MEM48002 — Monitor ferrous melting and casting processes

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What an assessment for MEM48002 must cover

42 assessable components: 6 elements (20 performance criteria), 6 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 work information

2 Identify specifications for required casting

2.1Identify required material specification
2.2Identify mould requirements
2.3Identify any special appropriate requirements

3 Verify metal changes to melting

3.1Select required components to give the required metal specification
3.2Calculate required charge of each component
3.3Recommend changes or additions to the charge
3.4Monitor the preparation of the charge including checking for contaminants

4 Monitor furnace operation

4.1Check that the furnace is in good operational condition and that appropriate lining is present
4.2Identify need for maintenance and/or repairs and organise accordingly
4.3Monitor a melt to ensure the product meets specification

5 Monitor pouring of molten metal

5.1Check that the ladle is in good operational condition and that appropriate lining is present
5.2Check pouring is to procedures
5.3Take required samples for analysis

6 Control hazards

6.1Identify hazards in the metal melting and pouring process
6.2Assess the risks arising from those hazards
6.3Implement procedures to control those hazards in line with procedures and duty of care

Performance evidence

following work instructions, standard operating procedures (SOPs) and safe work practices
identifying and interpreting specifications, safety procedures, codes of practice and/or standards for the required melting and casting processes
calculating charges
checking for contaminates when verifying metal changes to melting criteria on at least two occasions and recommending changes or additions to the charge
performing visual checking of furnaces criteria on at least two occasions for operational condition and safety risks
taking samples on at least two occasions for analysis in accordance with work health and safety (WHS) and quality procedures.

Knowledge evidence

safe work practices and procedures and use of personal protective equipment (PPE)
charge calculations including importance of composition control, methods used to calculate for additions and types of alloy additions
steel including induction furnace melting (principles and refractories), arc furnace melting, acid, basic, single slag, double slag, deoxidisation and hydrogen control and ladle refining
cast iron including 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 inoculants, spheroidal graphite formation and treatment methods and casting characteristics of grey, SG (ductile) and malleable cast irons
ferrous alloys including definitions of iron and steel and their physical properties including density, tensile, hardness, melting points, shrinking percentage, casting temperature, SG (ductile) iron, carbon steel, grey and white irons, alloy cast irons, alloy steels, chilled and malleable iron
selection including customer and manufacturer’s requirements, metal analysis and Australian Standards
types of furnaces and maintenance including blast furnace, cupola, induction, direct arc, indirect arc, open hearth, reverberatory and rotary
refractories including dolomite, silica brick, chrome brick, ganister, fireclay, firebrick, magnesite, kyanite and fused alumina
linings including monolithic, castable, rammable, bricks, basic, acid and neutral
ladles including types (lip, tea pot and bottom pour), maintenance and safe working practices
safety including housekeeping, PPE, dry area, pre-heating of ladles and overhead cranes
furnace operation procedures including PPE, dry charging equipment, pre-heating, scrap selection, housekeeping, melting and alloying program, calculations including percentages and ratio, charge calculations and maintenance
types of control equipment including carbon equivalent, wedge test, fluidity spiral test, chemical analysis, wet chemical analysis, spectrograph, sample spoons, sample moulds, deoxidising, degassing and temperature measurement
quality control including accurate weighing, correct chemical analysis, temperature control, slag control (including chemistry and interaction with molten bath), alloying procedure, thermal analysis, degassing and deoxidising
types of defects including contamination, gas absorption, metal analysis, temperature control and oxidation
alloy production including charge analysis, charge calculation, charge preparation, melt control, tapping and pouring.

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 MEM48002

What does an assessment tool for MEM48002 need to cover?

To satisfy the Principles of Assessment and Rules of Evidence, an assessment for MEM48002 needs to address all 42 unit components: 6 elements with 20 performance criteria, 6 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 MEM48002?

Auditori pulls the current release of MEM48002 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 MEM48002 — with no card and no subscription required. After that it's pay-as-you-go per unit.

Can I check my existing MEM48002 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 MEM48002, showing exactly what's covered and what's missing. Mapping costs a quarter of a credit.

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