Weld using gas metal arc welding process. This assessment resource supports the unit of competency MEM05017 Weld using gas metal arc welding process.

Transcription

1 Weld using gas metal arc welding process This assessment resource supports the unit of competency MEM05017 Weld using gas metal arc welding process.

2 These materials were developed by Manufacturing Skills Australia. Manufacturing Skills Australia With the exception of any material protected by a trade mark and where otherwise noted, all material presented in this document is provided under a Creative Commons Attribution-No Derivative Works 3.0 Australia licence. Disclaimer This work is the result of consultations with Australian industry participants. It is a collaborative view and does not necessarily represent the view of Manufacturing Skills Australia or any specific body. For the sake of brevity it may omit factors which could be pertinent in particular cases. While care has been taken in the preparation of this material, Manufacturing Skills Australia and the original developer do not warrant that any licensing or registration requirements specified here are either complete or upto-date for your State or Territory. Manufacturing Skills Australia and the original developer do not accept any liability for any damage or loss (including indirect and consequential loss) incurred by any person as a result of relying on the information contained in this material. Manufacturing Skills Australia, does not accept any liability to any person for the information or advice (or the use of such information or advice) which is provided in this material or incorporated into it by reference. The information is provided on the basis that all persons accessing this material undertake responsibility for assessing the relevance and accuracy of its content. No liability is accepted for any information or services which may appear in any other format. No responsibility is taken for any information or services which may appear on any linked websites. Published by: Manufacturing Skills Australia Release Date: October 2010 For further information about this resource or any other work being undertaken by Manufacturing Skills Australia (MSA), please visit: Manufacturing Skills Australia Level 3, 104 Mount Street North Sydney NSW 2060 T: F: E: info@mskills.org.au W: Manufacturing Skills Australia Page 2

3 Overview This unit covers preparing materials, selecting and setting up gas metal arc welding equipment, carrying out the welding, visually inspecting welds and correcting defects. Welds are associated with heavy or light fabrication. Welds include fillet and butt welds in all positions on a range of materials that may include carbon steel or stainless steel or aluminium. Weld quality would typically conform to Australian Standard 1554 General Purpose, American Bureau of Shipping (ABS) or equivalent. All work and work practices must be undertaken to regulatory and legislative requirements. It is applicable in both a learning and assessment pathway and an assessment only pathway. This competence is performed in the context that all materials and equipment needed to carry out this function have been provided, including learning materials, learning programs and learning resources. Elements To achieve competency in this unit you must demonstrate your ability to: 1. Prepare materials for gas metal arc welding (GMAW); 2. Select welding components; 3. Assemble and set up welding equipment; 4. Minimise and rectify distortion; 5. Weld to job specification using GMAW; 6. Ensure weld conformance; and 7. Maintain weld records as required. Manufacturing Skills Australia Page 3

4 Pre requisite units of competence MEM05050 MEM05051 MEM05052 MEM12023 MEM18001 MEM18002 Perform routine gas metal arc welding Select welding processes Apply safe welding practices Perform engineering measurements Use hand tools Use power tools/hand held operations Assessment In order to found competent in this unit you must competently complete all of the following Assessment tasks: Method of Assessment Task 1 Task 2 Task 3 Task 4 Task 5 Written Short Answer Questions Practical Observation Report Third Party/Supervisor Report Indirect Evidence Note: There may be more assessment methods listed here than what is necessary to determine Competence. It is the individual RTO s decision to determine the methods that best suit their delivery arrangements and list them in their Training & Assessment Strategy in addition to removing those methods that are not required from this document. Assessment Mapping Element Performance Criteria Written Short answer questions Practical Observation Third Party Report 1 Prepare materials for gas metal arc welding (GMAW) 1.1 Weld requirements are identified from specifications and/or drawings 1.2 Material is correctly prepared 1.3 Materials are assembled / aligned to specification where required. Manufacturing Skills Australia Page 4

5 2 Select welding components and consumables 2.1 Welding machine settings, accessories and consumables are identified and selected 3 4 Assemble and set up welding equipment. Minimize and rectify distortion 3.1 Welding equipment is assembled and set up 4.1 Appropriate distortion prevention measures are selected and applied 4.2 Distortion is rectified 5 Weld to job specification using GMAW 5.1 Weld deposit is to specifications 5.2 Joints are cleaned to specifications 6 Ensure weld conformance Weld joints are visually inspected for conformance to specifications Defects are removed with minimum loss of sound metal using correct and appropriate techniques and tools 7 Maintain weld records as required 7.1 Weld records are completed correctly * * Required Skills and Knowledge Mapping Written Short answer questions Practical Observation Third Party Report Skills Identifying and interpreting welding specifications including appropriate standards e.g. Australian standard 1554 general purpose, american bureau of shipping (abs) or equivalent Selecting and using appropriate tools and equipment Using a variety of welding machines and electrodes Identifying and rectifying weld defects Applying techniques for distortion prevention and rectification Cleaning welds Reading and interpreting information on sketches, written job instructions, specifications, standard operating procedures and engineering drawings Manufacturing Skills Australia Page 5

6 Recording routine information including routine weld records related to GMAW onto proformas and standard workplace forms Following oral instructions Measurement skills relating to joint preparation and GMAW Knowledge Types of gases and their uses The relationships between amperage/wire feed, voltage, gas flow, electrode and material The application of weld metal transfer (short arc, spray etc.) Correct welding machine, leads, hand pieces and electrodes Material preparation Joint preparations Electrode classification Causes of distortion for materials within the scope of this unit Safe welding practices Use and application of personal protective equipment for GMAW Manufacturing Skills Australia Page 6