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FAB2120 Foundry – Split Pattern

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

Description
Students expand their pattern making and foundry skills to produce split pattern moulds and finished castings.
Prerequisite
FAB1120: Foundry – One-piece Pattern
Parameters
Access to a fabrication work centre, complete with foundry equipment and supplies, and to instruction from an individual with specialized training in foundry practices.

Outcomes The student will:

  • 1 describe the essential similarities and differences between a one-piece pattern and a split pattern

    • 1.1 from a selection of cast objects, list those made from two-part patterns and identify the parting line on each casting

    • 1.2 describe the type of pattern used to make a mould for cylindrical/spherical objects

    • 1.3 explain how a split pattern is aligned and why this is necessary

    • 1.4 compare the shrinkage allowances for:

      • 1.4.1 aluminum

      • 1.4.2 brass

      • 1.4.3 cast iron

    • 1.5 explain how the two parts of the mould are aligned correctly

  • 2 describe safe start-up and shut-down procedures for the operation of a foundry furnace

    • 2.1 identify safe start-up and shut-down procedures for a given furnace

    • 2.2 identify appropriate fluxes to be used with the melting process

    • 2.3 identify the dangers related to:

      • 2.3.1 handling ceramic crucibles

      • 2.3.2 moisture in contact with molten metal

      • 2.3.3 metals splashing

      • 2.3.4 moulds incorrectly vented

      • 2.3.5 metal escape if mating flask surfaces are damaged

      • 2.3.6 water as a sand binder

      • 2.3.7 fumes from metal, fluxing and binders

    • 2.4 identify common foundry practices to avoid injury in all of the above

  • 3 demonstrate basic pattern making skills to make a split pattern

    • 3.1 list and describe common foundry furnaces and accessories

    • 3.2 describe the correct use of foundry tools and equipment to make a mould from a two-part pattern

    • 3.3 describe the correct pouring temperature for both aluminum alloy and lead-based alloys

    • 3.4 describe a safety plan in case of an accident

  • 4 apply sand casting principles and skills to make a casting from a split pattern

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

      • 4.1.1 construct a split pattern

      • 4.1.2 create a sand mould

      • 4.1.3 pour

      • 4.1.4 cool

      • 4.1.5 remove flash, gates and runners

      • 4.1.6 finish a sand casting

    • 4.2 identify the cause of porosity in a casting and take appropriate measures to correct the problem

  • 5 demonstrate basic competencies

    • 5.1 demonstrate fundamental skills to:

      • 5.1.1 communicate

      • 5.1.2 manage information

      • 5.1.3 use numbers

      • 5.1.4 think and solve problems

    • 5.2 demonstrate personal management skills to:

      • 5.2.1 demonstrate positive attitudes and behaviours

      • 5.2.2 be responsible

      • 5.2.3 be adaptable

      • 5.2.4 learn continuously

      • 5.2.5 work safely

    • 5.3 demonstrate teamwork skills to:

      • 5.3.1 work with others

      • 5.3.2 participate in projects and tasks

  • 6 identify possible life roles related to the skills and content of this cluster

    • 6.1 recognize and then analyze the opportunities and barriers in the immediate environment

    • 6.2 identify potential resources to minimize barriers and maximize opportunities

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