Weld using manual metal arc welding process This assessment resource supports the unit of competency MEM05015 Weld using manual metal arc welding process.
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Overview This unit covers preparing the materials and carrying out routine manual metal arc welding (MMAW). This unit applies in a maintenance or manufacturing environment where the welding is not required to meet an Australian standard or equivalent. Fillet and butt welds would typically be performed on low carbon/mild steels. 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. Identify weld requirements; 2. Prepare materials for welding; 3. Prepare equipment for welding; and 4. Perform routine welding using MMAW. Pre requisite units of competence MEM05012 MEM05051 MEM05052 MEM12023 MEM18001 MEM18002 Perform routine manual metal arc welding Select welding processes Apply safe welding practices Perform engineering measurements Use hand tools Use power tools/hand held operations Manufacturing Skills Australia Page 3
Written Short answer questions Pracrical Observation Third Party Report Weld using manual metal arc welding process 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 1 Prepare materials for manual metal arc welding (MMAW 1.1 Weld requirements are identified from specifications and/or drawings. 1.2 Materials are correctly prepared. 1.3 Materials are assembled/aligned to specification, where required. 4,15,19 3,4,5,6 1.1 1.1 10,16,17, 20 1 1.2 1.2 6,10,18 3,4,5,6 1.3 1.3 2 Select welding equipment and consumables 2.1 Welding equipment and electrodes appropriate to the material and the weld are identified and selected. 3,4 2 2.1 2.1 3 Assemble and set up welding equipment. 3.1 Welding equipment is assembled and set up. 2,3,4 2 3.1 3.1 Manufacturing Skills Australia Page 4
Written Short answer questions Practical Observation Third Party Report Weld using manual metal arc welding process 4 5 Minimise and rectify distortion Weld to job specification using MMAW. 4.1 Appropriate distortion prevention measures are selected and applied. 6,11 3,4,5,6 4.1 4.1 4.2 Distortion is rectified. 3,4,5,6 4.2 4.2 5.1 Weld deposit is to specification 1,3,5,7,8,9,11, 3,4,5,6 5.1 5.1 5.2 Joints are cleaned to specifications. 14 3,4,5,6 5.2 5.2 6 Ensure weld conformance. 6.1 6.2 Defects are rectified with minimum loss of sound metal using correct techniques and tools. Weld joints are visually inspected for conformance to specifications. 1,3,5,7,1 2 3,4,5,6 6.1 6.1 7,12,14 7,8 6.2 6.2 7 Where required, maintain weld records. 7.1 Where required, weld records are completed correctly. 13 7,8 7.1 7.1 Required Skills and Knowledge Mapping Skills Identifying and interpreting welding specifications including appropriate standards e.g. Australian standard 1554 general purpose, American bureau of shipping (abs) or equivalent 19 3,4,5,6 1.1 1.1 Selecting and using appropriate tools and equipment 14,15,16 1,2,3 4,5,6 2.1 2.1 Using a variety of welding machines and electrodes 5 3,4,5,6 2.1,3.1 2.1,3.1 Identifying and rectifying weld defects 1,12 3,4,5,6 6.1 6.1 Applying techniques for distortion prevention and rectification 2,7,8,17 1,3,4, 5,6 4.1 4.1 Cleaning welds 3,18 3,4,5,6 5.2 5.2 Reading and interpreting information on sketches, written job instructions, specifications, standard operating procedures and engineering drawings 9 1 1.1 1.1 Recording routine information including routine weld records related to MMAW onto proformas and standard workplace forms 13 8 6.2 6.2 Following oral instructions 20 8 Manufacturing Skills Australia Page 5
Measurement skills relating to joint preparation and MMAW 15,16 1 3.1 3.1 Knowledge Material preparation 10 1 1.2 1.2 Joint preparations 9 3,4,5,6 1.3 1.3 Electrode classification 4 2 2.1 2.1 Causes of distortion for materials within the scope of this unit 1,2,8 3,4,5,6 4.1 4.1 Causes of defects and methods of rectification 2,3,12,17 3,4,5,6 4.1 4.1 The relationships between amperage, electrode and material 4,5,6,7 3,4,5,6 5.1 5.1 Safe welding practices 6,11 2 Use and application of personal protective equipment for MMAW 20 2 Manufacturing Skills Australia Page 6
Assessment Preparation Checklist Unit/s of Competency Weld using manual metal arc welding process Candidate Name RTO Assessor Name As the candidate are you ready for assessment? Has the assessment process been explained to you and that to achieve a successful outcome for this unit of Competency you must be deemed Satisfactory in all assessment tasks? Do you understand The Recognition of Prior Learning (RPL) process? Do you understand which evidence is to be collected and how? Do you understand the your rights and the appeal system? Have you discussed any special needs that should be considered during the assessment process? Do you require an adjustment to the conduct of the assessment to respond to a specific or a special need. e.g. Cultural, Language, Disability, Literacy or Numeracy purposes. I agree to undertake this assessment in the knowledge that the information gathered will only be used for the purpose of determining my skills as Satisfactory or Not Satisfactory for each assessment method. Additionally the information gathered is for the determination of my Competency by the collection of all assessment evidence for this unit of competency and can only be accessed by my workplace supervisor, my RTO and nominated regulatory authorities. Candidate Signature Date Assessor Signature Date Manufacturing Skills Australia Page 7
Written Short Answer Questions To be applied after the completion of formal information presentation methods It is suggested that this method be applied in a classroom or similar learning environment These questions can be used orally where needed but it is necessary to record the candidate responses Unit/s of Competency Weld using manual metal arc welding process Candidate Name RTO Assessor Name Overview This unit covers preparing the materials and carrying out routine manual metal arc welding (MMAW). This unit applies in a maintenance or manufacturing environment where the welding is not required to meet an Australian standard or equivalent. Fillet and butt welds would typically be performed on low carbon/mild steels. 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. Instructions This assessment method is one (1) of several assessment tasks that you will be set for the determination of your success for this unit of competency. You will be provided time to complete this assessment and all written work must be submitted by the date allocated by your trainer/assessor; you are free to work on your submission in your own time and also you are free to use whatever resources you consider appropriate for the task. As the candidate you must have been notified that an assessment is to be conducted, ensuring that you are fully aware of Competency Based Training and assessment and that you have adequate time to prepare. Please notify your Manufacturing Skills Australia Page 8
trainer/assessor if you feel you have not had adequate time to prepare for this assessment. The evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria of this unit and include demonstration of some or all of the application in this assessment method by applying: You must be able to prepare materials, select and set up the welding equipment, carry out MMAW and examine for and correct defects. Please write your answers on a separate sheet of paper Please put your name and unit title at the top of the page Question One Why is it important to strike the arc only in the weld joint? Question Two What problems may result by using an electrode at too high a current setting? Question Three What makes some spatter "hard"? Question Four What factors should be considered when selecting an electrode size? Manufacturing Skills Australia Page 9