Required knowledge includes: charge calculations: importance of composition control methods used to calculate for additions types of alloy additions and their effects on casting behaviour and finished product steel: induction furnace melting, principles, refractories suitable for steelmaking and their characteristics arc furnace melting; acid, basic, single slag, double slag, deoxidisation and hydrogen control ladle refining cast iron: types of cast iron influence of carbon and silicon contents carbon equivalent effect of cooling rate microstructure and classification of graphite carbide stabilisers and graphite inoculation and types of innoculant spheroidal graphite formation and treatment methods casting characteristics of grey, S.G (ductile) and malleable cast irons ferrous alloys: definitions of ferrous metals the grades of iron and their applications, including S.G. iron, ductile iron, grey and white irons, alloy cast irons, chilled and malleable iron the grades of steel and their applications including carbon steel and alloys steels methods of controlling physical properties advantages/disadvantages of density of each type of ferrous metal methods of controlling tensile strength of ferrous metals methods of controlling the hardness of ferrous metals the influence of melting points on production processes the shrinkage percentage of the types of ferrous metals how to control metal fluidity the use of degassing to control gas defects be able to take action to control grain size casting temperature make a selection of ferrous metal based on required properties conduct metal analysis on ferrous metal use Australian standards (or other appropriate standard) for ferrous metals types of furnaces and their relative advantages and disadvantages: blast furnace cupola induction direct arc indirect arc open hearth reverberatory rotary maintenance refractory types and purposes including: dolomite silica brick chrome brick ganister fireclay firebrick magnesite kyanite fused alumina linings types and purposes including: monolithic castable rammable bricks basic acid neutral types of ladles: lip tea pot bottom pour safe working with ladles: pre-heat ladles ladle maintenance check mechanical condition of ladles including gearboxes and safety locks use of lifting and handling equipment including: tongs shanks cranes hoists bogey ladles maintenance supervision of other staff in melting and casting safety including: housekeeping personal protective clothing dry area and tools pre-heating of ladles safe working load of overhead cranes furnace operation procedures including: ensuring a dry and safe charge warm and dry equipment pre-heating scrap selection housekeeping melting schedule pouring schedule calculations including volume and mass calculations charge calculations maintaining supply maintenance of melting and pouring equipment types of control equipment: thermal analysis pyrometers gas analysis chemical analysis wet chemical analysis spectrograph fluidity test quality control and procedures for: accurate weighing correct chemical analysis covers and fluxes mould/metal reactions conduct and interpretation of thermal analysis alloying procedure thermal analysis degassing deoxidising ladle refining chill/wedge test customer requirements types of defects and prevention including but not limited to: contamination gas absorption metal analysis temperature control oxidation other defects common to iron and steel tapping and pouring operations including: when to pour according to job and furnace specification availability of emergency pour out pits and other safety equipment availability of cranes or other transport pour out rate ensure mechanical test bar is available and taken if required ensure pig pouring and tagging is performed correctly |