1. Jo Richardson Community School

2. BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1a Grading Criteria: P1Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Understanding material melting processes In order for you to understand producing molten material safely for a given scale of casting or moulding production you must define and provide images for the following: Single melt Batch melt Continuous melt Combined methods

3. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1a Grading Criteria: P1Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Understanding material melting processes In order for you to understand producing molten material safely for a given scale of casting or moulding production you must define and provide images for the following: (continued) Types of furnace: Cupola Induction Rotary Bale out Lift out crucible Tilting crucible Direct or indirect arc Air circulating ovens for thermoplastic melting

4. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1b Grading Criteria: P1Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Understanding material melting processes In order for you to understand material melting processes, you must know the material properties of that you wish to make molten. Define, give examples and provide images for the following: Ferrous alloys, Non-ferrous alloys, Thermoplastics; Measurement of temperature e.g. pyrometers

5. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1c Grading Criteria: P2Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Understanding material melting processes In order for you to understand removing and finishing molten material safely for a given scale of casting or moulding production you must define and provide images for the following: Component removal and finishing Knocking castings out of moulds Removing components from the moulding material or dies De-coring Removing runner/riser/feeder system Processes used Manual Vibratory tables/grids Punch-out mechanisms Chemical leaching

6. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1c Grading Criteria: P2Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Understanding material melting processes In order for you to understand removing and finishing molten material safely for a given scale of casting or moulding production you must define and provide images for the following: (continued) Tooling used Work-holding devices (vice, clamps, jigs and fixtures) Disc/angle grinder Pedestal grinder Slitting saw Band saw Laser cutter Linisher Pneumatic chipping hammers Wire brush Scraper Hacksaw File Abrasive stone Abrasive paper Hammer Blasting Air Water Sand Plastic trimming knives and cutters

7. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1di, iiGrading Criteria: P2Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Understanding casting removal processes When sand casting, you are required to remove patterns from the sand, before and after the casting process, and removing the casting surplus once the cast is cooled. Describe briefly, the process that you took to remove the pattern including reference to tools you may have used before creating the runner and riser system for pouring Describe briefly, the process that you took to remove the aluminium cast including reference to tools you may have used once the casting process was complete Describe briefly, the finishing process that you took to remove the surplus (runner and riser) including reference to tools you may have used after the casting process ii) YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS GRADE CRITERIA.

8. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1eGrading Criteria: M1Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Hazards and PPE during Casting Processes When sand casting your scribing block base, it has been necessary to identify the risks and hazards that are in the foundry area of the workshop. On the grid below, create a plan view for the foundry area showing where there are assessed risks. Include labels to show how these risks and hazards are controlled.

9. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1fi, iiGrading Criteria: M1Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Hazards and PPE during Casting Processes Label and explain the use of the correct PPE on the man belowInsert a photograph of yourself here to show that you can demonstrate good use of PPE when using the foundry area in the workshop ii) YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS GRADE CRITERIA.

10. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1gGrading Criteria: M1Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Hazards and PPE during Casting Processes Explain the importance of identifying hazards and wearing personal protective equipment when melting metals and removing and finishing castings

11. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2a Grading Criteria: P3Key Skills: Assignment: 2 – Understand how casting processes are used Understanding Sand Casting Define and provide images for the following: What are the two parts of the moulding box called? Describe each of their purposes. Part a) Part b) What is a pattern used for? You have created a pattern for the manufacture of your aluminium cast of the scribing block base. Include a photograph in your answer. Explain the function of the runner and riser in sand casting What is the type of sand used in sand casting? Why is this used in the workshop in school?

12. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2b Grading Criteria: P3Key Skills: Assignment: 2 – Understand how casting processes are used Understanding Sand Casting For this task you will be required to provide evidence to show that you are able to understand and inform others in how to sand cast a component that you will be making in the workshop. You have already created a drawing for your mould. You must now describe the processes from making the pattern to manufacturing an aluminium cast in order to inform your working colleagues the appropriate steps you have undertaken. Include Health and Safety considerations you have made. Create a leaflet or poster that can be used in the workshop in the foundry area that offers guidance and important key terms to others.

13. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2c Grading Criteria: P3Key Skills: Assignment: 2 – Understand how casting processes are used Understanding Sand Casting You have been developing your skills in the foundry by producing aluminium casts for your scribing block base. During this task you will be observed on the following Following the steps of the sand casting procedure explained in task 2b Disseminating accurate information to your working colleagues Working with others in a respectable and co-operative manner Following appropriate Health and Safety considerations YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS GRADE CRITERIA.

14. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2d Grading Criteria: P4Key Skills: Assignment: 2 – Understand how casting processes are used Understanding Investment Casting Briefly describe investment casting? Define the following terms used in investment casting processes Wax patterns Single waxes Wax assemblies Mounting of wax patterns Handles Bars, Hangers Slurry

15. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2d Grading Criteria: P4Key Skills: Assignment: 2 – Understand how casting processes are used Understanding Investment Casting Define the following terms used in investment casting processes (continued) Producing shells/moulds… Manually Automatically Combined manual Semi-automatic Single Multiple curing shells/moulds natural air forced air gas activated

16. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2e Grading Criteria: P4Key Skills: Assignment: 2 – Understand how casting processes are used Understanding Investment Casting For this task you will be required to provide evidence to show that you are able to understand investment casting. You must watch the video that has been played to you and take notes on the stages of manufacture. Use this page to record your notes. http://www.youtube.com/watch?v=BX8w-GUPz1w Using your notes, create a simplified version in the form of a flow chart showing each of the main steps. You must also include the Health and Safety considerations you must make during the process as well as the quality control procedures taken in industry.

17. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2f Grading Criteria: D1Key Skills: Assignment: 2 – Understand how casting processes are used Understanding Investment Casting Using information on the video, justify why investment casting is used in industry. Give and explain its advantages and disadvantages.

18. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2gGrading Criteria: D3Key Skills: Assignment: 2 – Understanding why casting processes are used Casting Processes Justify why you have used Aluminium Sand Casting to produce the scribing block base.

19. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3a Grading Criteria: P5Key Skills: Assignment: 3 – Understand how die casting processes are used Understanding Gravity Die Casting Define and provide images for the following: Common die locations Floor Fixed base Movable base Carousel Conveyor/roller track

20. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3aGrading Criteria: P5Key Skills: Assignment: 3 – Understand how die casting processes are used Understanding Gravity Die Casting Define and provide images for the following: (continued) Types of die Split die with no secondary movement, Split die with one secondary movement, Split die with two or more secondary movements, Split die with no cores, Split die with one core, Split die with two or more cores, Water cooling Use of cores

21. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3bGrading Criteria: P5Key Skills: Assignment: 3 – Understand how die casting processes are used Understanding Gravity Die Casting Describe the gravity die casting process when used safely to produce a component

22. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3cGrading Criteria: P6Key Skills: Assignment: 3 – Understand how die casting processes are used Understanding Pressure Die Casting Define and provide images for the following: Types of pressure Die Casting processes High pressure hot chamber High pressure cold chamber Squeeze process water cooling; use of cores

23. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3cGrading Criteria: P6Key Skills: Assignment: 3 – Understand how die casting processes are used Understanding Pressure Die Casting Define and provide images for the following: (continued) Types of die Split die with no secondary movement, Split die with one secondary movement, Split die with two or more secondary movements, Split die with no cores, Split die with one core, Split die with two or more cores, Core assembly with external cores, Core assembly with internal cores,

24. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3dGrading Criteria: P6Key Skills: Assignment: 3 – Understand how die casting processes are used Understanding Pressure Die Casting Describe the pressure die casting process when used safely to produce a component

25. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3eGrading Criteria: M2Key Skills: Assignment: 3 – Understand how die casting processes are used Understanding Die Casting Often it is necessary as a manufacture to weigh up the advantages and disadvantages of different manufacturing processes. Explain when die casting would be used in preference to sand casting. Note the advantages and disadvantages of each and conclude. http://www.castingstechnology.com/public/services/technologies/TECGravityDieCasting.asp

26. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3fGrading Criteria: D2Key Skills: Assignment: 3 – Understand how die casting processes are used Understanding Die Casting Justify why it is sometimes necessary to make the use of a pressure die casting process for components. List the advantages of Pressure Die Casting.

27. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 4a Grading Criteria: P7Key Skills: Assignment: 4 – Understand how plastic moulding processes are used Understanding Injection Moulding Label the parts of the diagram and briefly describe the four main stages of the process. Use images to support your understanding. (http://technologystudent.com/equip1/inject1.htm)http://technologystudent.com/equip1/inject1.htm Name two types of plastic that can be used in this process 12341234

28. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 4bGrading Criteria: P8Key Skills: Assignment: 4 – Understand how plastic moulding processes are used Understanding Vacuum Forming You need to produce a casing for your electronic circuit so that it is secure. Create an informative guide that can be used to assist a Year 8 Design and Technology student through the process of Vacuum Forming. http://technologystudent.com/equip1/vacform1.htm Make notes below to show the 6 main stages of the process. Name two types of plastic that can be used in this process

29. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 4c I, iiGrading Criteria: P8Key Skills: Assignment: 4 – Understand how plastic moulding processes are used Understanding Vacuum Forming You need to produce a casing for your electronic circuit so that it is secure. You will be observed operating the Vacuum Former safely. Show using a photograph that you can demonstrate this well and the Health and Safety considerations you have made. YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS GRADE CRITERIA.

30. Jo Richardson Community School BTEC First Diploma in Engineering Name:Candidate No: Unit 22: Casting and Moulding Engineering components Task: 4dGrading Criteria: M3Key Skills: Assignment: 4 – Understand how plastic moulding processes are used Understanding Wet Lay-up Composite Moulding Briefly describe the Wet Lay-Up technique Explain when a wet lay-up technique would be used in preference to injection moulding or vacuum forming