| 1 | 1a. Prepare Friction Welding Machines for Production | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Follow the relevant joining procedure specification and job instructions for the work to be produced |
| 1.3 | Check that the equipment is as specified and in usable condition |
| 1.4 | Confirm the friction welding equipment is suitable for production by carrying out all of the following checks: • the equipment is correctly maintained and in a safe and usable condition • the equipment is correctly calibrated • all electrical and mechanical systems function smoothly • equipment shut down systems function correctly |
| 1.5 | Obtain the required components and check that the joint preparation complies with the specification |
| 1.6 | Set up the handling, work-holding and associated equipment to achieve correct joint positioning |
| 1.7 | 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: • surface preparation and condition of joint faces is according to specification • handling and loading equipment • workholding devices • transfer mechanisms • safety devices |
| 2 | 1b. Prepare Friction Welding Machines for Production (continued) | 2.1 | Select and prepare the appropriate consumables in line with the joining procedure specification |
| 2.2 | Set and adjust the machine operating conditions to achieve joints of the required quality and within specified dimensional accuracy |
| 2.3 | Set up the welding equipment and parameters in accordance with the welding procedure specification to include setting all of the following as is applicable to the type of installation: • friction and forge cycle times • friction and forge loads (forces) • frictional burn-off characteristics and forge displacement • rotational speed or other appropriate friction conditions • braking effort |
| 2.4 | Set up the equipment to produce welded components which covers both of the following: • two different components • two different material groups |
| 2.5 | Check that all safety mechanisms are in place and that the equipment is operating satisfactorily |
| 2.6 | 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: • visual appearance of weld • dimensional accuracy • quality of weld • machine settings are as specified • in-process monitoring and data acquisition |
| 2.7 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 2.8 | Solve problems in production relating to all of the following as is applicable: • machine performance • joint set-up • condition of prepared materials being joined • consumables |
| 3 | 2a. Know how to Prepare Friction Welding Machines for Production | 3.1 | Explain the safe working practices and procedures to be observed when setting and operating friction welding installations (working with machinery; the use of appropriate personal protective equipment; machine guards; ventilation and fume extraction; machine safety devices; stopping the machine in an emergency; 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) |
| 3.2 | The hazards associated with friction welding machines and how they can be minimised (dangers from live electrical components; fumes; hot metal; moving parts of machinery and components) |
| 3.3 | Explain the basic principles of friction welding (using heat generated by friction to join metals by welding; rotational and orbital methods of heat generation, forming a weld; use of filler metal; principal features of a welded joint; welding cycle, parameters, heat input; how variation in the settings influences the weld features, quality and output; terminology used in welding) |
| 3.4 | Describe the key components and features of the equipment (types of machines; constructional features; mechanical features, drive train, driven and stationary component holding devices, force generation, and control systems, in-process monitoring features, data acquisition and sensors; braking systems; welding cycle control; feedback and recording) |
| 3.5 | Explain the basic principles of mechanised and automated welding (types of installations; machine functions: loading, handling, clamping and transfer of components; control of machine functions; safety features) |
| 3.6 | Explain how to extract the information required from the drawings and welding procedure specifications |
| 4 | 2b. Know how to Prepare Friction Welding Machines for Production (continued) | 4.1 | Describe the preparation of the joint faces; finish, tolerances |
| 4.2 | Describe the problems that can occur with the welding activities and explain how these can be overcome (welding characteristics of parent materials and sources of weld defects; methods of prevention |
| 4.3 | Explain how to setup the welding equipment to the welding procedure specification (setting welding cycle; heating and forging forces, rotational speed) |
| 4.4 | Explain how to check that the machine functions to the required specification (running pre-production trials to prove that the installation is working satisfactorily) |
| 4.5 | Describe the organisational quality systems (standards to be achieved; production records to be kept, methods of testing friction welds and principles of quality control in production) |
| 4.6 | Explain the personal approval tests and their applicability to their work |
| 4.7 | Describe the extent of their responsibility and explain whom they should report to if they have problems that they cannot resolve |
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