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Evidence Guide: MSATCM303A - Monitor non-ferrous melting and casting processes

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

 

MSATCM303A - Monitor non-ferrous melting and casting processes

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

Identify specifications for required casting

  1. Identify required material specification
  2. Identify mould requirements
  3. Identify any special requirements for this job
Identify required material specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify mould requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify any special requirements for this job

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Verify metal charges to melting

  1. Calculate required charge of each component
  2. Select required components to give the required metal specification
  3. Recommend changes/additions to the charge
  4. Monitor the preparation of the charge including checking for contaminants
Calculate required charge of each component

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select required components to give the required metal specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recommend changes/additions to the charge

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor the preparation of the charge including checking for contaminants

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor furnace operation

  1. Check that the furnace is in good operational condition
  2. Organise for maintenance/repairs as required
  3. Monitor a melt to ensure the product meets specification
Check that the furnace is in good operational condition

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Organise for maintenance/repairs as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor a melt to ensure the product meets specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor pouring of molten metal

  1. Check pouring is to procedures
  2. Take required samples for analysis
Check pouring is to procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take required samples for analysis

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control hazards

  1. Identify hazards in the metal melting/pouring process
  2. Assess the risks arising from those hazards
  3. Implement procedures to control those hazards in line with procedures and duty of care
Identify hazards in the metal melting/pouring process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess the risks arising from those hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

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, 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.

Required Skills and Knowledge

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

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.

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