HEAT TREATMENT NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR HEAT TREATMENT NC II

The HEAT TREATMENT NC II Qualification consists of competencies that a person must achieve to be able to select the appropriate process of heat treatment to achieve the desired result, recording and maintaining the heat treatment information in the manufacture of many other metals. It also covers heat treatment of ferrous and non-ferrous metals using a variety of equipment such as box type pit type, boggie type furnaces either gas, oil-fired or electrically heated. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering and quenching.

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

A student who has achieved this TESDA Course in HEAT TREATMENT NC II is competent to be:

• Heat Treater

HEAT TREATMENT NC II – TRAINING AND REGULATION MODULE

Course Title: HEAT TREATMENT
Level: NC II
Nominal Training Duration : 86 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual in the field of HEAT TREATMENT. This course consists of competencies that a person must achieve to be able to select the appropriate process of heat treatment to achieve the desired result, recording and maintaining the heat treatment information in the manufacture of many other metals. It also covers heat treatment of ferrous and non-ferrous metals using a variety of equipment such as box type pit type, boggie type furnaces either gas, oil-fired or electrically heated. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering and quenching.

This course is also designed to enhance the basic and common knowledge, skills and attitudes of an individual in the field of foundry-pattern making.

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 experience in basic machining
• Can communicate both orally and in writing; and
• Physically and mentally fit

COMPETENCIES REQUIRED IN HEAT TREATMENT NC II

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

To obtain this TESDA course in HEAT TREATMENT NC II, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (48 Hours)
ALT812318	Select Heat Treatment Process
ALT812319	Perform Heat Treatment Process
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 (20Hours)
500311105	Participate in workplace communication
500311106	Work in a team environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

CORE COMPETENCIES

UNIT OF COMPETENCY : SELECT HEAT TREATMENT PROCESS
UNIT CODE : ALT812318

This unit covers selecting the appropriate process to achieve the desired result, recording and maintaining the heat treatment information.

1. Determine job requirements
   • Heat treatment process to achieve specified result is determined using reference materials, metallurgist’s report, consultation with technical specialists or other appropriate personnel.
   • Knowledge of metal composition and effects of heat and cooling is applied to selection of appropriate process and equipment.
2. Test materials and record and maintain heat treatment information
   • Properties of materials is tested using appropriate testing equipment as required
   • Heat treatment faults are identified and reported to concerned personnel
   • Heat treatment faults are rectified according to standard operating procedure
   • Information relating to equipment and processes is maintained as required

UNIT OF COMPETENCY : PERFORM HEAT TREATMENT PROCESS
UNIT CODE : ALT812319

This unit covers heat treatment of ferrous and non-ferrous metals, selecting the appropriate process to achieve the desired result using a variety of equipment such as box type, pit type, boggie type furnaces either gas, oil-fired or electrically heated.

1. Determine job requirements and set up equipment
   • Job requirements are determined from engineering drawing, job sheet or verbal instruction from metallurgist and other concerned personnel.
   • Heating equipment is selected for the required heat treatment process.
   • Equipment is set up according to standard operating procedures and/or manufacturer’s instructions
   • Personal protective equipment/devices are used in accordance with occupational health and safety (OH & S) requirements
2. Load/ arrange materials
   • Material is piece- or batch-loaded and unloaded in accordance with standard operating procedures.
   • Fixtures are used to avoid /minimize damage to the material during handling and heating or cooling.
   • Equipment appropriate to the situation is applied according to standard operating procedure.
3. Operate and monitor heating equipment
   • Furnace start-up is performed as per standard operating procedures and safety requirements.
   • Information related with equipment and process is recorded as per standard procedures.
   • Required heating temperature, soaking time and cooling time is applied and maintained according to standard operating procedure.
   • Hazards are identified and control measures are implemented to maintain a safe work environment.
   • Optimum furnace operation requirement is maintained as per standard operating procedures.
   • Furnace atmosphere is maintained as per standard operating procedures
   • Temperature distribution inside the furnace is monitored and adjusted, if necessary, in accordance with standard operating procedures.
4. Heat treat materials
   • Quenching medium /tank is prepared as required by the process.
   • Air blast for air cooling is prepared, if required by the process.
   • Material is removed from the furnace as per standard operating procedures and safely requirements
   • Materials is heat treated to achieve required result in accordance with standard operating procedures and customer requirements
5. Shut down furnace
   • Furnace is shut down as per standard operating procedures
   • Routine maintenance is performed on thermo-couples and temperature meter as per standard operating procedures

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING)

UNIT OF COMPETENCY : 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 : ALT723205

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

UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements.

1. Obtain and convey workplace information
   • Specific and relevant information is accessed from appropriate sources
   • Effective questioning, active listening and speaking skills are used together and convey information
   • Appropriate medium is used to transfer information and ideas
   • Appropriate non- verbal communication is used
   • Appropriate lines of communication with supervisors and colleagues are identified and followed
   • Defined workplace procedures for the location and storage of information are used
   • Personal interaction is carried out clearly and concisely
2. Participate in workplace meetings and discussions
   • Team meetings are at ended on time
   • Own opinions are clear expressed and those of others are listened to without interruption
   • Meeting inputs are consistent with the meeting purpose and established protocols
   • Workplace interactions are conducted in a courteous manner
   • Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to.
   • Meetings outcomes are interpreted and implemented
3. Complete relevant work related documents
   • Range of forms relating to conditions of employment are completed accurately and legibly
   • Workplace data is recorded on standard workplace forms and documents
   • Basic mathematical processes are used for routine calculations
   • Errors in recording information on forms/documents are identified and properly acted upon
   • Reporting requirements to supervisor are completed according to organizational guidelines

UNIT OF COMPETENCY : WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team.

1. Describe team role and scope
   • The role and objective of the team is identified from available sources of information
   • Team parameters, reporting relationships and responsibilities are identified from team discussions and appropriate external sources.
2. Identify own role and responsibility within team
   • Individual role and responsibilities within the team environment are identified.
   • Roles and responsibility of other team members are identified and recognized.
   • Reporting relationships within team and external to team are identified.
3. Work as a team member
   • Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives.
   • Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context.
   • Observed protocols in reporting using standard operating procedures.
   • Contribute to the development of team work plans based on an understanding of team’s role and objectives and individual competencies of the members.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.

1. Integrate personal objectives with organizational goals
   • Personal growth and work plans are pursued towards improving the qualifications set for the profession
   • Intra- and interpersonal relationships is are maintained in the course of managing oneself based on performance evaluation
   • Commitment to the organization and its goal is demonstrated in the performance of duties
2. Set and meet work priorities
   • Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
   • Resources are utilized efficiently and effectively to manage work priorities and commitments
   • Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
3. Maintain professional growth and development
   • Trainings and career opportunities are identified and availed of based on job requirements
   • Recognitions are sought/received and demonstrated as proof of career advancement
   • Licenses and/or certifications relevant to job and career are obtained and renewed

UNIT OF COMPETENCY : DEVELOP CAREER AND LIFE DECISIONSUNIT OF COMPETENCY : PRACTICE  OCCUPATIONAL HEALTH AND SAFETY PROCEDURES
UNIT CODE : 500311108

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety.

1. Identify hazards and risks
   • Safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
   • Hazards/risks in the workplace and their corresponding indicators are identified to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures
   • Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
2. Evaluate hazards and risks
   • Terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
   • Effects of the hazards are determined
   • OHS issues and/or concerns and identified safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation
3. Control hazards and risks
   • Occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently
     followed
   • Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
   • Personal protective equipment (PPE) is correctly used in accordance with organization OHS procedures and practices
   • Appropriate assistance is provided in the event of a workplace emergency in accordance with established organization protocol
4. Maintain OHS awareness
   • Emergency-related drills and trainings are participated in as per established organization guidelines and procedures
   • OHS personal records are completed and updated in accordance with workplace requirements

DEFINITION OF TERMS (HEAT TREATMENT)

• Heat Treatment – A process in which metal in the solid state is subjected to one or more temperature cycles to attain certain desired properties.
• Annealing – Heating to and holding above the critical range followed by controlled slow-cooling in the furnace.
• Quenching – Is a hardening process. It involves heating to a temperature within a critical temperature range followed by quenching in a medium which are liquid or air medium. Quenching is a distinct operation carried out external to the furnace.
• Thermal critical range – Metals have its own distinct chemical composition. The thermal critical range depends on the chemical composition of the metal. Heating above and below the critical temperature range changes in a solid state constitution. While major constitutional change cannot occur below the lower limits some changes in microstructure are do so.
• Precipitation hardening metals – Hardening in metals caused by the precipitation of a constituent from a supersaturated solid solution. This occurs after quenching of alloys especially the miraging steel groups and stainless steels.
• Differential hardening – Some techniques allow different areas of a single object to receive different heat treatments. This is called differential hardening. It is common in high quality knives and swords. The Chinese jian is one of the earliest known examples of this, and the Japanese katana the most widely known. The Nepalese Khukuri is another example.
• Ferrous metals – The term “ferrous” is derived from the latin word meaning “containing iron“. This can include pure iron, such as wrought iron, or an alloy such as steel. Ferrous metals are often magnetic, but not exclusively.
• Alloy An alloy is a mixture of two or more elements in solid solution in which the major component is a metal. Combining different ratios of metals as alloys modifies the properties of pure metals to produce desirable characteristics. The aim of making alloys is generally to make them less brittle, harder, resistant to corrosion, or have a more desirable color and luster. Examples of alloys are steel (iron and carbon), brass (copper and zinc), bronze (copper and tin), and duralumin (aluminum and copper). Alloys specially designed for highly demanding applications, such as jet engines, may contain more than ten elements.
• Metal – In chemistry, a metal (Greek: Metallo, Μέταλλο) is a chemical element whose atoms readily lose electrons to form positive ions (cations), and form metallic bonds between other metal atoms and ionic bonds between nonmetal atoms.