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 non-ferrous alloys: definition of non-ferrous metals methods of controlling physical properties advantages/disadvantages of density of each type of non-ferrous metal methods of controlling tensile strength of non-ferrous metals methods of controlling the hardness of non-ferrous metals influence of melting points on production processes shrinkage percentage of the types of non-ferrous metals how to control metal fluidity be able to make a refractory selection for non-ferrous alloys the use of degassing to control gas defects be able to take action to control grain size the grades of brass and their applications the grades of bronze and their applications the grades of gunmetal and their applications the grades of other copper based alloys and their applications the grades of aluminium based alloys and their applications the grades of lead based alloys and their applications the grades of zinc based alloys and their applications the grades of magnesium based alloys and their applications make a selection of non-ferrous metal based on required properties conduct metal analysis on non-ferrous metals use Australian standards (or other appropriate standard) for non-ferrous metals types of furnaces and their relative advantages and disadvantages: crucible oil gas induction channel coreless resistance reverberatory maintenance selection of appropriate refractories for non-ferrous melting: silica ganister coatings others common to non-ferrous melting selection of the form of linings for non-ferrous melting: monolithic castable rammable bricks selection of the appropriate ladles/crucibles with regard to: types ladles crucibles safety maintenance including checking of mechanical condition of gearboxes and safety locks care of crucibles porous plug 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 including procedures for: ensuring a dry and safe charge warm and dry equipment pre-heating scrap selection scrap segregation housekeeping melting schedule pouring schedule charge calculations calculations including volume and mass calculations maintenance of melting and pouring equipment use of lifting and handling equipment including: tongs shanks cranes hoists bogey ladles maintenance types of control equipment: thermal analysis pyrometers gas analysis chemical analysis wet chemical analysis spectrograph fluidity test shrinkage test quality control and procedures for: accurate weighing correct chemical analysis temperature control covers and fluxes mould/metal reactions conduct and interpretation of thermal analysis degassing deoxidising ladle refining customer requirements types of defects and prevention including but not limited to: contamination gas absorption metal analysis temperature control oxidation other defects common to non-ferrous metals 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 |