BTEC Assignment Brief

Qualification Pearson BTEC Level 3 National Extended Diploma in Engineering

Unit number
and title Unit 13: Welding Technology

Learning A: examine common welding processes used to produce welded joints

aim(s) (For NQF safely for different applications
only)
Assignment Assignment 1: Examine Common Welding Processes Used to Produce
title Welded Joints
Mr J Cooke
Assessor

Issue date
26/9/2017
Hand in
deadline 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
Vocational these components. Your manager is pleased with your work and has
Scenario or decided that you should be given some more responsibility. Management
Context 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

THE WRITTEN REPORT

Once you have completed the practical investigation you will need to write
Task 1 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:

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 • 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
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 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 A written report examining the suitability of welding processes for the
evidence given two configurations, examining applications, explaining the
required 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
To achieve the criteria you must show that you are able to:
reference
Explain the choice of welding processes, parameters and settings for
13/A.P1 two given welding applications, explaining the equipment, terminology
and safe working practices that apply.
Analyse the choice of welding processes, parameters and settings
13/A.M1 for two given welding applications, explaining the equipment,
terminology and safe working practices that apply.
Justify, using language that is technically correct and of a high
standard, the choice of welding processes, parameters and settings for
13/A.D1
two given welding applications, explaining the equipment, terminology
and safe working practices that apply.

Sources of Textbooks
information to Pearson textbook specific to new BTEC Nationals in Engineering
support you Davies A C –The Science and Practice of Welding, Vol. 1,
with this Davies A C – The Science and Practice of Welding, Vol. 2,
Assignment

Clarke MIG 151TE Instruction Manual

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