Using resistance spot welding to join marine sheet metal materials

This standard identifies the competences you need to set up and use portable and simple fixed spot welding machines, in a marine engineering environment, in accordance with approved instructions or welding procedures. You will be expected to check that the equipment is fit for purpose, that electrodes are correctly profiled and that the component parts are in the correct condition for spot welding. In preparing the equipment, you will need to set the welding current, welding and squeeze times and electrode pressure. You must operate the equipment safely and correctly and make any necessary adjustments to the equipment settings and parameters, within permitted tolerances, in order to achieve weld quality and tolerances that meet the specification.

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

Your underpinning knowledge will be sufficient to provide a sound basis for your work and will provide an informed approach to applying spot welding procedures and instructions in a marine environment. You will have an understanding of how the resistance spot welding process works and will know about the equipment, materials and consumables, in adequate depth to provide a sound background to the process operation and for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the resistance spot welding 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.

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1. work safely at all times, complying with health and safety and other relevant regulations. directives and guidelines
2. follow the relevant joining procedure and work instructions
3. confirm that the machine is set up and operating correctly, ready for the joining operations to be carried out
4. check that the parent material, components, consumables and joint preparation comply with specifications
5. carry out the welding and monitor the machine operations in accordance with specifications and job instructions
6. achieve joints of the required quality and specified dimensional accuracy
7. make sure that the rate of output is as specified
8. deal promptly and effectively with problems within your control and report those that you cannot solve
9. shut down the equipment to a safe condition on conclusion of the joining activities

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1. the specific safety precautions to be taken when operating resistance welding equipment (including working with machinery, the use of appropriate personal protective equipment (PPE); the use of safety screens; operation of equipment safety devices; closing down the equipment on completion of the welding activities)
2. the statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations, that apply to the work undertaken
3. the hazards associated with using resistance welding equipment (including danger from live internal electrical components, fumes, hot metal, expulsion of hot particles, moving parts of machines) and how they can be minimised
4. the basic principles of resistance welding (such as heat and pressure to form a weld, welding and pressure cycles, terminology used in welding)
5. the key components and features of the equipment used (including power source; welding head; electrical parameters such as arc voltage, current, electrode pressure and welding time; systems for parameter control; how variation in the parameters influence weld features, quality and output)
6. how to extract the information required from drawings and procedure specifications (to include symbols and conventions to appropriate BS EN or ISO standards in relation to the work undertaken)
7. operation of the equipment controls and their function; equipment care procedures
8. monitoring the equipment during the welding process; fine tuning parameters to maintain quality; recognition of problems and action to be taken
9. why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
10. problems that can occur with the welding activities, materials and weld quality
11. how to carry out self inspection of completed work
12. organisational quality systems (such as standards to be achieved; production records to be kept)
13. the safe disposal of waste materials
14. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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1. Ensure that the resistance spot welding equipment is fit for purpose, by carrying out all of the following checks:

   1. equipment range is suitable for the operations to be performed
   2. portable equipment power leads are undamaged and securely connected
   3. electrodes are of the correct type, size and profile
   4. all equipment mechanical and electrical systems operate correctly
   5. supplies of components are adequate and suitably prepared
   6. appropriate safety screens are available

2. Operate one of the following resistance spot welding machines:

   1. portable spot welding machines
   2. fixed simple spot welding machines

3. Set up the equipment parameters, in accordance with instructions and the welding procedure specification, to include setting all of the following:

   1. electrode tip diameter/profile
   2. welding current
   3. welding and squeeze times
   4. electrode pressure
   5. water cooling flow rate (as applicable)

4. Monitor the process operation and make adjustments to parameters, in order to produce welded components covering both of the following:

   1. two different components
   2. two different material thicknesses

5. Produce welded components which meet all of the following requirements:

   1. achieve a weld quality as specified in the application standard
   2. spot welds are correctly pitched out
   3. welded components meet the required dimensional accuracy, within specified tolerances

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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

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2

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01 Feb 2021

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Current

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Original

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Semta

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SEMME2073

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Engineering, Engineering and Manufacturing Technologies

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5235

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Engineering; marine; joining; welding; sheet metal; resistance spot weld; spot welder; parameters; monitor; weld condition

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