This unit forms part of the Course in MCAST Award in Manual Metal Arc Welding Pipe (MMA). Once a learner complete all the units in this course satisfactorily; that is has obtained a pass mark in the assessment and respected the 80% attendance s/he will achieve an award pegged at MQF Level 4, 11 ECVET Credits.
The course is designed for those determined to obtain a qualification to work in the industry with enough skills to produce sound welded joints in a selection of complex fixed positions to meet industry requirements. MMA technology, plate and pipe preparation for welding and weld specimen destructive testing are covered in depth to enable learners to work on their own directly from job specifications.
This course provides progression across a range of welding processes.
This is a 32 hrs of guided learning course. Students need to invest further hours in the course, which will include private study and home assignments.
Lessons are held as indicated on the prospectus and website.
This unit covers the underpinning knowledge of Manual Metal Arc Welding process (Plate Welding); the importance of following technical procedures and the health and safety issues when working individually and in teams with MMA welding equipment. The technological requirements to set and use welding equipment, destructive testing and macro examinations are essential topics of this course.
Learning Outcome 1: Identify hazards when working with Manual Metal Arc Welding equipment
- Fires and explosions, burns, fumes, electric shock, toxic gases generated by welding processes (Nitrous Oxides), radiation heat stress dust, appropriate personal protective equipment (PPE); arc welding rays hoe metal/ slag
Learning Outcome 2: Identify hazards when working in teams at the place of work
- Health and Safety legislation in relation to welding, industry and working at sites:
Excessive noise; unexpected tripping hazards; access and scaffolding hazards; escape routes; warning signs; safety lines; safety rails; emergency lighting; fire extinguishers
Learning Outcome 3: Identify Various Manual Metal Arc Welding equipment and accessories
- Power Sources: DC/ AC Weld Sets: single phase and three phase weld sets, transformers, transformer/ rectifier, inverter, generator, rated output; Electrode holders; Power Supply; Electrodes; Current adjustments (moving coil); Electrical symbols on weld sets and weld diagrams; electrical fuse; electrical resistor/ capacitor/ transformer/ diode
- Covered Electrodes: Classification; AWS/ BS Standards (E7016/E7018/E6013etc); Dia. Of electrodes: 2.5/3.25/ etc. and common electrodes; electrode coating functions; storing of electrodes BS EN 499 (1994); Designations: product/ process used; strength and elongation of the weld metal; impact properties of the weld metal; chemical composition of the weld metal; type of electrode covering, recovery rate and current type; welding position; hydrogen content of the deposit. Electrode covering type: cellulosic, rutile, basic, iron powder; electrode covering function.
- Appropriate techniques when working with various electrodes: Cellulosic, rutile, basic, iron powder (type of current, electrode polarity, welding current range, voltage)
- Fundamentals of Arc Welding: Basic Arc-welding circuit; Nature of the Arc; arc Shielding; Overcoming Current Limitations; welding parameters for specific applications
- Weldability of carbon and Low-Alloy Steels: factors causing underbread cracking; the effect of section thickness; the effect of joint restraint
- Joint Design and Welding Instructions: symbols conform to BS EN 22553: face, toes, root, HAZ, convex fillet, concave fillet, mitred fillet, leg, throat, root face, root gap, bevel angle, included angle, weld width, fusion zone, excess weld, penetration, fusion line. Weld symbols on drawings.
- Weld diagrams terms: penetration, weld metal, weld root, parent metal, bevel, bevel angle, root face, root gap,
- Weld positions notification: PC horizontal position, PD horizontal/ overhead position, PE overhead positions – etc; both EN ISO 6947 and ASME IX.
- Weld defects: slag inclusion, lack of fusion, undercut
- Distortion control: run-on and off plates, strong backs, pre-setting,
Learning Outcome 4: Identify various destructive tests
- Root bend test; macro section inspection; nick-break fracture test
The following are the suggested pre-requisites and/or entry requirements needed:
- Students must be capable to take their own responsibility to follow health and safety requirements and technical procedures for the welding and preparation of materials
- Over 16 years old and satisfactory completed the Level 3 course in Manual Metal Arc Welding
Course participants may be awarded either an MCAST Certificate of Attendance or an MCAST Certificate of Achievement.
MCAST Certificate of Attendance
- An MCAST Certificate of Attendance will be awarded to those candidates who attend at least 80% of the lessons.
MCAST Certificate of Achievement
- An MCAST Certificate of Achievement will be awarded to those candidates who satisfy the 80% attendance criteria AND ALSO choose to sit and pass the course assessment/s.
- Students who opt not to sit for the assessment/s or fail (the assessment/s) will however be awarded an MCAST Certificate of Attendance provided that they fulfill the minimum attendance criteria as stated above.
If the student intends to obtain a Certificate of Achievement, she/he is required to sit for an assessment/s. Assessment/s may take various forms such as a home assignment, class assignment, practical test and time constrained test. However, the assessment/s is not compulsory and an applicant may choose not to sit for it.
During the lessons, students should have their own safety gear to industry standards. (Gear to include safety shoes, cotton boiler suit, safety glasses and gloves)