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.
Application of knowledge of the materials, equipment and process sufficient to recognise material and equipment conditions which may lead to out of specification production. For example, excess resin will only add weight and weaken the finished product. Therefore care needs to be taken to ensure the correct resin to fibre ratio is used.
Knowledge of organization procedures, quality requirements at each stage, relevant regulatory requirements and the ability to implement them within appropriate time constraints and work standards.
Application of the knowledge of managing risks using the hierarchy of controls applied to construction of composite moulds. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.
Skill to identify the range of possible product faults.
Knowledge about appropriate resins includes:
polyester resin materials knowledge: basic ingredients and their functions; types and uses; grades; fillers; shelf life; storage and safety; cure process; exotherm graph; factors affecting the cure process; post curing
epoxy resin materials knowledge: uses; cure reaction; exotherm graph; effects of temperature; effects of hardener; advantages and disadvantages; safety precautions
vinylester resin materials knowledge: uses; cure reaction; catalyst/promoter systems, types and effects; advantages and disadvantages compared with other resins; safety precautions
dicyclopentadiene (DCPD) - filled resin system
catalysts and promoters materials knowledge: terminology;
types; grades; uses; storage and safety.
Knowledge about appropriate reinforcement materials includes:
basic characteristics and property differences of E Glass, S2 Glass, Carbon, Aramid;
formulations;
manufacturing terminology;
types of finish and binders;
common weights available;
resin to glass ratios;
glass content and comparative strength of the basic forms;
the effect of increasing fibre content on reducing thickness and flexural properties;
basic effect of proportion and direction of fibre orientation.
Knowledge as a basis for solving processing and material problems including:
characteristics of materials and behaviour in relation to heat, pressure, flow rates, resin to fibre ratios and outside air temperatures and conditions
impact of variations in raw materials and equipment operation in relation to final product
waste management and importance of non-conforming materials
key requirements of the product which impact on the mould construction
hazards of the materials and process and appropriate hazard control procedures.
Competence also includes the ability to:
plan own work, including predicting consequences and identifying improvements
maintain output and product quality using appropriate tools, controls and test information
identify and describe own role and role of others involved directly in the process or constructing composite moulds
identify factors which may affect product quality or production output and appropriate remedies
identify when assistance is required to solve problems.
Language, literacy and numeracy requirements
This competency requires the ability to communicate with a wide range of personnel and to interpret product specifications and mould requirements.
Numeracy is required to the level of determining required weights/volumes of materials in a resin mix for different circumstances (say using a data sheet), number of layers of impregnated matrix required to yield the required product laminate thickness, and similar activities.
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Add any 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.
Where reference is made to industry codes of practice and/or Australian/international standards, the latest version must be used.
Context
This competency unit includes the use of equipment and materials to form moulds for composite products.
Procedures
All operations are performed in accordance with procedures.
Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards. These may include:
construction of moulds
preparation of resins, including mixing as required
preparation of fibre reinforcement, including cutting and trimming
application of composite materials to the mould by hand lay up.
use of composites materials including gel coats, resins and fibres.
Tools and equipment
This competency includes use of equipment and tools such as:
plugs/patterns
hand tools and power tools for use with composite and other materials such as metal and timber
hand mixing equipment and stirrers
hand application tools, rollers
relevant personal protective equipment.
Hazards
Typical hazards include:
hand and power tools
temperature
hazardous materials and vapours
fire hazards due to flammable nature of resins used
manual handling hazards
knife hazards
equipment operations.
Problems
'Anticipate and solve problems' means resolve a wide range of routine and non-routine problems using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.
Typical process and product problems may include:
structural strength, rigidity and durability of the mould
dimensional accuracy of the mould
placement of flanges, closures and fitments
attachment of substructures.
wrong materials for the mould construction
incorrect fibre-to-resin ratios.
Appropriate action for problems outside of area of responsibility may be reporting to an appropriate person.
Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/sources.
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