Carry out motor vehicle body structural aluminium welding operations

Business Sectors (Suites): Coachbuilding
Developed by: IMI
Approved on: 30 Mar 2023


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

Performance criteria

You must be able to:

P1 use the appropriate personal protective equipment (PPE) when carrying out aluminium welding operations 
P2 protect the vehicle and its contents effectively when carrying out aluminium welding operations 
P3 prepare material surfaces and align to enable suitable join to be achieved, ensuring mating flanges are treated following manufacturers' procedures before joining
P4 select, set up and use the correct tools and equipment in order to correctly carry out aluminium welding operations 
P5 ensure that the tools, equipment and PPE you require are in a safe working condition and are correct for the joining operation that you are to be completing 
P6 set up your equipment to carry out aluminium welding operations checking:

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)

Knowledge and Understanding

You need to know and understand:

K1 the health, safety and legal requirements relating to the joining of materials using aluminium welding techniques 
K2 your workplace procedures for: 

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


All of the items listed below form part of this National Occupational Standard.

1. Personal protective equipment (PPE) for aluminium welding operations includes: 

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

Scope Performance

Scope Knowledge





Links To Other NOS

External Links

Version Number


Indicative Review Date

30 Mar 2026





Originating Organisation


Original URN


Relevant Occupations

Body Repair and Alignment Technician (Automotive), Body Repair Technician (Automotive), Engineering, Vehicle Trades, Coachbuilder

SOC Code



Motor; vehicle; body; aluminium; welding; operations;