FROM-TO

Foundry – training tailored to the individual needs of the client

to be agreed Duration

Training mode

Closed training

Course level

FROM-TO

Prerequisites

Module 1 – Brak
Module 2 – Basic knowledge of materials engineering, metallurgy, basic knowledge of metal casting
Module 3 and 4 – Basic knowledge of metallurgy and alloy casting. Knowledge of basic casting production technologies.

Course Objective

Course objective:

Module 1 - Casting metal alloys and their smelting methods
- Possesses knowledge of the basic materials (metal alloys) used to produce castings
- Knows the processes of melting foundry alloys in various foundry furnaces
- Knows the most important health and safety rules in a metal foundry

Module 2 - Modern casting manufacturing technologies
- He has knowledge in the field of development of foundry technologies, especially mechanization, automation and robotization of foundry processes.
- He has knowledge of modern pressure die casting.
- He has knowledge in the field of manufacturing precision castings using the investment casting method.

Module 3 - Casting defects and ways to prevent them
- He has extensive knowledge of the terminology and causes of defects in castings made of ferrous alloys and non-ferrous metals.
- Knows the principles of casting design that ensure the reduction of the risk of casting defects
- Knows the principles of optimizing foundry technology (type and parameters of molding sand, geometry of the gating system, mold coating, overheating temperature of the liquid alloy and mold pouring, etc.) to minimize the possibility of defects

Module 4 - Resource and Waste Management in the Foundry
- Knows the current guidelines for foundry waste
- Familiar with the issue of NDT – Best Available Techniques (BAT) for the foundry industry
- Has knowledge of molding sand regeneration methods
- Possesses knowledge in the field of optimizing foundry processes (melting, forming, cleaning of castings, etc.) in terms of resource consumption and minimizing waste generation

Course program

Below we present a broad range of topics that form the basis for developing a dedicated training program.

Day 1 - Module 1	Division of casting alloys – ferrous and non-ferrous alloys Trends in the development and application of modern casting alloys (ADI cast iron, vermicular cast iron, nickel superalloys, aluminum alloys, skeleton castings, etc.)
Day 2 - Module 1	Types of foundry furnaces and the melting processes carried out in them electric arc furnace electric induction stove cupola gas stoves other types of foundry furnaces
Day 3 - Module 1	Calculating the charge (measurement) for melting – exercises Health and safety in the processes of melting, transporting liquid metal, its processing and pouring casting molds
Day 1 - Module 2	Trends in the development of global foundry industry Automatic box casting lines Automatic flaskless casting lines
Day 2 - Module 2	Low- and high-pressure casting Combining foundry technologies with other manufacturing techniques (squeeze casting, rheocasting, metal-plastic hybrid casting, etc.)
Day 3 - Module 2	Manufacturing precision castings using the investment casting method Basics of robotization of foundry processes
Day 1 - Module 3	Classification of casting defects and the terminology used in this field Standards for casting defects and casting quality Casting acceptance criteria
Day 2 - Module 3	Shape defects Defects of the raw surface Breaks in continuity Internal defects
Day 3 - Module 3	Methods of preventing defects, including: the influence of the molding sand on the quality of castings the influence of the quality of the liquid alloy and its parameters on the intensity of defects the influence of the geometry of the casting mold on the formation of casting defects solidification and crystallization of the casting and its influence on its internal defects Computer-aided casting production process as a tool to minimize the risk of producing defective castings
Day 1 - Module 4	Resource flow in the foundry NDT Best Available Techniques (BAT) for the foundry industry
Day 2 - Module 4	Requirements for the handling of foundry waste Methods of regeneration of used molding sand – their application, advantages and disadvantages
Day 3 - Module 4	Modern methods to reduce the consumption of various resources in basic foundry processes and technologies, including Monitoring the wear of melting furnace linings Reducing energy consumption in the process of melting foundry alloys Modern methods of pouring and feeding castings to reduce the amount of liquid alloy and increase yield Possibilities of utilizing foundry waste in foundries and other sectors of the economy

Laboratory equipment

During training at the Client's premises, we can work using the equipment and machinery available at the given workplace.

NO Online

Closed training Training mode

YES Certificate

Gliwice,
EMT-Systems Headquarters Training location See the map

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Training objectives

After completing the training, the participant:

Module 1 - Casting metal alloys and their smelting methods
- Possesses knowledge of the basic materials (metal alloys) used to produce castings
- Knows the processes of melting foundry alloys in various foundry furnaces
- Knows the most important health and safety rules in a metal foundry
Module 2 - Modern casting manufacturing technologies
- He has knowledge in the field of development of foundry technologies, especially mechanization, automation and robotization of foundry processes.
- He has knowledge of modern pressure die casting.
- He has knowledge in the field of manufacturing precision castings using the investment casting method.
Module 3 - Casting defects and ways to prevent them
- He has extensive knowledge of the terminology and causes of defects in castings made of ferrous alloys and non-ferrous metals.
- Knows the principles of casting design that ensure the reduction of the risk of casting defects
- Knows the principles of optimizing foundry technology (type and parameters of molding sand, geometry of the gating system, mold coating, overheating temperature of the liquid alloy and mold pouring, etc.) to minimize the possibility of defects
Module 4 - Resource and Waste Management in the Foundry
- Knows the current guidelines for foundry waste
- Familiar with the issue of NDT – Best Available Techniques (BAT) for the foundry industry
- Has knowledge of molding sand regeneration methods
- Possesses knowledge in the field of optimizing foundry processes (melting, forming, cleaning of castings, etc.) in terms of resource consumption and minimizing waste generation

By requirements

Module 1 – None.
Module 2 – Basic knowledge of materials engineering, metallurgy, basic knowledge of metal casting.
Module 3 and 4 – Basic knowledge of metallurgy and casting of metal alloys.
Knowledge of basic casting production technologies

Training program

1. Division of casting alloys – ferrous and non-ferrous alloys

2. Trends in the development and application of modern casting alloys (ADI cast iron, vermicular cast iron, nickel superalloys, aluminum alloys, skeleton castings, etc.)

1. Types of foundry furnaces and the melting processes carried out in them

electric arc furnace
electric induction stove
cupola
gas stoves
other types of foundry furnaces

1. Calculating the charge (measurement) for melting – exercises

2. Health and safety in the processes of melting, transporting liquid metal, its processing and pouring casting molds

1. Trends in the development of global foundry industry

2. Automatic box casting lines

3. Automatic flaskless casting lines

1. Low- and high-pressure casting

2. Combining foundry technologies with other manufacturing techniques (squeeze casting, rheocasting, metal-plastic hybrid casting, etc.)

1. Manufacturing precision castings using the investment casting method

2. Basics of robotization of foundry processes

1. Classification of casting defects and the terminology used in this field

2. Standards for casting defects and casting quality

3. Casting acceptance criteria

1. Shape defects

2. Defects of the raw surface

3. Breaks in continuity

4. Internal defects

1. Methods of preventing defects, including:

the influence of the molding sand on the quality of castings
the influence of the quality of the liquid alloy and its parameters on the intensity of defects
the influence of the geometry of the casting mold on the formation of casting defects
solidification and crystallization of the casting and its influence on its internal defects

2. Computer-aided casting production process as a tool to minimize the risk of producing defective castings

1. Resource flow in the foundry

2. NDT Best Available Techniques (BAT) for the foundry industry

1. Requirements for the handling of foundry waste

2. Methods of regeneration of used molding sand – their application, advantages and disadvantages

1. Modern methods to reduce the consumption of various resources in basic foundry processes and technologies, including

Monitoring the wear of melting furnace linings
Reducing energy consumption in the process of melting foundry alloys
Modern methods of pouring and feeding castings to reduce the amount of liquid alloy and increase yield

2. Possibilities of utilizing foundry waste in foundries and other sectors of the economy

Below we present a broad range of topics that form the basis for developing a dedicated training program.

Certificate

Upon completion of the training, each participant receives a bilingual, personalized certificate descriptively confirming the acquired skills in accordance with the PN-EN ISO 9001:2015 quality management system implemented at EMT-SYSTEMS Sp. z o.o. , supervised and certified by TUV Nord Polska.