In a typical scenario, a technician will be required to draw conclusions as to the appropriateness of mould/core design and sand type chosen, and make recommendations as to design of mould/cores and selection of sands.

Pre-requisite Units

ELEMENT

PERFORMANCE CRITERIA

1. Control hazards

1.1. Identify hazards in the sand/mould/core making process

1.2. Assess the risks arising from those hazards

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

2. Select appropriate sand characteristics for job and process

2.1. Determine requirements of the casting

2.2. Identify types of sand appropriate for the type of mould/core

2.3. Identify types of binders appropriate for the job

2.4. Select sand/binder mix appropriate for the job

3. Prepare, test and evaluate moulding sand to desired characteristics

3.1. . Monitor preparation of bonded sand mix

3.2. Test materials prepared

3.3. Evaluate test results and report as appropriate

4. Evaluate finished casting for defects related to sand characteristics.

4.1. Examine casting for sand related defects such as wash, expansion, scabbing, rat-tails etc.

4.2. Determine cause of sand related defects

4.3. Recommend improvements to sand type and/or preparation

5. Report results

5.1. Identify reporting requirements

5.2. Prepare report to meet requirements

5.3. Circulate and file report to procedures

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

Required skills:

take samples

prepare standard samples

use test equipment

use and calibrate mixing machines

Required knowledge:

Competency includes sufficient knowledge of:

Sources of sands and their characteristics

green sand, resin and silicate bond moulds , shell moulds

relationship of moulding sand properties and characteristics to casting defects.

expansion, scabbing, rat-tails, hardness.

sand grain shape and distribution, permeability, gas evolution, blow holes.

mould properties, green strength, shatter.

refractoriness

mould dilation

definition of clay bonded sand

testing clay bonded sand

A.F.S. standard compression sample

moisture content

clay content

green compression

green permeability

mould hardness

shatter index

sieve analysis

loss of ignition (LOI)

A.F.S. fineness number

other tests as appropriate

organic and inorganic bonded and core sands

drying oils: stoving, characteristics

cold setting oils: characteristics

synthetic resins, characteristics and applications

shell moulding

sodium silicate binders, characteristics

phenolic urethanes

furfuryl alcohol

phenolic esters

alkaline phenolics

testing hardened sands: tensile

compression hardness

choice of binder.

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 and test sands, cores and moulds. 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:

Prepare and test sand samples

Monitor and interpret results

Apply corrections to the sand system as dictated by the sand testing results

Relate sand-related casting defects to sand properties and recommend corrective actions

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

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 using sand casting. 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.

Hazards

Hazards to be identified by standard techniques such as Material Safety Data Sheets (MSDS) and controlled according to the hierarchy of control.

Mould/core

Mould/core means sand mould/core

Bonded

Bonding materials for sand include clay, organic and inorganic binders

Unit Sector

Metallurgy

This unit contains employability skills.