Carry out motor vehicle body structural aluminium welding operations

This unit is about joining materials safely, correctly and effectively using aluminium welding techniques and procedures.

P6.1 suitability of gas/filler wire and size for material to be joined 

P6.2 parameters are set correctly 

P6.3 consumables are correct 

P6.4 feed rollers and welding tip 

P6.5 test kit 

P7 carry out aluminium welding operations following: 

P7.1 recognised researched repair methods

P7.2 test procedures, including providing test coupons on equivalent material in accordance with recognised standards 

P7.3 manufacturers' processes, methods and procedures 

P7.4 your workplace procedures 

P7.5 health, safety and legal requirements 

P8 avoid damaging other components, units, panels and surfaces on the vehicle and the surrounding work area 

P9 recognise when your weld is not forming correctly and what action needs to be taken 

P10 inspect and assess aluminium weld quality in accordance with industry recognised standards including: 

P10.1 dye penetrate 

P10.2 crack testing 

P11 check integrity of the weld and record the type of weld achieved on the appropriate paper work 

P12 ensure test pieces are recorded and stored 

P13 dress the joint area without reducing material thickness and protect the repaired area to inhibit corrosion where applicable 

P14 clean and store PPE and equipment in appropriate manner 

P15 promptly report any additional faults you notice during the course of your work to the relevant person(s)  

P16 promptly report any delays in completing your work to the relevant person(s)  

P17 carry out aluminium welding operations within the agreed timescale 

P18 complete work records accurately, in the format required and promptly pass them to the relevant person(s)

K2.1 the referral of problems 

K2.2 reporting of delays to the completion of work 

K2.3 completion of work records 

K3 the work that needs to be done and the standard required 

K4 the requirements for protecting the vehicle and contents from damage before, during and after the joining of materials using aluminium welding operations 

K5 the importance of selecting, using and maintaining the appropriate PPE when joining materials using aluminium welding operations 

K6 how to find, interpret and use sources of information applicable to the joining of materials using aluminium welding operations and the implications of not fully understanding the repair methods presented

K7 how to select, check, maintain and set up all of the tools and equipment required to correctly join materials using aluminium welding techniques 

K8 the different types of welding processes, techniques and joints used for the joining of materials when using aluminium welding operations 

K9 the correct surface preparation methods to ensure a good aluminium weld is achieved and the reasons why surface preparation is important 

K10 the faults and defects that can occur when carrying out aluminium welding and the common causes of these faults 

K11 the need for correct alignment of materials and the methods used to achieve this 

K12 the types of quality control checks that can be used to ensure correct joining of materials including: 

K12.1 dye penetrate 

K12.2 crack tests

K13 how to inspect and assess aluminium weld quality in accordance with industry recognised standards 

K14 the different types of joint that can be used to join materials using aluminium welding, including 

K14.1 lap plug 

K14.2 lap seam 

K14.3 butt joint 

K14.4 brace joint 

K14.5 fillet joint 

K15 when aluminium welding techniques should be used 

K16 how to ensure cross contamination does not occur and the effect of cross contamination on aluminium

K17 the implications of electro-magnetic fields and the effects on medical devices

K18 the ihazards of inhaling welding fumes

1.1. face mask with appropriate eye protection 

1.2. protective/flame retardant coveralls 

1.3. protective/flame retardant gauntlets 

1.4. steel toe cap boots 

1.5. appropriate vehicle protection 

1.6. appropriate protection for others in the workshop 

1.7. appropriate fume mask

2. Tools and equipment are: 

2.1. anti-static extraction

2.2. designated aluminium environment

2.3. designated aluminium tooling

2.4. fume extraction