Assessor Resource

MSATCM302A
Monitor ferrous melting and casting processes

Assessment tool

Version 1.0
Issue Date: April 2024


In a typical scenario, a technician will be required to monitor a ferrous melting and casting operation, ensuring that correct quantities and temperatures are used and correct procedures followed.

This unit covers the knowledge and skills needed to monitor the melting and casting of the alloys of iron, steel

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Prerequisites

Pre-requisite Units

Employability Skills

This unit contains employability skills.



Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for the TrainingPackage.

Overview of assessment

A person who demonstrates competency in this unit must be able to monitor basic ferrous melting and casting processes. Critical aspects for assessment and evidence are required to demonstrate competency in this unit

Critical aspects for assessment and evidence required to demonstrate competency in this unit

It is essential that competence is demonstrated in the ability to:

Monitor the melting and casting of ferrous metal. Evidence should be provided from a number of castings using different alloys and or different moulds.

Safely operate melting furnace

Safely handle pouring equipment

Relationship to other units

This unit may be assessed concurrently with other relevant units.

Assessment method and context

Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the elements, performance criteria, skills and knowledge. A holistic approach should be taken to the assessment.

Assessors should gather sufficient, fair, valid, reliable, authentic and current evidence from a range of sources. Sources of evidence may include direct observation, reports from supervisors, peers and colleagues, project work, samples, organisation records and questioning. Assessment should not require language, literacy or numeracy skills beyond those required for the unit.

The assessee will have access to all techniques, procedures, information, resources and aids which would normally be available in the workplace.

The method of assessment should be discussed and agreed with the assessee prior to the commencement of assessment.

Resource implications

This section should be read in conjunction with the range of variables for this unit of competency. Resources required include suitable access to an organisation where ferrous casting is done. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

This describes the essential skills and knowledge and their level, required for this unit.

Required skills:

take calculations needed for determining charges

perform visual checking of furnaces for operational condition and safety risks

take of samples

follow safety and quality procedures

Required knowledge:

Charge Calculations

importance of composition control.

methods of calculation used to correct for

additions.

types of alloy additions.

Steel

induction furnace melting; principles; refractories.

arc furnace melting; acid, basic, single slag,

double slag, deoxidisation, hydrogen control.

ladle refining

Cast iron

types of cast iron

influence of carbon and silicon contents

carbon equivalent. effect of cooling rate.

microstructure, classification of graphite.

carbide stabilisers and graphite.

innoculation, types of innoculant.

spheroidal graphite formation and treatment

methods.

casting characteristics of grey, S.G and malleable

cast irons.

Ferrous alloys:

definitions:

iron

steel

physical properties:

density

tensile

hardness

melting points

shrinkage percent

casting temperature

S.G. iron

ductile iron

carbon steel

grey and white irons

alloy cast irons

alloys steels

chilled and malleable iron

selection:

customer requirements

manufacturer's requirements

metal analysis

Australian standards

Types of furnaces:

blast furnace

cupola

induction

direct arc

indirect arc

open hearth

reverberatory

rotary

maintenance

Refractories:

dolomite

silica brick

chrome brick

ganister

fireclay

firebrick

magnesite

kyanite

fused alumina

Linings:

monolithic

castable

rammable

bricks

basic

acid

neutral

Types of ladles:

lip

tea pot

bottom pour

safety with ladles

maintenance

Safety:

house keeping

personal clothing/gear

dry area

pre-heat ladles

overhead cranes

Furnace operation:

personal clothing/gear

dry charge/equipment

pre-heating

scrap selection

house keeping

melting program

alloying program

calculations

percentages, ratio

charge calculations

maintenance

Types of control equipment:

carbon equivalent

wedge test

fluidity spiral test

chemical analysis

wet

spectrograph

sample spoons

sample moulds

deoxidising

degassing

temperature measurement

Quality control:

accurate weighing

correct analysis

temperature control

slag control (including chemistry and interaction with molten bath)

alloying procedure

thermal analysis

degassing

deoxidising

Defects:

contamination

gas absorption

metal analysis

temperature control

oxidation

Alloy production:

charge analysis

charge calculation

charge preparation

melt control

tapping/pouring

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Codes of practice/standards

Where reference is made to industry codes of practice, and/or Australian/international standards, it is expected the latest version will be used.

Contaminants

Contaminants include non specified metal, rubber, grease, water, paint and non-metallics, closed containers or pipes and pressure containers such as aerosols.

Material specification

Material specification includes ferrous metals and ferrous alloys as well as contaminants.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Identify required material specification 
Identify mould requirements 
Identify any special requirements for this job 
Select required components to give the required metal specification 
Calculate required charge of each component 
Recommend changes/additions to the charge 
Monitor the preparation of the charge including checking for contaminants 
Check that the furnace is in good operational condition and that appropriate lining is present 
Organise for maintenance/repairs as required 
Monitor a melt to ensure the product meets specification 
Check that the ladle is in good operational condition and that appropriate lining is present 
Check pouring is to procedures 
Take required samples for analysis 
Identify hazards in the metal melting/pouring process 
Assess the risks arising from those hazards 
Implement procedures to control those hazards in line with procedures and duty of care. 

Forms

Assessment Cover Sheet

MSATCM302A - Monitor ferrous melting and casting processes
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

MSATCM302A - Monitor ferrous melting and casting processes

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: