Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

AURTTM003 Mapping and Delivery Guide
Apply metal to rebuild engine components

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency AURTTM003 - Apply metal to rebuild engine components
Description
Employability Skills
Learning Outcomes and Application This unit describes the performance outcomes required to apply metal spray and hard chrome and weld materials, and perform the necessary machining to rebuild engine components. It involves preparing for the task, determining repair requirements, rebuilding engine components, bearing tunnels and connecting rods in engines, and completing workplace processes and documentation.It applies to those working in the automotive service and repair industry. The engine components include those in vehicles from all sectors of the industry.No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

Assessors must satisfy NVR/AQTF assessor requirements.

Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.

Assessment must include direct observation of tasks.

Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the engine components that they have worked on, e.g. repair orders.

Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.

The following resources must be made available:

automotive repair workplace or simulated workplace

workplace instructions

manufacturer engine specifications

multi-cylinder crankshafts, camshafts, and engine cylinder heads specified in the performance evidence

hand, air and power tools, welding equipment and materials for rebuilding engine components

precision measuring equipment, including:

dial indicators

inside and outside metric and imperial micrometers.
Prerequisites/co-requisites
Competency Field Mechanical Miscellaneous
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Prepare to undertake metal building procedures
  • Job requirements are determined from workplace instructions
  • Information is sourced, procedures and methods are analysed, and appropriate tools are selected for rebuilding engine components
  • Tools and measuring equipment are selected and checked for serviceability
  • Hazards associated with the work are identified and risks are managed
  • Engine component is prepared for appropriate metal application method according to workplace procedures and safety and environmental requirements
       
Element: Apply metal to engine component
  • Metal application process is used to rebuild damaged engine component according to workplace procedures and safety requirements, and following machinery safe operating procedures
  • Engine component is measured to ensure compliance with specifications
  • Metal application process is completed in readiness for further repair according to workplace procedures and safety requirements, and following machinery safe operating procedures
       
Element: Perform necessary machining to rebuild component
  • Machining is carried out according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
  • Component is measured to ensure compliance with manufacturer specifications
  • Machining operations are completed according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and following machinery safe operating procedures
       
Element: Complete rebuild processes
  • Component surfaces are finished to manufacturer specifications and within allowable tolerances according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
  • Final inspection is made to ensure finished work complies with workplace requirements
  • Bright surfaces are treated with rust prevention solution and engine component is prepared for further process or storage according to workplace procedures
  • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
  • Workplace documentation is processed according to workplace procedures
       
Element: Prepare to undertake metal building procedures
  • Job requirements are determined from workplace instructions
  • Information is sourced, procedures and methods are analysed, and appropriate tools are selected for rebuilding engine components
  • Tools and measuring equipment are selected and checked for serviceability
  • Hazards associated with the work are identified and risks are managed
  • Engine component is prepared for appropriate metal application method according to workplace procedures and safety and environmental requirements
       
Element: Apply metal to engine component
  • Metal application process is used to rebuild damaged engine component according to workplace procedures and safety requirements, and following machinery safe operating procedures
  • Engine component is measured to ensure compliance with specifications
  • Metal application process is completed in readiness for further repair according to workplace procedures and safety requirements, and following machinery safe operating procedures
       
Element: Perform necessary machining to rebuild component
  • Machining is carried out according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
  • Component is measured to ensure compliance with manufacturer specifications
  • Machining operations are completed according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and following machinery safe operating procedures
       
Element: Complete rebuild processes
  • Component surfaces are finished to manufacturer specifications and within allowable tolerances according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
  • Final inspection is made to ensure finished work complies with workplace requirements
  • Bright surfaces are treated with rust prevention solution and engine component is prepared for further process or storage according to workplace procedures
  • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
  • Workplace documentation is processed according to workplace procedures
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements

Elements describe the essential outcomes.

Performance Criteria

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.

1. Prepare to undertake metal building procedures

1.1 Job requirements are determined from workplace instructions

1.2 Information is sourced, procedures and methods are analysed, and appropriate tools are selected for rebuilding engine components

1.3 Tools and measuring equipment are selected and checked for serviceability

1.4 Hazards associated with the work are identified and risks are managed

1.5 Engine component is prepared for appropriate metal application method according to workplace procedures and safety and environmental requirements

2. Apply metal to engine component

2.1 Metal application process is used to rebuild damaged engine component according to workplace procedures and safety requirements, and following machinery safe operating procedures

2.2 Engine component is measured to ensure compliance with specifications

2.3 Metal application process is completed in readiness for further repair according to workplace procedures and safety requirements, and following machinery safe operating procedures

3. Perform necessary machining to rebuild component

3.1 Machining is carried out according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures

3.2 Component is measured to ensure compliance with manufacturer specifications

3.3 Machining operations are completed according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and following machinery safe operating procedures

4. Complete rebuild processes

4.1 Component surfaces are finished to manufacturer specifications and within allowable tolerances according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures

4.2 Final inspection is made to ensure finished work complies with workplace requirements

4.3 Bright surfaces are treated with rust prevention solution and engine component is prepared for further process or storage according to workplace procedures

4.4 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

4.5 Workplace documentation is processed according to workplace procedures

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

repair a cast iron cylinder head

repair a crack in an aluminium alloy cylinder head

build up camshaft lobes or journals by welding, metal spraying and hard chroming, and machine to specifications

build up crankshaft journals or thrust surfaces or bearing faces by welding, metal spraying and hard chroming, and machine to specifications.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to applying metal to rebuild engine components, including procedures for :

selecting and using personal protective equipment (PPE)

safely operating welding, metal spraying and hard chroming machinery

environmental requirements, including procedures for trapping, storing and disposing of cooling and lubricating fluids released during the machining process

procedures for identifying existing heat treatment processes, including nitriding, Tufftriding and induction hardening

specific welding procedures, including:

manual metal arc welding (MMAW)

gas metal arc welding (GMAW)

gas tungsten arc welding (GTAW)

flux core

metal spraying

submerged arc

procedures for hard chrome application

repair operations for components, including:

crankshaft journals

camshaft journals and lobes

seal areas

crankshaft nose and keyway

pulley retaining thread damage

crankshaft radius treatment, including:

shot peening

radius rolling

deep fillet radius rolling

requirements of Australian standards relevant to engine reconditioning, including:

AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines

AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines

post-repair operations, including rust protection of machined surfaces.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

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.

Elements

Elements describe the essential outcomes.

Performance Criteria

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.

1. Prepare to undertake metal building procedures

1.1 Job requirements are determined from workplace instructions

1.2 Information is sourced, procedures and methods are analysed, and appropriate tools are selected for rebuilding engine components

1.3 Tools and measuring equipment are selected and checked for serviceability

1.4 Hazards associated with the work are identified and risks are managed

1.5 Engine component is prepared for appropriate metal application method according to workplace procedures and safety and environmental requirements

2. Apply metal to engine component

2.1 Metal application process is used to rebuild damaged engine component according to workplace procedures and safety requirements, and following machinery safe operating procedures

2.2 Engine component is measured to ensure compliance with specifications

2.3 Metal application process is completed in readiness for further repair according to workplace procedures and safety requirements, and following machinery safe operating procedures

3. Perform necessary machining to rebuild component

3.1 Machining is carried out according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures

3.2 Component is measured to ensure compliance with manufacturer specifications

3.3 Machining operations are completed according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and following machinery safe operating procedures

4. Complete rebuild processes

4.1 Component surfaces are finished to manufacturer specifications and within allowable tolerances according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures

4.2 Final inspection is made to ensure finished work complies with workplace requirements

4.3 Bright surfaces are treated with rust prevention solution and engine component is prepared for further process or storage according to workplace procedures

4.4 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

4.5 Workplace documentation is processed according to workplace procedures

This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.

Measuring equipment must include:

dial indicators

inside and outside metric and imperial micrometers.

Safety and environmental requirements must include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures:

selecting and using personal protective equipment (PPE)

safely operating welding, metal spraying and hard chroming machinery

environmental requirements, including procedures for trapping, storing and disposing of cooling and lubricating fluids released during the machining process.

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

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Job requirements are determined from workplace instructions 
Information is sourced, procedures and methods are analysed, and appropriate tools are selected for rebuilding engine components 
Tools and measuring equipment are selected and checked for serviceability 
Hazards associated with the work are identified and risks are managed 
Engine component is prepared for appropriate metal application method according to workplace procedures and safety and environmental requirements 
Metal application process is used to rebuild damaged engine component according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Engine component is measured to ensure compliance with specifications 
Metal application process is completed in readiness for further repair according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Machining is carried out according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures 
Component is measured to ensure compliance with manufacturer specifications 
Machining operations are completed according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and following machinery safe operating procedures 
Component surfaces are finished to manufacturer specifications and within allowable tolerances according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures 
Final inspection is made to ensure finished work complies with workplace requirements 
Bright surfaces are treated with rust prevention solution and engine component is prepared for further process or storage according to workplace procedures 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Workplace documentation is processed according to workplace procedures 
Job requirements are determined from workplace instructions 
Information is sourced, procedures and methods are analysed, and appropriate tools are selected for rebuilding engine components 
Tools and measuring equipment are selected and checked for serviceability 
Hazards associated with the work are identified and risks are managed 
Engine component is prepared for appropriate metal application method according to workplace procedures and safety and environmental requirements 
Metal application process is used to rebuild damaged engine component according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Engine component is measured to ensure compliance with specifications 
Metal application process is completed in readiness for further repair according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Machining is carried out according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures 
Component is measured to ensure compliance with manufacturer specifications 
Machining operations are completed according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and following machinery safe operating procedures 
Component surfaces are finished to manufacturer specifications and within allowable tolerances according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures 
Final inspection is made to ensure finished work complies with workplace requirements 
Bright surfaces are treated with rust prevention solution and engine component is prepared for further process or storage according to workplace procedures 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Workplace documentation is processed according to workplace procedures 

Forms

Assessment Cover Sheet

AURTTM003 - Apply metal to rebuild engine components
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

AURTTM003 - Apply metal to rebuild engine components

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: