Required skills

Required skills include

applying scientific principles to foundry mould design

examining mould designs using basic metallurgical skills and techniques to suit specific applications

calculating mould runner and feeding systems

selecting appropriate techniques and associated software and hardware technologies to suit specific applications in foundry mould design

presenting methoding solution and any associated limitations to mould design referring to the original aim of the application and any relevant instructions from metallurgist

Required knowledge

Required knowledge includes

ability to perform calculations related to methoding and feeding including

measuring dimensions of runner systems

calculating crosssectional areas of sprue runners and ingates

volumes and dimensions of feeders

the effects on solidification of

nucleation

growth mechanisms crystal and interfacial

dendrite coherency

constitutional undercooling

superheat effects control and minimisation of excess heat

eutectic and peritectic solidification

grain structure

the principles underpinning the effective operation of running gating and feeding systems including

runner and gating principles ratios

determining type and placement of sprue runners and ingates

inclusion control slag and erosion

calculations and effect of metal flow lamellar and turbulent velocity and temperature

calculation of feeder size

principles used in the determination of the location of feeders end and feed zones neighbourhood effect and feeding distances including effect on solidification

exothermic and insulating feeding aids sleeves and topping

feeding mechanisms liquid mass interdendritic burst and solid

use of computer packages runner and feeder calculations and mould simulations including benefits and limitations

yield calculations

risk management strategies to minimise defect formation and the methods for minimising

shrinkage

porosity

segregation

hot tearing

shear

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package

Overview of assessment

Evidence should be provided from the evaluation of a number of moulds Evidence must be provided of manual calculations and compared to computer program results

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

Assessors should ensure that candidates can competently and consistently

calculate manually and by use of computer programs runner and feeding systems for casting designs within defined design parameters

examine mould designs for suitability against job specifications

understand the interplay between moulds cores gating and feeding

examine the resulting casting for success of gating and feeding

compare casting results with computer simulated predictions

Context of and specific resources for assessment

Assessment may occur on the job or in an appropriately simulated environment Access is required to real or appropriately simulated situations including work areas materials and equipment and to information on workplace practices and OHS practices

Where applicable reasonable adjustment must be made to work environments and training situations to accommodate ethnicity age gender demographics and disability

Access must be provided to appropriate learning andor assessment support when required Where applicable physical resources should include equipment modified for people with disabilities

Method of assessment

Assessment must satisfy the endorsed assessment guidelines of the MEM Metal and Engineering Training Package

Assessment must satisfy the endorsed assessment guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance over time and in a range of workplace relevant contexts together with application of underpinning knowledge

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure its correct interpretation and application

Assessment may be applied under project related conditions real or simulated and require evidence of process

Assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance but is able to be transferred to other circumstances

Assessment may be in conjunction with assessment of other units of competency where required

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed

Codes of practice/standards

Size and number of feeder heads and gating