Assignment 1_brief_unit 13 _la 062016 No Com.docx

BTEC Assignment Brief Qualification

Pearson BTEC Level 3 National Extended Diploma in Engineering

Unit number and title

Unit 13: Welding Technology

Learning aim(s) (For NQF

A: examine common welding processes used to produce welded joints safely for different applications

only)

Assignment title Assessor Issue date Hand in deadline

Vocational Scenario or Context

Assignment 1: Examine Common Welding Processes Used to Produce Welded Joints Mr J Cooke

26/9/2017 06/11/2017

You are working as a final year apprentice in a small engineering company. The company makes small metal components and repairs them by welding. You have recently been part of your team involved in welding these components. Your manager is pleased with your work and has decided that you should be given some more responsibility. Management have tasked you with writing a report looking at whether the company is using the most appropriate materials to make their components and the most appropriate welding techniques to repair them. Your report will impact upon company investment decisions in the future.

THE PRACTICAL INVESTIGATION You will investigate how metal can be joined with different processes and the differences within these processes when you use different materials. The metal you will be investigating will be of a similar thickness to that used in the components that your company manufactures. You are to investigate joining metal with the following dimensions.

20mm x 90mm x 03mm

Task 1

THE WRITTEN REPORT Once you have completed the practical investigation you will need to write up your findings in a report. Your report must use specialist terminology, and vocabulary and be technically correct. It must also reflect high standards of written communication. Your report will make the correct use of abbreviations and must include; advantages and disadvantages, potential problems, methods of safe handling, the working quality of the welds likely to be produced with the processes you suggest and discuss. You will justify the best types of materials to be used for each of two positional configurations illustrated below.

You will also need to detail what type of welding process parameters apply to each configuration e.g. if the process is an electrical one you will need to specify correct voltages for the types and thickness of material. The report will also include consumables, tools, equipment, setting and types of welding joint to use for each configuration.

CONFIGURATON A (metal side by side) You will investigate and justify an appropriate type of welding joint for welding two pieces of metal side by side. You will choose from a number of different weld joints that could be used to join them together. You will also suggest a type of welding process to use.

CONFIGURATION B (metal at right angles to each other) You will investigate and justify a good type of welding joint for two pieces of metal at right angles to each other. You will choose from a number of different weld joints that could be used to join metal at right angles. You will also suggest a type of welding process to use. There are other many options and variables that you may wish to consider before making recommendations in your report: METALS Metals that might be considered include steel, stainless steel, aluminium, alloyed aluminium or other non-alloyed and alloyed metals. JOINTS Welding joints that might be considered include butt weld, vee butt weld, fillet weld, corner weld. WELDING PROCESSES Your company currently owns a Clarke 151TE MIG welder (the operating manual may provide useful information for your report). However, there are many forms of welding process to choose from. Here is a list of some of them: Other processes and information to be investigated are listed below: •Oxy-Acetylene welding Automated and mechanised welding processes, e.g. orbital welding, resistance welding. A2 Gas-shielded arc welding – shielding gases The characteristics and operating principles: 2 BTEC Assignment Brief v1.0 BTEC Internal Assessment QDAM January 2015

• processes, including TIG, MIG/MAG, flux-cored welding • shielding gas used for each process • safe handling and storage of shielding gases • standards for shielding gases and filler materials • potential hazards and methods of safe handling and working. A3 Common welding processes Welding processes:• • TIG welding process, including arc ignition methods and their applications, common applications for each type of current, polarity and electrode type, use of and care for the equipment and accessories, standards for consumables, joint preparation and potential problems to overcome and potential hazards, and methods of safe handling and working• • MIG/MAG welding, including metal transfer modes and their applications, selection of appropriate type of current, polarity and electrode according to application, appropriate joint preparations and potential problems to be overcome, welding parameters on the weld bead and be able to outline the welding parameters for particular applications, main components of the equipment and accessories, appropriate standards for consumables and how they are to be selected, care for the equipment and accessories, potential hazards and methods of safe handling and working•

• FCAW process, including common applications for each type of current, polarity and electrode, appropriate joint preparations and potential problems to be overcome, appropriate welding parameters on the weld bead and outlining welding parameters for particular applications, potential hazards and methods of safe handling and working, functions of the main components of the equipment and accessories, appropriate standards for consumables, how consumables should be selected, and care for the equipment and accessories

• MMA welding process, including principles of MMA welding, selection of the appropriate type of current, polarity and electrode according to application, applications, appropriate joint preparations and potential problems to be overcome, range of welding parameters or particular applications, hazards and methods of safe handling and working, component of the equipment and accessories, handling, control and storage of the various types of electrodes, use of appropriate standards, influence of electrode coating on droplet transfer and weld metal properties. A4 Welding electrotechnics. • The function of welding power source components: o alternating current (AC) and direct current (DC) and give examples of their individual application to different welding processes o transformers o rectifiers, including bridge (half and full wave). Power sources for arc welding: o how a welding power source works (AC and DC), including the most common devices used 3 BTEC Assignment Brief v1.0 BTEC Internal Assessment QDAM January 2015

o arc welding power source, including the voltage static characteristic, operation point and control of arc stability o open-circuit voltage, arc voltage short-circuit current, duty cycle of a power source, voltage losses, and current to cable section relationship o appropriate power sources for a given welding process o settings and switches on different power sources and their effects on the welding process. 

Checklist of evidence required

A written report examining the suitability of welding processes for the given two configurations, examining applications, explaining the equipment, terminology and examining the implication of material choices for each configuration. The report will also cover the safe working practices and equipment required.

Criteria covered by this task: Unit/Criteria reference

To achieve the criteria you must show that you are able to:

13/A.P1

Explain the choice of welding processes, parameters and settings for two given welding applications, explaining the equipment, terminology and safe working practices that apply.

13/A.M1

Analyse the choice of welding processes, parameters and settings for two given welding applications, explaining the equipment, terminology and safe working practices that apply.

13/A.D1

Justify, using language that is technically correct and of a high standard, the choice of welding processes, parameters and settings for two given welding applications, explaining the equipment, terminology and safe working practices that apply.

Sources of information to support you with this Assignment

Textbooks Pearson textbook specific to new BTEC Nationals in Engineering Davies A C –The Science and Practice of Welding, Vol. 1, Davies A C – The Science and Practice of Welding, Vol. 2, Clarke MIG 151TE Instruction Manual

4 BTEC Assignment Brief v1.0 BTEC Internal Assessment QDAM January 2015