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SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE:

Join metals using the resistance welding process

SAQA US ID	UNIT STANDARD TITLE
12482	Join metals using the resistance welding process
ORIGINATOR
SGB Manufacturing and Assembly Processes
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-
FIELD			SUBFIELD
Field 06 - Manufacturing, Engineering and Technology			Manufacturing and Assembly
ABET BAND	UNIT STANDARD TYPE	PRE-2009 NQF LEVEL	NQF LEVEL	CREDITS
Undefined	Regular	Level 2	NQF Level 02	4
REGISTRATION STATUS		REGISTRATION START DATE	REGISTRATION END DATE	SAQA DECISION NUMBER
Passed the End Date - Status was "Reregistered"		2018-07-01	2023-06-30	SAQA 06120/18
LAST DATE FOR ENROLMENT		LAST DATE FOR ACHIEVEMENT
2024-06-30		2027-06-30

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.

This unit standard does not replace any other unit standard and is not replaced by any other unit standard.

PURPOSE OF THE UNIT STANDARD

Joining metals using the resistance welding process. This includes preparing and maintaining the equipment and controlling the quality of the completed welds.

The skills, values and knowledge reflected in this unit standard are required by people in the field of engineering fabrication, which includes boilermaking, sheetmetal working, welding and vehicle body building. The learning outcomes in this unit standard contribute to the exit level outcomes required for the National Certificate in Fabrication (NQF level 2) and related qualifications.

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

This unit standard has been designed as part of a progression. It is one of a series of unit standards for welding metals in the fabrication field.

The credits allocated to this unit standard assume that a learner has already learned to understand and apply safe work practices and to select, use and care for engineering hand and power tools.

UNIT STANDARD RANGE

A general guide to the scope, context conditions, and level at which I am expected to perform.
The scope and level of this unit standard is determined by the ranges as indicated under the specific outcomes. All work is performed under supervision.

Specific Outcomes and Assessment Criteria:

SPECIFIC OUTCOME 1

Prepare for work activity.

OUTCOME NOTES

Interpret job instructions and determine sequence of operations

Find relevant worksite procedure and determine operational requirements

Select and prepare equipment for operation including routine maintenance and pre-operational checks

Implement maintenance procedures for copper electrodes

Adjust settings and assemble equipment

Check that consumables required are at the workstation

Prepare materials for welding

Identify hazards and take preventative action

OUTCOME RANGE

Worksite procedure: international, national and company quality procedures which govern the welding operation

Resistance welding process variations include spot welding (RSW), projection welding (RPW) and seam welding (RSEW)

Hazards include electrical, hot metal, fumes, fire and/or explosion, mechanical

Equipment includes power source rating and duty cycle, electrodes, cooling system, electrode force

Metals include carbon steel, galvanised steel

Material characteristics include electrical and thermal conductivity; surface conditions include coatings, corrosion

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. Welded metals meet job and quality specifications.

ASSESSMENT CRITERION NOTES

Indicators :

1. Finished weld operation meets all quality procedure requirements
2. Correct welding equipment is selected
3. Correct consumables are chosen for parent metals
4. Equipment is set up to work safely and without damage to work piece or equipment
5. Safe working practices are adhered to
6. Materials are prepared before welding
7. Materials are welded according to specifications
8. Welding defects are identified and corrected
9. Welds are cleaned after welding
10. A clean and tidy work environment is maintained
11. Hazards are identified and avoided

Understanding confirmed :

Explain and discuss
1. Process of resistance welding
2. Equipment, functions, parts, consumables and set up
3. Requirements in worksite procedure
4. Applicable theory
5. Metals - Characteristics and surface condition
6. Welding defects and hazards
7. Safety procedures and equipment
8. Reporting procedures
9. Methods of cleaning welds

SPECIFIC OUTCOME 2

Join metals using the resistance welding process.

OUTCOME NOTES

Set up workpiece

Establish welding parameters

Weld materials

Dispose of waste materials

Store reusable material

OUTCOME RANGE

Welding parameters include welding current, electrode force, welding time, electrode material and design

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. Welded metals meet job and quality specifications.

ASSESSMENT CRITERION NOTES

SPECIFIC OUTCOME 3

Apply quality checks on welded metals.

OUTCOME NOTES

Identify and correct welding defects

Clean welds after welding

Check completed weld using visual examination

OUTCOME RANGE

Tests to identify defects include peel and chisel tests
Cleaning tools include wire brushes, chipping hammer, pneumatic chipping hammer

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. Welded metals meet job and quality specifications.

ASSESSMENT CRITERION NOTES

SPECIFIC OUTCOME 4

Recognise and report problems of quality, operation, output, safety.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. Welded metals meet job and quality specifications.

ASSESSMENT CRITERION NOTES

SPECIFIC OUTCOME 5

Report outcomes of work done.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. Welded metals meet job and quality specifications.

ASSESSMENT CRITERION NOTES

SPECIFIC OUTCOME 6

Apply safe working practices and discuss issues related to safety of self, fellow workers.

OUTCOME NOTES

Apply safe working practices and discuss issues related to safety of self, fellow workers, machines, equipment, materials and the environment.

OUTCOME RANGE

Safe working practices include use of appropriate personal protective equipment, isolation from electrical shocks, taking extra precautions in damp areas, ensuring adequate ventilation

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. Welded metals meet job and quality specifications.

ASSESSMENT CRITERION NOTES

UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS

My assessment will be governed by the policies and guidelines of the MERSETA ETQA, which has the jurisdiction over this field of learning. My assessor will (at the very least) be accredited and have a technical qualification in this learning area.

I can be assessed in the language of my choice although if I have to report incidents or conditions to someone else, I will be assessed on my ability to report in the language commonly used in my working environment.

I will be assessed in the workplace but I can submit documents, projects, test results and assignments that were produced outside of the workplace.

I can be assessed against this unit standard to obtain credits, or as part of an integrated assessment for a qualification.

UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE

Names & functions of:

Types of resistance welding

Types of equipment

Attributes, descriptions, characteristics & properties:

Spot welding

Projection welding

Seam welding

Electrodes

Sensory cues

Smell indicating overheating equipment

Purpose of:

Resistance welding

Selecting correct electrodes

Safety checks

Quality checks

Processes, events, causes and effects, implications:

Implications of using incorrect or defective equipment

Effects of welding current, electrode force, welding time and electrode material and design on weld quality

Influence of metal characteristics and surface condition on welding parameters

Implications of ignoring potential hazards

Implications of not checking for welding defects

Implications for not preparing workpiece before welding

Causes of weld defects

Procedures and techniques:

Set up procedures for resistance welding

Resistance welding procedures

Preparation for welding

Safety procedures

Quality procedures

Reporting procedures

Regulations, legislation, agreements, policies, standards:

Applicable safety, health and environmental protection legislation and standards

Theory: rules, principles, laws:

Principles of expansion and contraction

Basic principles of electricity

Electrode classification

Relationships, systems:

Relationship between the welding cycle parameters and the mechanical properties of welded joints

Critical Cross-field Outcomes (CCFO):

UNIT STANDARD CCFO IDENTIFYING

Identify and solve problems:

Recognise problems while welding and respond appropriately

Defects are recognised and corrected

Hazards are identified and avoided

UNIT STANDARD CCFO WORKING

Work together with others:

Participate in efforts of workgroup

UNIT STANDARD CCFO ORGANISING

Organise and manage myself and my activities:

Plan sequence of operations based on job instructions and set up equipment appropriately

UNIT STANDARD CCFO COLLECTING

Collect, analyse, organise and critically evaluate information:

Visually examine quality of weld for non-conformance

UNIT STANDARD CCFO COMMUNICATING

Communicate effectively:

Report outcome of work to appropriate personnel

UNIT STANDARD CCFO SCIENCE

Use science and technology effectively and critically:

Understanding electrical and mechanical principles

Characteristics of materials

Principles of expansion and contraction

UNIT STANDARD CCFO DEMONSTRATING

Demonstrate an understanding of the world as a set of related systems:

Explain the role of resistance welding in the fabrication environment

REREGISTRATION HISTORY

As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015.

QUALIFICATIONS UTILISING THIS UNIT STANDARD:

	ID	QUALIFICATION TITLE	PRE-2009 NQF LEVEL	NQF LEVEL	STATUS	END DATE	PRIMARY OR DELEGATED QA FUNCTIONARY
Elective	22869	National Certificate: Engineering Fabrication	Level 2	NQF Level 02	Passed the End Date - Status was "Reregistered"	2007-08-16	MERSETA
Elective	58722	National Certificate: Engineering Fabrication	Level 2	NQF Level 02	Passed the End Date - Status was "Reregistered"	2023-06-30	As per Learning Programmes recorded against this Qual
Elective	58720	National Certificate: Engineering Fabrication	Level 3	NQF Level 03	Passed the End Date - Status was "Reregistered"	2023-06-30	As per Learning Programmes recorded against this Qual

PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD:

This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.

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