| 1 | 1a. Prepare and use manual flame brazing and bronze welding equipment | 1.1 | Work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines |
| 1.2 | Prepare for the manual flame brazing or bronze welding process by carrying out all of the following: • adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations • check that hoses, regulators and valves are securely connected and free from leaks and damage • check/fit the correct size gas nozzle to the torch • check that a flashback arrestor and check valves are fitted • set appropriate gas pressures • use the correct procedure for lighting, adjusting and extinguishing the flame • use appropriate and safe procedures for handling and storing of gas cylinders (where appropriate) • prepare the work area for the activities (such as positioning screens and fume extraction equipment) • prepare the materials and joint in readiness for brazing or bronze welding (such as cleaning of joint faces, setting up the joint, supporting ... |
| 1.3 | ... the joint) • make sure the work area is maintained and left in a safe and tidy condition |
| 1.4 | Plan the brazing or bronze welding activities before they start them |
| 1.5 | Obtain and prepare the appropriate manual flame brazing or bronze welding equipment and consumables |
| 1.6 | Set up, check, adjust and use two of the following manual flame processes and related equipment: • brazing • bronze welding • braze welding |
| 1.7 | Use specified consumables appropriate to the parent metals, to include one of the following: • self fluxing rods • flux coated/impregnated rods • powder/paste flux and rods |
| 1.8 | Prepare and support the joint, using the appropriate methods |
| 1.9 | Tack the joint at appropriate intervals, and check the joint for accuracy before final brazing or bronze welding |
| 1.10 | Produce the brazed or bronze welded joints of the required quality and of specified dimensional accuracy |
| 1.11 | Produce joints in two of the following materials: • copper to copper • brass to brass • copper to brass • copper to carbon • other appropriate materials |
| 2 | 1b. Prepare and use manual flame brazing and bronze welding equipment (continued) | 2.1 | Produce joints in good access situations, covering two of the following: • lap joints • Tee joints • corner joints • butt joints • socket joints |
| 2.2 | Produce joints in the following positions: For brazing, use one of the following: • horizontal flow • vertical down flow • vertical up flow For bronze or braze welding, use one of the following: • flat position • horizontal-vertical position |
| 2.3 | Produce joints in both of the following: • sheet/plate • pipe/tube |
| 2.4 | Use appropriate methods and equipment to check the quality, and that all dimensional and geometrical aspects of the joint are to the specification |
| 2.5 | Carry out destructive tests on weld specimens, using one of the following: • macroscopic examination • nick break test |
| 2.6 | Identify all of the following brazing and bronze/braze welding defects: • lack of continuity of the brazed or bronze welded joint • uneven and irregular ripple formation • incorrect joint size or profile Plus three more of the following: • overlap • inclusions • porosity • surface cracks • lack of penetration |
| 2.7 | Produce brazed or bronze/braze welded components which meet all of the following: • achieve the specified joint quality • meet the required dimensional accuracy within specified tolerance • are of good appearance, free from flux residues and excess filler metal |
| 2.8 | Deal promptly and effectively with problems within their control, and seek help and guidance from the relevant people if they have problems that they cannot resolve |
| 2.9 | Shut down and make safe the brazing or bronze welding equipment on completion of the activities |
| 3 | 2a. Know how to prepare and use manual flame brazing and bronze welding equipment | 3.1 | Describe the safe working practices and procedures to be observed when working with manual flame gas brazing and bronze/braze welding equipment (such as general workshop safety; appropriate personal protective equipment; fire and explosion prevention, protecting other workers, safety in enclosed/confined spaces; fume extraction/control) |
| 3.2 | Describe the hazards associated with flame brazing and bronze/braze welding (such as naked flames, explosive gas mixes, oxygen enrichment, fumes and gasses, hot metal, enclosed spaces), and how they can be minimised |
| 3.3 | Describe the personal protective equipment to be worn for the brazing and bronze/braze welding activities (such as correctly fitting overalls; leather aprons, eye protection with the appropriate shade of filter) |
| 3.4 | Describe the correct handling and storage of gas cylinders (such as manual handling and use of cylinder trolley, leak detection procedures, relevant BCGA codes of practice, cylinder identification, gas pressures, cylinder and equipment safety features) |
| 3.5 | Describe the manual flame brazing and bronze/braze welding process (such as basic principles of the process, wetting and capillary flow, deposition of brazed/bronze beads, role of fluxes) |
| 3.6 | Describe the types of filler metal and fluxes; forms of filler metal |
| 3.7 | Describe the types of joints to be produced (such as lap, tee, corner, butt) |
| 3.8 | Explain how to set up and support the joint (such as methods of cleaning joint faces; use of jigs and fixtures, restraining devices; self-locating joints; pre-placement of filler metal and flux) |
| 3.9 | Explain how to prepare the brazing and bronze welding equipment, and the checks to be made to ensure that it is safe and ready to use (such as connection of hoses, torch, flashback arrestors, hose check valves and regulators) |
| 3.10 | Explain how to check hose connections for leaks, and the methods that are used |
| 3.11 | Explain how to set gas working pressures; reading the gauges to establish content and pressures |
| 3.12 | Explain how to prepare the materials in readiness for the brazing and bronze welding activity (such as ensuring that the material is free from surface contamination -such as rust, scale, paint, oil/grease and moisture; ensuring edges to be brazed/bronze welded are correctly prepared - such as made flat, square) |
| 3.13 | Describe the correct use of the torch to produce a range of joints (such as selection of nozzle, adjustment of the flame, application of flux and the correct manipulation of torch and filler wire) |
| 4 | 2b. Know how to prepare and use manual flame brazing and bronze welding equipment (continued) | 4.1 | Describe the control of heat input to prevent filler material and parent material faults (such as brazing/bronze welding sequence; deposition technique) |
| 4.2 | Describe the safe and correct sequence for shutting down the brazing or bronze welding equipment (such as sequence of turning off the gases, extinguishing the flame and closing valves on gas supply/cylinders) |
| 4.3 | Describe the importance of complying with job instructions and the joining procedure specification |
| 4.4 | Describe the problems that can occur with the joining activities (such as incorrect heat pattern (hot or cold spots); fluxing technique; formation of oxides during the process; distortion of the joint due to overheating), and how these can be overcome |
| 4.5 | Describe the methods of removing flux residues and cleaning the finished joint |
| 4.6 | Describe the safe working practices and procedures to be adopted when preparing the brazed and bronze/braze welded joints for examination (such as handling hot materials, using chemicals for cleaning, using equipment to fracture joints) |
| 4.7 | Explain how to prepare the joints for examination (such as removing surface irregularities; cleaning and degreasing the brazed or bronze/braze welded joint, making saw cuts on joints to be fracture tested) |
| 4.8 | Explain how to check the brazed or bronze welded joints for uniformity, alignment, position, joint size and profile |
| 4.9 | Describe the various procedures for carrying out destructive tests on the joints (such as macroscopic examination and nick break tests) |
| 4.10 | Explain how to examine the joints after the tests and check for such things as the degree of penetration, inclusions, porosity, cracks |
| 4.11 | Explain when to act on their own initiative and when to seek help and advice from others |
| 4.12 | Describe the importance of leaving the work area and equipment in a safe condition on completion of the brazing or bronze welding activities (such as isolation of gas cylinders; safely storing cylinders, hoses and torches; storing filler rods; removing and disposing of waste) |
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