In a typical scenario, a technician will be required to monitor a ferrous melting and casting operation, ensuring that correct quantities and temperatures are used and correct procedures followed.

Pre-requisite Units

ELEMENT

PERFORMANCE CRITERIA

1. Identify specifications for required casting

1.1. Identify required material specification

1.2. Identify mould requirements

1.3. Identify any special requirements for this job

2. Verify metal charges to melting

2.1. Select required components to give the required metal specification

2.2. Calculate required charge of each component

2.3. Recommend changes/additions to the charge

2.4. Monitor the preparation of the charge including checking for contaminants

3. Monitor furnace operation

3.1. Check that the furnace is in good operational condition and that appropriate lining is present

3.2. Organise for maintenance/repairs as required

3.3. Monitor a melt to ensure the product meets specification

4. Monitor pouring of molten metal

4.1. Check that the ladle is in good operational condition and that appropriate lining is present

4.2. Check pouring is to procedures

4.3. Take required samples for analysis

5. Control hazards

5.1. Identify hazards in the metal melting/pouring process

5.2. Assess the risks arising from those hazards

5.3. Implement procedures to control those hazards in line with procedures and duty of care.

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, S.G and malleable

cast irons.

Ferrous alloys:

definitions:

iron

steel

physical properties:

density

tensile

hardness

melting points

shrinkage percent

casting temperature

S.G. iron

ductile iron

carbon steel

grey and white irons

alloy cast irons

alloys steels

chilled and malleable iron

selection:

customer requirements

manufacturer's 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 clothing/gear

dry area

pre-heat ladles

overhead cranes

Furnace operation:

personal clothing/gear

dry charge/equipment

pre-heating

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

tapping/pouring

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 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.

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.

Unit Sector

Metallurgy

Competency Field

This unit contains employability skills.