MEM07043 — Identify causes of faulty aluminium extrusions

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What an assessment for MEM07043 must cover

56 assessable components: 7 elements (32 performance criteria), 8 performance evidence and 16 knowledge evidence requirements. An audit-defensible tool maps every question and task back to these — that mapping is the coverage matrix Auditori generates alongside the assessment.

Elements & performance criteria

1 Determine job requirements

1.1Follow standard operating procedures (SOPs)
1.2Comply with work health and safety (WHS) requirements at all times
1.3Use appropriate personal protective equipment (PPE) in accordance with SOPs
1.4Identify job requirements from specifications, drawings, job sheets or work instructions

2 Collect information on faulty extrusion

2.1Liaise with extruder operator on die service or fault correction requests
2.2Access and examine die in accordance with procedures
2.3Examine extruder records and identify any previous die corrections
2.4Consult with die designer on faults, where required
2.5Examine extruder maintenance records and liaise with maintenance department

3 Interpret die drawing and specifications

3.1Identify layout and pre-forming of die apertures
3.2Identify bearing and pocket design/specification
3.3Identify measurements and tolerances for bearings, die components and die support system
3.4Identify bolster and spacer specification for die
3.5Identify press specifications
3.6Identify speed estimate for die
3.7Identify ports and bridges for hollow dies

4 Examine faulty extrusions

4.1Check extrusions for shape distortion
4.2Check extrusion measurements are to specification
4.3Inspect surface finish of extrusions for defects
4.4Identify whether faults apply from the start to the end of extrusion runouts
4.5Make a preliminary assessment as to whether faults are related to die or die support system or other factors

5 Check for faults not related to die or die support system

5.1Examine die and billet heating and temperature records and confirm heating and temperature was to specification
5.2Confirm extruder was run at correct speed and other settings were to specification
5.3Examine billet history and determine if billet was recycled or faulty
5.4Confirm with maintenance department that extruder is free of mechanical, electrical, control or structural faults

6 Identify die and die support related faults

6.1Access die and die support system
6.2Inspect die for overall wear, dishing, damage and other defects
6.3Inspect bearings for shortening, surface defects, loss of specified angle and clearances
6.4Determine if die can be corrected, scrapped or returned to manufacturer
6.5Inspect die support system and components for defects and die slide misalignment

7 Record cause of fault and communicate as required

7.1Prepare recommendations for die correction and obtain any required approvals
7.2Prepare recommendations for any changes to process or temperature settings and distribute, as appropriate

Performance evidence

following work instructions, standard operating procedures (SOPs) and safe work practices
complying with work health and safety (WHS), regulatory requirements and risk management procedures
identifying bearings, apertures, components, and critical measurements and tolerances on die drawing
liaising with extruder operators, die designers die makers and maintenance personnel to obtain information to assist in the identification of causes of faults
identifying root cause of faults in both hollow and solid die extrusions
identifying die, die support, process and temperature-related shape and surface faults
identifying appropriate action to take to remedy extrusion faults
accessing, analysing and adding to die history records.

Knowledge evidence

safe work practices and procedures and use of personal protective equipment (PPE)
die components in an extrusion machine: die, die support, container, support tooling, die holder, bolsters – single and split systems, die slide, tool stack, bearing, feeder plate, backer, platen plate
aluminium extrusion process, including: die heating, billet heating, loading of dies and billets, breakthrough control, flow speed, rolling, quenching, stretching
aluminium extrusion alloys and their extrusion performance
extruder components and controls
requirements of AS/NZS 1866:1997 Aluminium and aluminium alloys – Extruded rod, bar, solid and hollow shapes for extruded products
causes of die deformation, including: damaged or die, poor or incorrect die support due to: poor manufacture, wear, incorrect component placement/selection
die and die support design and die manufacturing related faults, including: tolerances and clearances too tight and beyond range of realistic correction by die corrector, tolerances and clearances too great causing components to move out of position during extrusion leading to flow blockage
reasons for die blockage, including: die damage, over polishing or incorrect die polishing, tongue bending, bearing clearances too tight, overheating of billet
indicators of die support faults, including: deflecting mandrels, die dishing, die movement during extrusion, check for metal extruding inwards or outwards
effects of nitriding and re-nitriding on die performance
billet composition and billet heating procedures
changes in billet composition caused by re-heating
process related faults: incorrect temperature settings for pre-heating of billet, bad breakthrough control by operator (setting too fast or too high a pressure): poor extruder settings, speed through die too fast/slow, fouling of section on relief, unsuitable support of extrusion after exiting die, poor/incorrect quenching
faults not subject to action by die corrector: poor quality billet, mechanical/electrical fault with extruder
types of extrusion faults and their relationship to die correction techniques and die correction limitations, including: shape distortion: during extrusion, on exit from die, loss during quenching, length overruns, section collapse; surface faults including: breakdown, pickup, tearing, streaking, die lines.

Unit content sourced from training.gov.au — © Commonwealth of Australia, licensed under CC BY 4.0. Auditori is not affiliated with the Department of Employment and Workplace Relations.

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Questions about assessing MEM07043

What does an assessment tool for MEM07043 need to cover?

To satisfy the Principles of Assessment and Rules of Evidence, an assessment for MEM07043 needs to address all 56 unit components: 7 elements with 32 performance criteria, 8 performance evidence requirements, 16 knowledge evidence requirements, and the foundation skills. A coverage matrix mapping each question and task to these components is what an auditor looks for.

How does Auditori generate an assessment tool for MEM07043?

Auditori pulls the current release of MEM07043 from training.gov.au and generates a complete package: candidate assessment, assessor guide with model answers and observation criteria, and a coverage matrix mapping every component. A suitably qualified person then reviews and approves the draft in a built-in workflow — consistent with ASQA's guidance on AI use in VET — before export as branded PDF and editable Word.

Is the first assessment tool really free?

Yes. Every new account includes one free credit — enough to generate the complete assessment tool for MEM07043 — with no card and no subscription required. After that it's pay-as-you-go per unit.

Can I check my existing MEM07043 assessment instead of generating a new one?

Yes — upload your existing assessment or learner guide and Auditori maps it against every element, performance criterion, PE and KE of MEM07043, showing exactly what's covered and what's missing. Mapping costs a quarter of a credit.

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