Assessor Resource

MSATCM515A
Analyse metallurgical failures of components and recommend preventative measures

Assessment tool

Version 1.0
Issue Date: May 2024


This unit applies to the identification and analysis of failures in metallic engineering components where the failure is suspected of being related to the production or composition of the component. The unit applies to technician level activities in a manufacturing or engineering environments.

This unit applies to identifying and analysing metallurgical failures in engineering components and recommending preventative measures

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

MSATCM406A

Interpret basic binary phase diagrams

MSATCM401A

Prepare and examine metallographic samples

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 Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to analyse metallurgical failures of engineering components. 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:

Correctly diagnose the mode of failure of selected cases

recommend appropriate preventative measures

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 operating plant or equipment that allows for appropriate and realistic simulation. 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:

interpret and follow procedures

identify inspection areas

conduct visual inspections

identify discontinuities and defects

select and use appropriate testing techniques, procedures and equipment

assess risk

perform measurements needed to meet the requirements of this unit

undertake root cause analysis

locate, read and interpret information on written job instructions, specifications, drawings, charts, lists and other reference documentation

plan, sequence operations

Required knowledge:

Competency includes sufficient knowledge of:

cleaning and preparation processes for a range of test surfaces

procedure, statutory and OH&S requirements in relation to the preparation process

established assessment procedures and techniques

testing techniques and procedures for a range of situations

tools, equipment, techniques

hazards and safety requirements associated with testing

maintenance and storage procedures for test equipment

common faults and damage

range of defects

meaning and application of national and international codes and standards

methods/procedures for reporting test results

implications of test results for the particular material/application

any applicable industry standards, national/australian standards, nohsc guides, state/territory regulatory codes of practice/standards

use and application of personal protective equipment

safe work practices and procedures

relevant hazards and control measures related to the competency

Types of discontinuities and their consequences/effect on the material including:

Plastic Deformation

elastic and plastic strain, dislocations, pile-up and interaction.

work hardening.

changes in strength, ductility, yield point, hardness, conductivity, corrosion resistance.

Annealing

dislocation movement and realignment during heating

recovery. nucleation of strain free areas. recrystallisation. grain growth.

accompanying changes in mechanical and physical properties listed above.

Hot&Cold Working

changes in deformation mechanism with rising heat input

the effects of strain rate and temperature on work hardening.

recrystallisation and dynamic recovery.

resulting microstructure and properties.

Ductile and Brittle Fracture

crack theory, mechanism of fracture

factors affecting fracture modes, Brittle fracture, Ductile fracture

Fatigue

mechanism of fatigue crack nucleation

mechanism of fatigue crack growth

engineering considerations of fatigue, metallurgical factors affecting fatigue

Creep

creep mechanisms

metallurgical factors affecting creep

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.

Preparation processes

Surface cleaning ,drying, preservation of fracture surfaces

Obvious flaws

Observed changes in material homogeneity

Most appropriate tests

collection of background data and selection of samples

preliminary examination of the failed part

non-destructive testing

mechanical testing

section, preservation and cleaning of fracture surfaces

microscopic and microscopic preparation of metallographic sections

SEM evaluation for fracture mode

EDS for chemical inconsistancies

determination of fracture type and failure origin

chemical analysis

application of fracture mechanics

simulated service testing

analysing the evidence

formulating conclusions and writing the report

Reported

Accurate identification of cause of failure and recommendation of preventative measures

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
Inspection areas are identified, cleaned and prepared for testing using appropriate procedures and materials. 
Preparation processes are carried out in accordance with the relevant procedures, statutory and OH&S requirements. 
Inspection areas are visually assessed and any defects identified. 
The most appropriate test for the material/application is selected. 
Test equipment is selected and prepared in accordance with standards and/or procedures. 
Test equipment is checked for defects, maintained and stored in accordance with procedures, OH&S requirements and manufacturer instructions. 
Indications are assessed and defects are detected and classified in accordance with national and international codes and standards. 
Defects are confirmed in accordance with enterprise procedures and industry practices. 
Test results are reported in accordance with enterprise procedures, accepted industry practices and customer service requirements. 
Recommendations are made to prevent future failures. 

Forms

Assessment Cover Sheet

MSATCM515A - Analyse metallurgical failures of components and recommend preventative measures
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

MSATCM515A - Analyse metallurgical failures of components and recommend preventative measures

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: