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Elements and Performance Criteria

1. Demonstrate basic knowledge of casting processes
   • Identify the major areas and activities of foundry work including melting, casting, heat treatment, pattern and mould making, finishing and despatch
   • Identify the major items of equipment and their purpose in each foundry area
   • Describe the most common metals and alloys used in casting processes
   • Describe in the correct order the flow of metal through the foundry
2. Demonstrate knowledge of foundry terminology
   • Correct names are used for foundry processes and equipment
   • Metals and alloys are properly identified including their chemical composition
3. Identify basic understanding of commercial aspects of foundry operations
   • Major advantages and disadvantages of casting over other metal manufacturing processes are identified
   • Key cost factors are identified including energy, material, labour
   • A basic understanding of OHS and environmental obligations of foundries is demonstrated

Required Skills

This describes the essential skills and knowledge and their level required for this unit

Required skills

Explain basic metal casting processes Identify basic items of casting equipment Identify product flow through a foundry or other casting operation Analyse mould materials and casting processes Identify casting defects Identify and control hazards

Required knowledge

Competency includes sufficient knowledge of Classification of casting processes Sand casting investment casting die casting lost foam vacuum process and protective atmospheres ingot casting Preparation of a mould types of mould shell moulds dies pattern types materials construction design raw materials sand bonds other additives sand moulding processes manual moulding machine moulding moulding equipment machines and applications safety around machinery cores basic coremaking procedures equipmentampmachines mould assembly and handling ancillary equipment sand handling mould handling and processing Preparation of molten alloys ferrous alloys cast irons white grey malleable and SG cast irons cast steels carbon steels and alloy steels nonferrous alloys cast aluminium alloys AlSi alloys cast copper magnesium titanium and zinc alloys Melting type of furnaces with applications electricarc furnace induction furnace structure and melting principles Pouring pouring and molten metal safety pouring equipment running and gating systems solidification process including grain growth effects of super heat mould geometry chill feeding risers outline of basic principles Cleaning of castings shakeout cleaning room practices methods and equipment removing the mould materials removing gate and risers finish cleaning Inspection of castings visual examination magnetic penetrant methods radiographic ultrasonic methods chemical metallographic mechanical testing Repair of casting aligning welding filling

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 demonstrate basic knowledge of casting operations 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 identify casting processes and equipment Demonstrate knowledge of casting principles and practices Evidence should be provided that knowledge can be applied to a number of castings using different alloys and or different moulds
Relationship to other units	This unit may be assessed concurrently with other relevant metallurgy 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 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 or 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.
Casting processes	Includes melting, pouring, casting, patternmaking, mould preparation including sand moulds, dies, metal moulds, lost wax and lost foam casting, heat treatment, finishing, despatch and testing
Equipment	Includes equipment associated with the processes listed above

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