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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
   • Calculate required charge of each component
   • Select required components to give the required metal specification
   • 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
   • Organise for maintenance/repairs as required
   • Monitor a melt to ensure the product meets specification
4. Monitor pouring of molten metal
   • 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 visually check furnaces for operational condition and safety risks take 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 Nonferrous alloys definition physical properties density tensile hardness melting points shrinkage percentage fluidity brass bronze gunmetal copper based alloys aluminium based alloys lead selection requirements customer manufacturers metal analysis Australian standards Types of furnaces crucible oil gas induction channel coreless resistance reverberatory maintenance Refractories silica ganister coatings others common to nonferrous Linings monolithic castable rammable bricks Ladlescrucibles types ladles crucibles safety maintenance care of crucibles porous plug Safety house keeping personal clothing gear dry area preheat ladles overhead cranes Furnace operation personal attire dry charge dry equipment preheating scrap selection house keeping melting program alloying program charge calculations percentages ratio and proportion calculations volume mass operation maintenance Lifting and handling equipment tongs shanks cranes hoists bogey ladles maintenance Types of control equipment thermal analysis pyrometers gas analysis chemical analysis wet dry spectrograph fluidity shrinkage test Quality control accurate weighing correct analysis temperature control covers and fluxes mouldmetal reactions thermal analysis degassing deoxidising ladle refining Defects contamination gas absorption metal analysis temperature control oxidation other defects common to nonferrous metals methods of avoidingovercoming defects Alloy production charge analysis calculation preparation melt control Tappingpouring pouring method sequenced temperature check capacity requirements ladlecrucibles checks preparation preheating transfer safety clips filling metal maintenance coversfluxes temperature metal pouring mould condition test bar reasons method pig pouring and tagging ladlecrucible return emptying cleaning maintaining lubrication repairs to refractory cleaning of refractory

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 Training Package
Overview of assessment	A person who demonstrates competency in this unit must be able to monitor basic nonferrous 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 melting and casting operations 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 nonferrous 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.
Mould	Moulds are sand, die and investment moulds.
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 non-ferrous metals and non -ferrous alloys as well as contaminants

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