding box is selected including location of rigging according to job requirements
   • Molding allowances are determined according to job requirements
3. Make mold
   • Pattern is set up/positioned according to standard operating procedures
   • Mold making is performed according to standard operating procedures
   • Riser, gating system, vents, flow-off is located according to casting plan
   • Mold is inspected, repaired and finished according to standard operating procedures.
4. Apply mold coating
   • Mold coating is prepared / mixed according to standard operating procedures.
   • Mold pre-heated with LPG burner according to standard operating procedures.
   • Mold coating applied to appropriate mold surface including riser and gating system.
   • Mold secured prior to mold assembly and pouring according to standard operating procedures.
   • Tasks are completed in accordance with standard operating procedures and occupational health and
     safety (OH & S) requirements.

UNIT OF COMPETENCY : POUR MOLTEN METAL TO HEAVY CASTINGS
UNIT CODE : ALT812314

This unit covers the competency in manually pouring molten metal as part of metal casting and molding process with ladle capacities of 500Kgs or more using bull ladle, crane ladle a bottom poured ladle.

1. Prepare for pouring molten metal
   • Condition of the mold is checked according to standard operating procedures.
   • Condition of the ladle is checked and appropriate measures are undertaken to correct ladle defects according to standard operating procedures.
   • Temperature of molten metal is checked for conformance to specification and pouring method is sequenced to standard operating procedures.
   • The capacity of the required pour is identified against specification according to standard operating procedures.
   • Over-head cranes, wire-ropes, metal shield are checked according to standard operating procedures.
   • Ladle is pre-heated according to prescribed procedures.
2. Transfer ladle to furnace
   • Safety clips of the lifting hooks are checked according to standard operating procedures.
   • Ladle is filled with appropriate weight and transferred to the pouring area in accordance with standard operating procedures.
   • Required additives / ferro-alloys and metal cover determined from specification and added to molten metal as required.
   • Chill, wedge test is undertaken as required to standard operating procedures.
3. Maintain quality of metal as required
   • Slag or dross is removed as necessary.
   • The temperature is monitored by contact thermocouple as required.
   • Sample for chemical analysis is taken and submitted to laboratory according to standard operating procedures.
4. Pour molten metal.
   • Personnel in the immediate area of metal pour are informed that pouring is to take place and appropriate safety clothing and equipment is used as specified in standard operating procedures.
   • Metal is poured safely in accordance with standard operating procedures and occupational health and safety (OH & S) requirements.
   • Metal is poured at an appropriate and continuous rate without over-flowing or splashing.
   • Co-workers are instructed to assist in firing of the mold to ignite gasses escaping in the parting line, venting, risers and flow-off.
   • Test bar is poured in accordance with standard operating procedures.
5. Empty excess metal for the ladle
   • Pig-molds are poured and tagged.
   • Dross/slagged poured in tote boxes
   • The ladle is appropriately cleaned and maintained as per standard operating procedures.

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING)

UNIT TITLE: READ, INTERPRET AND APPLY ENGINEERING DRAWINGS.
UNIT CODE: ALT742201

This unit deals with identifying, interpreting and applying specification from Engineering blue prints or drawings that provides the measurements of the product and pattern that is to be produced.

1. Identify and access engineering drawings/specification
   • Appropriate Engineering drawings are identified and accessed as per job requirements.
   • Version and date of drawing is checked to ensure correct specification and procedure are identified.
2. Interpret drawings
   • Relevant dimensions and sections of the drawings/specifications are located in relation to the work to be conducted
   • Information in the manual are interpreted in accordance to industry practices
3. Apply information in the drawings & specifications
   • Engineering drawing is interpreted according to job requirements
   • Work steps are correctly identified in accordance with the specifications in the drawings.
   • Dimensional data and shape are applied according to the given task
4. Store drawings
   • The drawings and specification are stored properly to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY: PERFORM MENSURATION AND CALCULATION
UNIT CODE: ALT311202

This unit includes identifying, caring for, handling, using and maintaining measuring instruments.

1. Select measuring instruments
   • Object or component to be measured is identified
   • Correct specifications are obtained from relevant source
   • Appropriate measuring instrument is selected according to job requirements
2. Carry out measurements and calculation
   • Measuring tools are selected in line with job requirements
   • Accurate measurements are obtained to job
   • Calculation needed to complete work tasks are performed using the four basic process of addition (+), subtraction (-), multiplication (x) and division (/).
   • Calculations involving fractions, percentages and mixed numbers are used to complete workplace tasks.
   • Numerical computation is self-checked and corrected for accuracy
   • Instruments are read to the limit of accuracy of the tool.
3. Maintain measuring instruments
   • Measuring instruments are kept free from corrosion
   • Measuring instruments are not dropped to avoid damage
   • Measuring instruments are cleaned before and after using.

UNIT OF COMPETENCY: READ, INTERPRET AND APPLY SPECIFICATION AND MANUALS.
UNIT CODE: ALT723203

This unit deals with identifying, interpreting and applying service specification manuals, maintenance procedure manuals and periodic maintenance manual.

1. Identify and access manual/specification
   • Appropriate manuals are identified and accessed as per job requirements.
   • Version and date of manual is checked to ensure correct specification and procedure are identified.
2. Interpret manuals
   • Relevant sections, chapters of manuals/specifications are located in relations to the work to be conducted
   • Information and procedure in the manual are interpreted in accordance to industry practices
3. Apply information in manual
   • Manual is interpreted according to job requirements
   • Work steps are correctly identified in accordance with manufacturer specification
   • Manual data is applied according to the given task
   • All correct sequencing and adjustments are interpreted in accordance with information contained on the manual or specifications
4. Store manuals
   • Manual or specification are stored appropriately to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE
UNIT CODE : ALT723204

This unit deals with inspecting and cleaning of work area including tools, equipment and facilities. Storage and checking of tools/ equipment and disposal of used supplies/materials are also incorporated in this competency.

1. Inspect/clean tools and work area
   • Cleaning solvent used as per workshop/tools cleaning requirement
   • Work area is checked and cleaned
   • Wet surface/spot in work area is wiped and dried
2. Store/arrange tools and shop equipment
   • Tools/equipment are checked and stored in their respective shelves/location
   • Corresponding labels are posted and visible
   • Tools are safely secured and logged in the records
3. Dispose wastes/used lubricants
   • Containers for used lubricants are visibly labeled
   • Wastes/used lubricants are disposed as per workshop SOP
4. Report damaged tools/equipment
   • Complete inventory of tools/equipment is maintained
   • Damaged tools/equipment/facilities are identified and repair recommendation is given
   • Reports prepared has no error/discrepancy

BASIC COMPETENCIES

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

UNIT OF COMPETENCY : LEAD WORKPLACE COMMUNICATION
UNIT CODE : 500311109

This unit covers the knowledge, skills and attitudes required to lead in the dissemination and discussion of ideas, information and issues in the workplace.

1. Communicate information about workplace processes
   • Appropriate communication method is selected
   • Multiple operations involving several topics areas are communicated accordingly
   • Questions are used to gain extra information
   • Correct sources of information are identified
   • Information is selected and organized correctly
   • Verbal and written reporting is undertaken when required
   • Communication skills are maintained in all situations
2. Lead workplace discussions
   • Response to workplace issues are sought
   • Response to workplace issues are provided immediately
   • Constructive contributions are made to workplace discussions on such issues as production, quality and safety
   • Goals/objectives and action plan undertaken in the workplace are communicated
3. Identify and communicate issues arising in the workplace
   • Issues and problems are identified as they arise
   • Information regarding problems and issues are organized coherently to ensure clear and effective communication
   • Dialogue is initiated with appropriate personnel
   • Communication problems and issues are raised as they arise

UNIT OF COMPETENCY : LEAD SMALL TEAMS
UNIT CODE : 500311110

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.

1. Provide team leadership
   • Work requirements are identified and presented to team members
   • Reasons for instructions and requirements are communicated to team members
   • Team members’ queries and concerns are recognized, discussed and dealt with
2. Assign responsibilities
   • Duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
   • Duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
   • Performance expectations are established based on client needs and according to assignment requirements
   • Performance expectations are based on individual team members duties and area of responsibility
   • Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
   • Monitoring of performance takes place against defined performance criteria and/or assignment instructions and corrective action taken if required
   • Team members are provided with feedback, positive support and advice on strategies to overcome any deficiencies
   • Performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
   • Team members are kept informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and satisfaction
   • Team operations are monitored to ensure that employer/client needs and requirements are met
   • Follow-up communication is provided on all issues affecting the team
   • All relevant documentation is completed in accordance with company procedures

UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS
UNIT CODE : 500311111

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.

1. Plan negotiations
   • Information on preparing for negotiation is identified and included in the plan
   • Information on creating non verbal environments for positive negotiating is identified and included in the plan
   • Information on active listening is identified and included in the plan
   • Information on different questioning techniques is identified and included in the plan
   • Information is checked to ensure it is correct and up-to- date
2. Participate in negotiations
   • Criteria for successful outcome are agreed upon by all parties
   • Desired outcome of all parties are considered
   • Appropriate language is used throughout the negotiation
   • A variety of questioning techniques are used
   • The issues and processes are documented and agreed upon by all parties
   • Possible solutions are discussed and their viability assessed
   • Areas for agreement are confirmed and recorded
   • Follow-up action is agreed upon by all parties

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATED TO WORK ACTIVITIES
UNIT CODE : 500311112

This unit of covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause of problems.

1. Identify the problem
   • Variances are identified from normal operating parameters; and product quality
   • Extent, cause and nature are of the problem are defined through observation, investigation and analytical techniques
   • Problems are clearly stated and specified
2. Determine fundamental causes of the problem
   • Possible causes are identified based on experience and the use of problem solving tools / analytical techniques.
   • Possible cause statements are developed based on findings
   • Fundamental causes are identified per results of investigation conducted
3. Determine corrective action
   • All possible options are considered for resolution of the problem
   • Strengths and weaknesses of possible options are considered
   • Corrective actions are determined to resolve the problem and possible future causes
   • Action plans are developed identifying measurable objectives, resource needs and timelines in accordance with safety and operating procedures
4. Provide recommendation/s to manager
   • Report on recommendations are prepared
   • Recommendations are presented to appropriate personnel.
   • Recommendations are followed-up, if required

UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES
UNIT CODE : 500311113

This unit covers the knowledge, skills and attitudes required in the application of mathematical concepts and techniques.

1. Identify mathematical tools and techniques to solve problem
   • Problem areas are identified based on given condition
   • Mathematical techniques are selected based on the given problem
2. Apply mathematical procedure/solution
   • Mathematical techniques are applied based on the problem identified
   • Mathematical computations are performed to the level of accuracy required for the problem
   • Results of mathematical computation is determined and verified based on job requirements
3. Analyze results
   • Result of application is reviewed based on expected and required specifications and outcome
   • Appropriate action is applied in case of error

UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES
UNIT CODE : 500311114

This unit of competency covers the knowledge, skills, and attitude required in selecting, sourcing and applying appropriate and affordable technologies in the workplace.

1. Study/select appropriate technology
   • Usage of different technologies is determined based on job requirements
   • Appropriate technology is selected as per work specification
2. Apply relevant technology
   • Relevant technology is effectively used in carrying out function
   • Applicable software and hardware are used as per task requirement
   • Management concepts are observed and practiced as per established industry practices
3. Maintain/enhance relevant technology
   • Maintenance of technology is applied in accordance with the industry standard operating procedure, manufacturer’s operating guidelines and occupational health and safety procedure to ensure its operative ability
   • Updating of technology is maintained through continuing education or training in accordance with job requirement
   • Technology failure/ defect is immediately reported to the concern/responsible person or section for appropriate action

DEFINITION OF TERMS (FOUNDRY)

• Alloy – An alloy is a homogeneous blend of two or more elements  at least one of which is a metal, and where the resulting material as metallic properties.
• Carbon Dioxide Process – Carbon Dioxide Process consist of mixing a clean dry silica sand with a silicate binder, compacting the mixture to shape and hardening it by passing carbon dioxide gas.
• Casting – Casting is the term used to describe both the process and the product when molten metal is poured and solidified in a mold.
• Chemical Analysis – Analytical chemistry is the science that seeks ever improved means of measuring the chemical composition of natural and artificial materials.
• Cope – In a two-part mold, the cope is the name given to the top half of the pattern, flask, mold, or core.
• Core – The core is a sand shape that is inserted into the mold to produce the internal features of a casting, such as, holes or passages for water-cooling.
• Core Box – A core box is the mold or die used to produce casting cores.
• Core Print – The core print is the region added to the pattern, core, or mold that is used to locate and support the core within the mold.
• Draft – Draft is the taper on a pattern or casting that permits it to be withdrawn from the mold.
• Drag – The drag is the bottom part of the two-part mold.
• Dross – Dross is a mass of solid impurities floating on a molten metal bath. It appears usually on the melting of low melting point metals or alloys such as aluminum, copper, magnesium or each alloys.
• Fettle / Finishing – The process of cleaning the casting, removal of excess metal, grinding and inspection operation which may be required for some casting process.
• Flask – The flask is the box that contains the molding aggregate.
• Foundry – A Foundry is a factory which produces metal castings from either ferrous or non-ferrous alloys.
• Furnace – Furnaces are refractory lined vessels that contain the material to be melted and provide the energy to melt it.
• Gate – Gate is controlled entrances to the mold cavity.
• Gating System – Gating system is the network of channels used to deliver the molten metal to the mold cavity.
• Green Sand – The term Green Sand refers to that molded sand mixture which is allowed to remain moist and is used in casting ferrous and non-ferrous metals.
• Melting – The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove deleterious gasses and elements from the molten metal. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. During the tap, final chemistry adjustments are made.
• Molding – Is the process of making the mold cavity with a necessary allowances such as shrinkage, machining, taper, and surface finish. Usually it is done with green sand as the molding medium.
• Mold Cavity – The mold cavity is the shaped hole into which the molten metal is poured and solidified to produce the desired casting.
• Parting Line – Parting Line or Parting Surface is the interface that separates the cope and drag halves of a mold, flask, or pattern. The same part can also be found in some core making processes.
• Pattern – The pattern is the approximate copy of the final casting. The molding material (sand for sand molds) is then packed around the pattern and the pattern is removed to produce the mold cavity.
• Pattern Shrinkage  Allowance – Dimensions added to the pattern to compensate for the solid shrinkage or contraction occurs in the solidified casting as it cools to room / ambient temperature.
• Pouring Cup – A Pouring Cup or Pouring Basin is the portion of the gating system that initially receives the molten metal from the pouring vessel and controls its delivery to rest of the mold.
• Refractories – Refers to materials that are used to make crucibles, linings for furnaces, kilns, ovens and incinerators. A practical requirement is the ability of the material to withstand temperatures above 1100oC without softening.
• Riser – A riser is an extra void created in the mold that will also fill with molten metal. It provides a reservoir of molten metal that flow into the mold cavity to compensate for any shrinkage during solidification.
• Runners – Runners are the horizontal part of the gating system that is connected to the gate.
• Slag By-product of melting metals. They are composed of metal oxides and sulfides. The assist in melt temperature control and minimize oxidation of the liquid metal before casting.
• Sprue – From the pouring cup, the molten metal travels down the sprue the vertical part of the gating system that connects with the runners.
• Vents – Vents are additional channels providing an escape for the gasses that are generated within the mold.
• Wedge Chill Test – Indicates the chilling tendencies of cast iron melt which is related to melting conditions, chemical composition and casting section thickness.