Required skills

Required skills include

taking calculations needed for determining charges

performing visual checks of furnaces for operational condition and safety risks

taking samples

following safety and quality procedures

Required knowledge

Required knowledge includes

charge calculations

importance of composition control

methods used to calculate for additions

types of alloy additions and their effects on casting behaviour and finished product

steel

induction furnace melting principles refractories suitable for steelmaking and their characteristics

arc furnace melting acid basic single slag double slag deoxidisation and hydrogen control

ladle refining

cast iron

types of cast iron

influence of carbon and silicon contents

carbon equivalent

effect of cooling rate

microstructure and classification of graphite

carbide stabilisers and graphite

inoculation and types of innoculant

spheroidal graphite formation and treatment methods

casting characteristics of grey SG ductile and malleable cast irons

ferrous alloys

definitions of ferrous metals

the grades of iron and their applications including SG iron ductile iron grey and white irons alloy cast irons chilled and malleable iron

the grades of steel and their applications including carbon steel and alloys steels

methods of controlling physical properties

advantagesdisadvantages of density of each type of ferrous metal

methods of controlling tensile strength of ferrous metals

methods of controlling the hardness of ferrous metals

the influence of melting points on production processes

the shrinkage percentage of the types of ferrous metals

how to control metal fluidity

the use of degassing to control gas defects

be able to take action to control grain size

casting temperature

make a selection of ferrous metal based on required properties

conduct metal analysis on ferrous metal

use Australian standards or other appropriate standard for ferrous metals

types of furnaces and their relative advantages and disadvantages

blast furnace

cupola

induction

direct arc

indirect arc

open hearth

reverberatory

rotary

maintenance

refractory types and purposes including

dolomite

silica brick

chrome brick

ganister

fireclay

firebrick

magnesite

kyanite

fused alumina

linings types and purposes including

monolithic

castable

rammable

bricks

basic

acid

neutral

types of ladles

lip

tea pot

bottom pour

safe working with ladles

preheat ladles

ladle maintenance

check mechanical condition of ladles including gearboxes and safety locks

use of lifting and handling equipment including

tongs

shanks

cranes

hoists

bogey ladles

maintenance

supervision of other staff in melting and casting safety including

housekeeping

personal protective clothing

dry area and tools

preheating of ladles

safe working load of overhead cranes

furnace operation procedures including

ensuring a dry and safe charge

warm and dry equipment

preheating

scrap selection

housekeeping

melting schedule

pouring schedule

calculations including volume and mass calculations

charge calculations

maintaining supply

maintenance of melting and pouring equipment

types of control equipment

thermal analysis

pyrometers

gas analysis

chemical analysis

wet chemical analysis

spectrograph

fluidity test

quality control and procedures for

accurate weighing

correct chemical analysis

covers and fluxes

mouldmetal reactions

conduct and interpretation of thermal analysis

alloying procedure

thermal analysis

degassing

deoxidising

ladle refining

chillwedge test

customer requirements

types of defects and prevention including but not limited to

contamination

gas absorption

metal analysis

temperature control

oxidation

other defects common to iron and steel

tapping and pouring operations including

when to pour according to job and furnace specification

availability of emergency pour out pits and other safety equipment

availability of cranes or other transport

pour out rate

ensure mechanical test bar is available and taken if required

ensure pig pouring and tagging is performed correctly

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

Evidence should be provided from a number of castings using different alloys andor different moulds

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

Assessors should ensure that candidates can competently and consistently

monitor the melting and casting of ferrous metal

safely operate a melting furnace and monitor and supervise the operation of a furnace by other employees

safely handle pouring equipment and monitor and supervise the operation of pouring equipment by other employees

Context of and specific resources for assessment

Assessment may occur on the job or in an appropriately simulated environment Access is required to real or appropriately simulated situations including work areas materials and equipment and to information on workplace practices and OHS practices

Where applicable reasonable adjustment must be made to work environments and training situations to accommodate ethnicity age gender demographics and disability

Access must be provided to appropriate learning andor assessment support when required Where applicable physical resources should include equipment modified for people with disabilities

Method of assessment

Assessment must satisfy the endorsed assessment guidelines of the MEM Metal and Engineering Training Package

Assessment must satisfy the endorsed assessment guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance over time and in a range of workplace relevant contexts together with application of underpinning knowledge

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure its correct interpretation and application

Assessment may be applied under project related conditions real or simulated and require evidence of process

Assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance but is able to be transferred to other circumstances

Assessment may be in conjunction with assessment of other units of competency where required

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed

Codes of practice/standards

Contaminants

Material specification