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Follow the links below to find material targeted to the unit's elements, performance criteria, required skills and knowledge

Elements and Performance Criteria

1. Identify specifications for required casting
   • Identify required material specification
   • Identify mould requirements
   • Identify any special requirements for this job
2. Verify metal charges to melting
   • 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
3. Monitor furnace operation
   • 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
4. Monitor pouring of molten metal
   • 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
5. Control hazards
   • 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.

Required Skills

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 SG and malleable cast irons Ferrous alloys definitions iron steel physical properties density tensile hardness melting points shrinkage percent casting temperature SG iron ductile iron carbon steel grey and white irons alloy cast irons alloys steels chilled and malleable iron selection customer requirements manufacturers 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 clothinggear dry area preheat ladles overhead cranes Furnace operation personal clothinggear dry chargeequipment preheating 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 tappingpouring

Evidence Required

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 studiesscenarios 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

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Range Statement

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.

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