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Elements and Performance Criteria

1. Control hazards
   • Identify hazards in the sand/mould/core making process
   • Assess the risks arising from those hazards
   • Implement procedures to control those hazards in line with procedures and duty of care.
2. Select appropriate sand characteristics for job and process
   • Determine requirements of the casting
   • Identify types of sand appropriate for the type of mould/core
   • Identify types of binders appropriate for the job
   • Select sand/binder mix appropriate for the job
3. Prepare, test and evaluate moulding sand to desired characteristics
   • . Monitor preparation of bonded sand mix
   • Test materials prepared
   • Evaluate test results and report as appropriate
4. Evaluate finished casting for defects related to sand characteristics.
   • Examine casting for sand related defects such as wash, expansion, scabbing, rat-tails etc.
   • Determine cause of sand related defects
   • Recommend improvements to sand type and/or preparation
5. Report results
   • Identify reporting requirements
   • Prepare report to meet requirements
   • Circulate and file report to procedures

Required Skills

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 rattails 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 AFS standard compression sample moisture content clay content green compression green permeability mould hardness shatter index sieve analysis loss of ignition LOI AFS 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

Evidence Required

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 sandrelated 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 studiesscenarios 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

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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.
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

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