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Evidence Guide: MEM04002B - Perform gravity die casting

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

MEM04002B - Perform gravity die casting

What evidence can you provide to prove your understanding of each of the following citeria?

Prepare equipment

  1. Die coat is mixed in correct proportion.
  2. Die temperatures are lifted to, or maintained, at the correct level.
  3. Appropriate safety clothing and apparatus is used.
  4. Die coat is applied in correct sequence and in a safe manner according to standard operating procedures.
  5. Die is correctly located and closed.
  6. Die is correctly placed on machine, toggle clamps are attached and done up to required torque.
  7. Air cooling is attached to the die as specified if required.
Die coat is mixed in correct proportion.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Die temperatures are lifted to, or maintained, at the correct level.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Appropriate safety clothing and apparatus is used.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Die coat is applied in correct sequence and in a safe manner according to standard operating procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Die is correctly located and closed.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Die is correctly placed on machine, toggle clamps are attached and done up to required torque.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Air cooling is attached to the die as specified if required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out manual pouring

  1. Pour is made in manner to reduce porosity and lamination.
  2. Conditions are identified that contribute to inferior castings or rejects.
  3. Allowance is made for adequate cooling time.
  4. Pour is made at a continuous and appropriate rate during filling.
  5. Monitoring of die coating condition is carried out and re-spraying occurs as required.
Pour is made in manner to reduce porosity and lamination.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conditions are identified that contribute to inferior castings or rejects.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Allowance is made for adequate cooling time.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pour is made at a continuous and appropriate rate during filling.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitoring of die coating condition is carried out and re-spraying occurs as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove materials

  1. Parts are removed and stored in a manner that minimises damage. Any flash is removed from the die surface.
Parts are removed and stored in a manner that minimises damage. Any flash is removed from the die surface.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean die

  1. Shot blaster is operated in a safe manner and according to standard operating procedures.
  2. Chemical analysis of melt is taken and remedial action is applied as required to standard operating procedures.
  3. Furnace is drossed and/or degassed to standard operating procedures.
  4. Work area is cleaned of coating and shot residue to appropriate standard.
Shot blaster is operated in a safe manner and according to standard operating procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Chemical analysis of melt is taken and remedial action is applied as required to standard operating procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Furnace is drossed and/or degassed to standard operating procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Work area is cleaned of coating and shot residue to appropriate standard.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, 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 undertake gravity die casting. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both. Where assessment occurs off the job, i.e. the candidate is not in productive work, an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate.

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with gravity die casting or other units requiring the exercise of the skills and knowledge covered by this unit.

Method of assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

Required Skills and Knowledge

Required skills

Look for evidence that confirms skills in:

reading and interpreting routine information on written job instructions, specifications and standard operating procedures. May include drawings relating to gravity die casting

mixing of die coats in the correct proportions in accordance with standard operating procedures

maintaining of die at correct temperatures

pouring of molten metal

assessing correct curing times

applying die coats

removing of casting from die

operating shot blaster

using measurement skills needed to meet the requirements of this unit

entering routine and familiar information onto proforma and standard workplace forms

Required knowledge

Look for evidence that confirms knowledge of:

relevant written instructions

die coat function(s) in gravity die casting

correct proportions and consistency of die coats

correct identification of die coat materials

procedures for raising the temperature of the die to the correct level and maintaining the required temperature

procedures to be followed when pouring molten metal to produce sound castings

causes of defects in castings

curing times for castings of various volumes and materials

timing of die coat application and quantity of die coat to be used for different applications

correct procedures for removing castings from the die and storing of castings

die condition and need for shot blasting

shot blaster operating procedures

use and application of personal protective equipment

safe work practices and procedures

hazards and control measures associated with gravity die casting, including housekeeping

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.

Correct proportions

Will be determined by manufacturer specifications

Die temperatures

Will vary according to standard operating procedures and/or organisation's procedures

Appropriate safety clothing and apparatus

Aluminium Association safety status sheet recommendations, glasses, aluminised suits, masks, gloves, gauntlet, etc.