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

MSATCM303A Mapping and Delivery Guide
Monitor non-ferrous melting and casting processes

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MSATCM303A - Monitor non-ferrous melting and casting processes
Description This unit covers the knowledge and skills needed to undertake the melting and casting of non-ferrous alloys
Employability Skills This unit contains employability skills.
Learning Outcomes and Application In a typical scenario, a technician will be required to monitor a non - ferrous melting and casting operation, ensuring that correct quantities are used and correct procedures followed.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Pre-requisite Units
Competency Field
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: Identify specifications for required casting
  • Identify required material specification
  • Identify mould requirements
  • Identify any special requirements for this job
       
Element: 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
       
Element: 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
       
Element: Monitor pouring of molten metal
  • Check pouring is to procedures
  • Take required samples for analysis
       
Element: 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
       


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.

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 non-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 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 non-ferrous casting is done. A bank of case studies/scenarios 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.

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.

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.

Non-ferrous 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

× manufacturer's

metal analysis

Australian standards

Types of furnaces

crucible

oil

gas

induction

channel

coreless

resistance

reverberatory

maintenance

Refractories

silica

ganister

coatings

others common to non-ferrous

Linings

monolithic

castable

rammable

bricks

Ladles/crucibles

types

ladles

crucibles

safety

maintenance

care of crucibles

porous plug

Safety

house keeping

personal

clothing

gear

dry area

pre-heat ladles

overhead cranes

Furnace operation

personal attire

dry charge

dry equipment

pre-heating

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

mould/metal reactions

thermal analysis

degassing

deoxidising

ladle refining

Defects

contamination

gas absorption

metal analysis

temperature control

oxidation

other defects common to non-ferrous metals

methods of avoiding/overcoming defects

Alloy production

charge

analysis

calculation

preparation

melt control

Tapping/pouring

pouring method sequenced

temperature check

capacity requirements

ladle/crucibles

checks

preparation

pre-heating

transfer

× safety clips

filling

metal maintenance

covers/fluxes

temperature

metal pouring

mould condition

test bar

× reasons

× method

pig pouring and tagging

ladle/crucible return

emptying

cleaning

maintaining

lubrication

-repairs to refractory

cleaning of refractory

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

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
Identify required material specification 
Identify mould requirements 
Identify any special requirements for this job 
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 
Check that the furnace is in good operational condition 
Organise for maintenance/repairs as required 
Monitor a melt to ensure the product meets specification 
Check pouring is to procedures 
Take required samples for analysis 
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 

Forms

Assessment Cover Sheet

MSATCM303A - Monitor non-ferrous melting and casting processes
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

MSATCM303A - Monitor non-ferrous melting and casting processes

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: