Preparing electron beam welding machines for production

URN: SEMFWE313
Business Sectors (Suites): Fabrication and Welding Engineering Suite 3
Developed by: Enginuity
Approved on: 30 Mar 2017

Overview

This standard identifies the competencies needed to prepare electron beam welding machines for production in accordance with approved procedures. You will be required to set up and check both the welding installation and all associated mechanical and electrical apparatus forming part of the mechanised or automated installation. This will include setting up of handling and loading equipment, workholding arrangements, transfer mechanisms and safety equipment as is applicable to the machine type.

In setting up the welding conditions you will be expected to set the electrical parameters, beam characteristics, beam alignment, welding speed, vacuum pressure and chamber safety devices. You must produce trial welds and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification and solving machine related problems during production will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for setting up the welding equipment and to report any problems with the welding equipment or welding activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying electron beam welding procedures. You will understand the welding process carried out, and its application, and will know about the equipment, relevant materials and consumables in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


Performance criteria

You must be able to:

  1. work safely at all times, complying with health and safety and other relevant regulations and guidelines
  2. follow the relevant joining procedure specification and job instructions for the work to be produced
  3. check that the equipment is as specified and in usable condition
  4. obtain the required components and check that the joint preparation complies with the specification
  5. set up the handling, work-holding and associated equipment to achieve correct joint positioning
  6. select and prepare the appropriate consumables in line with the joining procedure specification
  7. set and adjust the machine operating conditions to achieve joints of the required quality and within specified dimensional accuracy
  8. check that all safety mechanisms are in place and that the equipment is operating satisfactorily
  9. deal promptly and effectively with problems within your control and report those that cannot be solved

Knowledge and Understanding

You need to know and understand:

  1. the safe working practices and procedures to be observed when setting and operating electron beam welding installations (working with machinery; care in presence of high voltages; the use of appropriate personal protective equipment (PPE); machine guards; ventilation and fume extraction; machine safety devices; x-ray dosimeters; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)
  2. the hazards associated with electron-beam welding machines and how they can be minimised (dangers from the mains and high voltage supplies; live electrical components; emission of x-rays, fumes and gases; hot metal; moving parts of machinery)
  3. the basic principles of electron beam welding (using an electron beam in vacuum to join metals by fusion; forming a weld; principal features of a welded joint; and penetration process principles, nature of the electron beam; generation and control of an electron beam; parameters, heat input; how variation in the parameters influences the weld features and penetration, quality and output; terminology used in welding)
  4. the key components and features of the equipment (electron gun and control of beam power and characteristics, vacuum chamber and its construction, vacuum system and controls, in-chamber manipulating equipment; power sources and power range, materials and thickness capabilities, safety features; facilities for locating chamber and work handling)
  5. extracting information required from drawings and welding procedure specifications (to include symbols and conventions to appropriate British, European or relevant International standards in relation to work undertaken)
  6. types of joints applicable and the edge preparation required
  7. problems that can occur with the welding activities and how these can be overcome (magnetic effect of component on beam/joint alignment; effect of metal vapour on beam characteristics and penetration; effects of increase in chamber pressure, welding characteristics of parent materials and sources of weld defects; methods of prevention)
  8. methods of setting up the components to achieve correct location and beam alignment; types of in-chamber manipulating equipment
  9. setting up the welding equipment to the welding procedure specification (setting electrical conditions; beam characteristics, welding speed)
  10. checking the machine functions to the required specification (running pre-production trials to prove that the installation is working satisfactorily)
  11. organisational quality systems (standards to be achieved; production records to be kept, quality control)
  12. personal approval tests and their applicability to your work
  13. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

Scope/range


Scope Performance

  1. Ensure the electron beam equipment is suitable for production by carrying out all of the following checks:

    1. the equipment is correctly maintained and in a safe and usable condition                  
    2. the accuracy of optical or other beam positioning devices
    3. the equipment is correctly calibrated          
    4. the smooth operation of in chamber mechanical equipment
    5. the chamber interior is in a clean condition                  
    6. the electron gun is clean                                 
    7. equipment shut down systems function correctly
    8. door faces and seals are sound                   
    9. the chamber vacuum system operates correctly
    10. the X -ray check list is complied with
  2. Set up the welding equipment and parameters in accordance with instructions and the welding procedure specification to include setting all of the following as is applicable to the type of installation:

    1. beam alignment       
    2. beam characteristics    
    3. chamber pressure
    4. electrical parameters   
    5. welding speed        
    6. chamber safety devices
  3. Set up the components to achieve correct joint fit-up and alignment to include setting and checking all of the following as is applicable to the type of installation:

    1. handling and loading equipment   
    2. surface preparation and condition of joint faces is according to specification
    3. workholding arrangements                    
    4. traversing or manipulating devices
    5. safety mechanisms
    6. transfer mechanisms
  4. Set up the equipment to produce welded components which covers both of the following:

    1. two different components
    2. two different material groups
  5. Prove the installation is operating correctly and is ready for production by producing specified trial welds and checking all of the following as is applicable to the application:

    1. visual appearance of weld             
    2. quality of weld
    3. dimensional accuracy                    
    4. machine settings are as specified
  6. Solve problems in production relating to two of the following:

    1. machine performance                 
    2. condition of materials being joined
    3. joint set-up                              
    4. consumables

Scope Knowledge


Values


Behaviours

​Additional Information

You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

  • strong work ethic
  • positive attitude
  • team player
  • dependability
  • responsibility
  • honesty
  • integrity
  • motivation
  • commitment

Skills


Glossary


Links To Other NOS


External Links


Version Number

3

Indicative Review Date

31 Mar 2020

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

SEMFWE313

Relevant Occupations

Engineering, Engineering and Manufacturing Technologies, Metal Forming, Welding and Related Trades

SOC Code

5213

Keywords

engineering; welding; fabrication; machine welding; setting; electron beam; parameters; equipment; transfer system; safety devices