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FAB1120 Foundry – One-Piece Pattern

Introductory · 1 credit · TMT - Trades, Manufacturing and Transportation

Description
Students develop the basic skills required to produce a simple one-piece pattern, a sand mould and a finished casting.
Prerequisite
FAB1010: Fabrication Tools & Materials
Parameters
Access to a materials work centre, complete with foundry supplies and equipment, and to instruction from an individual with specialized training in basic foundry.

Outcomes The student will:

  • 1 take preventive measures to avoid accidents and personal injury to self and others by recognizing health and safety hazards associated with casting metal

    • 1.1 describe the operation of a foundry furnace and safe methods of handling and pouring molten metal

    • 1.2 list the types of personal protective equipment and the circumstances under which it should be worn

    • 1.3 describe a safety plan in case of an accident

  • 2 demonstrate basic pattern making skills to make a one-piece mould

    • 2.1 outline the basic procedures used to make a mould with a one-piece pattern

    • 2.2 list and describe the types of patterns used to make sand moulds

    • 2.3 identify the types of materials that are suitable for making a pattern

    • 2.4 design or locate an article that can be cast using a one-piece pattern

    • 2.5 select a suitable pattern making material

  • 3 demonstrate basic sand casting skills, using a one-piece pattern

    • 3.1 list examples of everyday products that are made by casting

    • 3.2 explain how a cast part differs from a forged part

    • 3.3 list common metals used to make castings; e.g., aluminum, brass, bronze, iron

    • 3.4 describe the major casting processes including:

      • 3.4.1 sand casting

      • 3.4.2 die casting

      • 3.4.3 investment casting

    • 3.5 identify and describe the parts of a sand mould

    • 3.6 describe the advantages and disadvantages of a water-moistened sand and an oil-bonded sand

    • 3.7 explain why a flux is used when a metal is melted

    • 3.8 identify common tools and equipment used in sand casting

    • 3.9 describe the kind and amount of metal that is required for a given casting

    • 3.10 describe the melting point and appropriate flux for a specified metal

    • 3.11 evaluate the quality of sand and foundry metal

    • 3.12 use the appropriate tools, materials and processes to:

      • 3.12.1 make a pattern

      • 3.12.2 condition the sand

      • 3.12.3 create a mould

      • 3.12.4 heat and pour the molten metal

      • 3.12.5 remove and finish the casting

    • 3.13 research a completed casting and check to see that it is clean, free of voids and finished appropriately

  • 4 demonstrate basic competencies

    • 4.1 demonstrate fundamental skills to:

      • 4.1.1 communicate

      • 4.1.2 manage information

      • 4.1.3 use numbers

      • 4.1.4 think and solve problems

    • 4.2 demonstrate personal management skills to:

      • 4.2.1 demonstrate positive attitudes and behaviours

      • 4.2.2 be responsible

      • 4.2.3 be adaptable

      • 4.2.4 learn continuously

      • 4.2.5 work safely

    • 4.3 demonstrate teamwork skills to:

      • 4.3.1 work with others

      • 4.3.2 participate in projects and tasks

  • 5 make personal connections to the cluster content and processes to inform possible pathway choices

    • 5.1 complete/update a personal inventory; e.g., interests, values, beliefs, resources, prior learning and experiences

    • 5.2 create a connection between a personal inventory and occupational choices

Program of Studies 2010. Source document, © Alberta Education.