Qetf 004 1 0810

QETF/004 Joining engineering
materials
Credit Value 5 Level 1 GLH 40
Delivery pack
Unit purpose/aims
This unit is intended to give learners a broad introduction to the different methods used to join materials in
engineering. The content of the unit includes welding, brazing/soldering and the use of adhesives. The
knowledge requirement is intended to introduce a variety of methods to the learners and the practical activities
allow the learner to focus on the methods/processes that may have local significance.
This unit involves the use of tools, equipment or machinery and as such must be delivered in a secure and safe
environment; learners must be supervised at all times by competent and qualified staff to ensure their safety. All
tools, equipment or machinery must be maintained and presented in a safe and fit state for use.
The higher risk activities within this unit require safeguarding at all times.
Summary of learning outcomes

he learner will:
The learner will:
4.1 Demonstrate different joining processes
4.2 Prepare for joining activities
4.3 Carry out Joining activities
4.4 Check joining activities are carried out correctly
Assessment requirements
An assessed research task that will cover learning outcome 4.1
Two assessed practical tasks that will cover learning outcomes 4.2 4.4
The overall grading criteria and recording sheet for this unit is attached to learning outcome 4.4.
4.1 Learning outcome
Demonstrate different joining processes
The learner will need to have the following practical skills and knowledge in order to complete this learning
outcome.
Practical skills
The learner can
Use resources to research information
Knowledge requirements
The learner can
Define the safety requirements of different joining processes
Identify the industrial applications of joining methods
State why different joining processes are chosen for different applications
Delivery advice - is intended to assist the delivery staff in ensuring coverage of the learning outcome
requirements are achieved.
Learners must be aware of the safety considerations of the different joining processes:
Welding, brazing and soldering processes:

Handling hot metal Using and handling fluxes
Electric shock Using compressed gases
Fumes - extraction Condition of equipment
Arc radiation/heat exhaustion
Adhesives:
Hand, eye and body protection Protection from fumes
Requirements of COSHH regulations
The depth of knowledge required of each joining processes is an understanding of the basic equipment and
materials used and possible applications.
Welding process types: Methods of brazing/soldering:

Arc welding (heat source, basic equipment) Torch brazing
Gas welding (flame types) Soldering Irons (heating sources)
Spot welding (electrodes, pressure) Fluxes and solder/spelter commonly used
Learners should be aware of adhesive types for the joining operations:

Thermosetting and thermoplastic One pack and two pack adhesives
Continued on next page
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For every process of joining the learner must be able to state or show a typical use for each joining process
mentioned. They must be able to identify possible defects that may occur in the joining processes and know
how to prevent and control distortion.
Learners should be shown (using suitable media) the various industrial applications of the different joining
methods. A car is a good example that contains most methods of joining materials. They should be able to
identify the advantages and disadvantages of different joining methods and be able to understand why different
joining processes are chosen for different applications.
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Assessment details This assessment is intended to introduce the learners to the common joining
processes and to encourage the learners to consider the applications of them.
Learners should put at least one answer in each answer cell to achieve a final
unit grade of pass and at least two in each answer cell to achieve a merit, (refer
to grading sheet attached to outcome 4.4).
Objective of the assessment The learners should demonstrate an ability to use and record a range of
information sources whilst undertaking the assessment.
Preparation required The learning outcome knowledge requirements should be taught prior to the
assessment being completed.
Resources needed Blank assessment table

Access to information sources, such as:
o text books
o your notes
o the internet
o catalogues and manuals
Solutions and marking criteria

Attached to this learning outcome are:
Learner instructions assessment 4.1: Investigate joining processes
Solutions assessment 4.1: Investigate joining processes
The unit grading sheet is attached to learning outcome 4.4.
This sheet is to be filled in when the unit is completed and the learner is being assessed for an overall grade from
pass, merit and distinction.
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Unit 04 Learner instructions
Assessment 4.1: Investigate joining processes
WHY are we doing this?

To investigate why certain joining and assembling processes are used for certain applications
WHAT do we need?
Blank tables and pen or pencil
Access to information sources, such as:
o text books
o your notes
o the internet
o catalogues and manuals
o trade magazines
HOW do we make a start?

You must observe health and safety procedures at all times.
Firstly you should start looking through the information sources you have to hand and gather
information before starting to complete the table.
Try to put as many examples as you can in the table from everyday things that you use at home
or in school/college.
(If you fill the table up and want to put more examples in ask your tutor for another table to
complete)
Ask your tutor to help you if you are unsure of any points or terms used
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Unit 04 Assessment 4.1: Investigate joining processes
Learner Name: Learner No:
Date: Attempt No:
Joining/Assembling What types of materials can be What is the joining process Why is the joining process What are the health & Assessor
Processes joined with this type of actually used for? used? safety issues?
process?
Spot welding
(fusion)
Arc/gas welding
Soldering/Brazing
(non fusion)
Adhesives
Learners and/or assessors comments:
Assessor signature: Date:
Date of re-assessment:(if applicable)
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Unit 04 Assessment 4.1: Investigate joining processes (possible solutions)
Learner Name: Billy Bloggs Learner No: 12345
Date: 04/04/04 Attempt No: 1
Joining What types of materials can be What industrial applications is Why is the joining process What are the health & Assessor
Processes joined with this process? this joining process actually used? safety issues?
used for?
Answers like Answers like Answers like Answers like
Spot welding Steel Washing machines Strong welds Weld splash

(fusion) Aluminium Car manufacture Can be automated Trapping in machine
Stainless steel Computer cases Semi skilled workers
Arc/gas welding Steel Structural steel Very strong welds Fumes

Aluminium Pipework Good quality Electric shock
Stainless steel Agricultural equipment Versatile Heat exposure
Plastics
Soldering/Brazing Copper Sealing sheetmetal joints Non fusion (less heat) Fumes

(non fusion) Brass PCB manufacture Conductive Corrosive flux
Steel Electrical wiring Non corrosive Heat

Adhesives Car manufacture Car interiors (plastics) No heat Skin contact

Machine assembly Boat manufacture Waterproof Fumes
Composites Automotive assembly Very strong
Learners and/or assessors comments:
Good answers, well done!
Assessor signature: A Pedagogy Date: 05/04/04
Date of re-assessment: (if applicable) N/A

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Prepare for joining activities
outcome.
Practical skills
The learner can
Prepare tools, equipment and consumables for joining activities
Follow task instructions
Demonstrate to prepare and check the consumables used for joining
The learner can
Identify the types and function of the tools and equipment used in preparing for joining
State the importance of cleanliness in preparing for joining
Delivery Advice - is intended to assist the delivery staff in ensuring coverage of the learning outcome
This learning outcome should link with the content of the Using Hand Tools outcome in the mandatory unit.
This outcome should cover the types and function of the tools and equipment used in preparing for joining
processes.
Before starting joining/assembling activities learners must understand the requirements of preparing both the
workplace and a plan of how to carry out the operations. They should consider:
Checking the drawings/instructions are the correct issue number

The health and safety issues around the processes to be used
The requirements for a simple risk assessment
The availability and condition of tools and equipment (including PPE)
The specification and condition of the material to be joined
The quantity of materials required (have you enough to complete the job)
How and when quality will be checked
Leaving the work area in a clean and safe condition/disposal of waste
Learners should also be made aware of how to produce a plan of how they intend to carry out the joining
activities. This plan can be used as part of the practical task in learning outcome 4.4.
Learners must also know how to prepare the tools and consumables used for the specific joining processes
(welding, brazing/soldering), this must include:
Checking for condition
Suitability for task
Methods of mechanical and chemical cleaning (pre and post joining)
Preparation of surfaces (metallic and non metallic) prior to joining
Learners must be aware of the importance of cleanliness in preparing for joining in terms of:
Contamination of joints
Misalignment and inaccuracy due to trapped foreign particles
Personal hygiene when handling fluxes etc
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Prepare for joining activities
Assessment details The assessment for this learning outcome is common between outcomes 4.2
4.4. There are two tasks to complete; a simple lap joint is made between two
pieces of the same material and a simple box with sliding lid.
The joining process used is dependant on local requirements and can be chosen
from arc/gas welding, brazing/soldering, spot welding or adhesives. In all cases
the task should follow the drawing/learners assessment sheets. The learners
should complete the task and report sheets as directed.
Objective of the assessment The learners should demonstrate an ability to correctly prepare for joining
activities.
Preparation required Suitable tools and equipment checked and prepared prior to any activities being
carried out.
Resources needed Learners instructions and report sheets

Suitable joining equipment and consumables
Personal protective equipment (PPE)

The assessment for this learning outcome is attached to learning outcome 4.4:
Learner instructions assessment 4.2: Prepare for joining activities
Learner report Sheet assessment 4.2: Prepare for joining activities
The unit grading sheet is attached to learning outcome 4.4.
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Carry out Joining activities
outcome.
Practical skills
The learner can
Demonstrate and set up joining equipment
Demonstrate correct and safe use of equipment
Carry out joining activities safely and correctly
Carry out housekeeping activities to keep work area safe
Demonstrate how to use and handle adhesives
Demonstrate how to use hand tools correctly
The learner can
State the procedures for setting up welding/brazing/soldering equipment
How to set up and adjust welding/brazing/soldering equipment:

How the equipment is assembled correctly
The checks that need to be made to ensure the equipment is safe (damaged cables/hoses, split spanners
etc)
Setting up the equipment ready for joining and the shut down procedures
Selection and care of personal protection equipment (PPE)
Check that ventilation and local fume extraction equipment is in place and working correctly
Adjusting settings appropriate to the equipment used, (note the effects of adjusting equipment)
Using adhesives:
Explain the importance of the viscosity of the adhesive related to the joint clearance
Explain the importance of manufacturers cure times and the effect of temperature
Learners must understand the functions of different jig types appropriate for the joining process being carried
out.
Jigs are used in all joining processes to:
Ensure the work is supported
Ensure it is straight, square and at the right angle
Ensure the fit up of the joint is correct
Apply pressure to the joint area
Ensure any holes are aligned correctly
Jigs must be in good condition and suitable for the task
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Carry out Joining activities
Objective of the assessment The learners should demonstrate an ability to correctly carry out joining
activities.
carried out.


The assessment for this learning out come is attached to learning outcome 4.4:
Learner Instructions assessment 4.3: Carry out joining activities
Learner Report sheet assessment 4.3: Carry out joining activities
The unit grading sheet is attached to learning outcome 4.4. This sheet to be filled in when the unit is completed
and the learner is being assessed for an overall grade from pass, merit and distinction.
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Check joining activities are carried out correctly
outcome.
Practical skills
The learner can:
Demonstrate simple testing activities on joined materials
The learner can
Identify the methods used to check joining has been carried out correctly
Outline the importance of leaving the workplace and equipment in a safe and tidy condition
Learners should know the methods of checking joining activities:

Condition (marks, excessive filler material from joint and spatter)
Accuracy (squareness, angular alignment and level)
Orientation and fit up of parts
Distortion
Learners should be shown and practice simple methods of testing joining as appropriate to the process:
Visual
Peel test
Torsion test
Nick break
Macro etch
Learners must be aware of the importance of cleaning the workplace and why it should be restored at the end of
the activities and all equipment stored in the correct place. They must also how to safely and legally dispose of
waste materials and consumables.
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Check joining activities are carried out correctly
Objective of the assessment The learners should demonstrate an ability to check joining activities have been
carried out correctly.
carried out.



Attached to this learning outcome are:
Learner instructions assessment 4.4: Check joining activities
Learner report Sheet assessment 4.4: Check joining activities
The unit grading sheet is attached to this learning outcome.
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Assessment 4.4: Carry out joining activities
WHY are we doing this?

To demonstrate an ability to use joining processes
WHAT do we need?
Task instructions
Task drawing
Joining equipment
Suitable personal protective equipment (PPE)
Tools and equipment
HOW do we make a start?

You must observe health and safety procedures at all times.
1. Prepare The Work Area

Ensure you have the necessary tools and equipment before starting the task. Check that the work
area is clean and you know how any equipment works that you may need to use.
2. Simple Lap Joint

Using the details provided by your tutor you should join the materials using the appropriate joining
process as shown on the drawing issued to you.
3. Simple Box with Sliding Lid

Using the drawing provided by your tutor make the box as directed. You should join the corners
with spot welds and attach your nameplate using adhesives.
4. Checking Your Work

After you have finished the lap joint you must check how well it is joined. You must also check the
joining on your box. Check with your tutor on what is the best method to check your work.
Ask your Tutor to help you if you are unsure of any points or terms used
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5. Producing A Report
You should produce a report that gives details of how you carried out the cutting, forming and
assembling and checking activities. Your report should include details of the tools and equipment
you have used.
You should also include a section on what you have learned and what you might do differently if
you did it again. If things went wrong the first time you tried them, what you did differently the
second time.
Your report should be written in a way that someone else could use it as a guide to help them to
carry out their cutting, forming and assembling activities. Produce your report either by using the
one provided by hand or produce your own using a computer. If you use a computer you must
ensure that it is all your own work.
Ask your tutor to help you if you are unsure of any points or terms used
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Unit 04 Learner report
Learner name: Learner no:
Date: Page .. of
Report:
Assessors comments:
Assessor signature:
Date:
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Unit 04 Assessments 4.1 - 4.4
Joining engineering materials Unit grading sheet
Learner name: Learner no:

Date: Attempt no:
During the activity did the learner Please tick Assessor Comments

Mandatory unit assessment
(All must be completed before grading task)
1.1 Work safely at all times during the activities
1.2 Demonstrate an understanding of the requirements of the
task as given on the drawing/instructions
1.3 Select and use the appropriate tools and equipment
correctly and return after use
1.4 Select and use materials, consumables and equipment
correctly
1.5 Use appropriate problem solving techniques when needed
Pass
(All criteria must be completed to achieve pass grade)
P1 Learner has completed Investigate Joining task given in
outcome 4.1 with at least one example in each box
P2 Learner has successfully joined materials and completed
toolbox as instructed, with some defects but to acceptable
standard
P3 Learner has completed a basic procedure of joining activities
Merit
(All pass and merit criteria must be fully completed to achieve merit grade)
M1 Learners has completed joining and toolbox to a high
standard with minimal defects and distortion
M2 Learner has successfully carried out at least one testing
method on the lap joint
M3 Learner has completed Investigate Joining task given in
outcome 4.1 with at least two examples in each box
Distinction
(All pass, merit and distinction criteria must be fully completed to achieve distinction grade)
D1 Learners has completed a comprehensive report detailing,
procedures, tools/equipment and an evaluation of their
activities.
Grade given (P, M or D)
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Unit 04 Assessments 4.1 - 4.4
Joining engineering materials Unit grading sheet
Assessors general feedback:
Learner comment:(optional)
Date of re-assessment:(if applicable)

Assessor signature:
Learners signature:(if applicable)
2010 EMTA Awards Limited
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of
EAL EMTA Awards Limited
Requests should be made in writing and addressed to:
Product Development, EAL EMTA Awards Limited,
3365 Century Way, Thorpe Park, Leeds LS15 8ZB.
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QETF/004 Joining engineering

Credit Value 5 Level 1 GLH 40

Summary of learning outcomes

4.1 Demonstrate different joining processes

4.2 Prepare for joining activities

4.3 Carry out Joining activities

4.4 Check joining activities are carried out correctly

Welding, brazing and soldering processes:

Welding process types: Methods of brazing/soldering:

Learners should be aware of adhesive types for the joining operations:

Continued on next page

QETF-004 Issue 1.0 0810

QETF-004 Issue 1.0 0810

Resources needed Blank assessment table

Solutions and marking criteria

The unit grading sheet is attached to learning outcome 4.4.

QETF-004 Issue 1.0 0810

WHY are we doing this?

HOW do we make a start?

QETF-004 Issue 1.0 0810

Learner Name: Learner No:

Date: Attempt No:

Learners and/or assessors comments:

Assessor signature: Date:

Date of re-assessment:(if applicable)

QETF-004 Issue 1.0 0810

Learner Name: Billy Bloggs Learner No: 12345

Date: 04/04/04 Attempt No: 1

Answers like Answers like Answers like Answers like

Assessor signature: A Pedagogy Date: 05/04/04

Date of re-assessment: (if applicable) N/A

Checking the drawings/instructions are the correct issue number

QETF/004 Issue 1.0 0810

Resources needed Learners instructions and report sheets

Solutions and marking criteria

The unit grading sheet is attached to learning outcome 4.4.

QETF/004 Issue 1.0 0810

How to set up and adjust welding/brazing/soldering equipment:

QETF/004 Issue 1.0 0810

Resources needed Learners instructions and report sheets

Solutions and marking criteria

QETF/004 Issue 1.0 0810

Learners should know the methods of checking joining activities:

QETF/004 Issue 1.0 0810

Resources needed Learners instructions and report sheets

Solutions and marking criteria

The unit grading sheet is attached to this learning outcome.

QETF/004 Issue 1.0 0810

WHY are we doing this?

HOW do we make a start?

1. Prepare The Work Area

2. Simple Lap Joint

3. Simple Box with Sliding Lid

4. Checking Your Work

Continued on next page

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Learner name: Learner no:

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Learner name: Learner no:

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Assessors general feedback:

Date of re-assessment:(if applicable)