Introduction to Tungsten Inert Gas Welding Revision — Excellence, Achievement & Learning Limited Occupational Qualification

    Know the process and health & safety requirements for tungsten inert gas (TIG) welding, Be able to produce beads on plate in the PA flat position, Be able to produce a lap fillet weld in the PB horizontal/vertical position, Be able to produce a tee fillet weld in the PA flat position, Be able to produce a corner weld in the PA flat position

    Exam Tips

    Common Mistakes

    Key Marking Points

    Introduction to Tungsten Inert Gas Welding

    EXCELLENCE-ACHIEVEMENT-AND-LEARNING-LIMITED
    vocational

    This topic introduces Tungsten Inert Gas (TIG) welding, covering health and safety, equipment setup, and basic weld types. Learners will produce beads, lap fillet, tee fillet, and corner welds in flat positions.

    0
    Learning Outcomes
    10
    Assessment Guidance
    10
    Key Skills
    8
    Key Terms
    15
    Assessment Criteria

    Assessment criteria

    EAL Level 1 Award In Engineering Technologies
    EAL Level 1 Diploma In Engineering Technologies
    EAL Level 1 Certificate In Engineering Technologies

    Topic Overview

    The EAL Level 1 Award in Engineering Technologies is a foundational qualification designed to introduce students to the core principles and practices of engineering. It covers essential topics such as health and safety, engineering materials, hand tools, and basic measurement techniques. This award is ideal for students who are considering a career in engineering or related technical fields, as it provides a solid grounding in the practical skills and theoretical knowledge required for further study or entry-level roles.

    In the context of Design and Technology, this qualification bridges the gap between creative design and practical engineering. Students learn how to select appropriate materials, use tools safely and effectively, and apply measurement and marking-out techniques to produce accurate components. Understanding these fundamentals is crucial for progressing to higher-level engineering qualifications or apprenticeships, where precision and safety are paramount.

    This qualification also emphasizes the importance of working safely in an engineering environment. Students are introduced to risk assessments, personal protective equipment (PPE), and safe working practices, which are essential for any engineering or manufacturing setting. By the end of the course, students should be able to demonstrate basic competence in using hand tools, measuring instruments, and interpreting simple engineering drawings.

    Key Concepts

    Core ideas you must understand for this topic

    • →Health and safety regulations in engineering, including the Health and Safety at Work Act 1974 and COSHH (Control of Substances Hazardous to Health).
    • →Properties and applications of common engineering materials such as mild steel, aluminium, and plastics.
    • →Correct selection and safe use of hand tools (e.g., hacksaws, files, hammers) and measuring instruments (e.g., steel rules, callipers, micrometers).
    • →Basic marking-out techniques using scribers, centre punches, and engineers' squares.
    • →Interpretation of simple engineering drawings, including dimensions, tolerances, and symbols.

    What You Need to Demonstrate

    Key skills and knowledge for this topic

    • Follows health and safety procedures for TIG welding.
    • Sets up equipment correctly including gas flow and polarity.
    • Produces consistent beads on plate in flat position.
    • Creates sound lap, tee, and corner fillet welds.
    • Explains TIG welding process and safety requirements.
    • Produces a continuous bead on plate in PA position.
    • Produces a lap fillet weld in PB position.
    • Produces a tee fillet weld in PA position.

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Follows health and safety procedures for TIG welding.
    • Sets up equipment correctly including gas flow and polarity.
    • Produces consistent beads on plate in flat position.
    • Creates sound lap, tee, and corner fillet welds.
    • Explains TIG welding process and safety requirements.
    • Produces a continuous bead on plate in PA position.
    • Produces a lap fillet weld in PB position.
    • Produces a tee fillet weld in PA position.
    • Produces a corner weld in PA position.
    • Award credit for correct identification of hazards such as electric shock, fume inhalation, and radiation, with evidence of control measures like PPE, ventilation, and screens.
    • Award credit for clean preparation of base metal (free of contaminants) and proper assembly of the welding torch with undamaged ceramics.
    • Award credit for beads showing consistent width and height, straightness, and no visible defects like porosity, undercut, or spatter.
    • Award credit for lap fillet weld with throat thickness not less than 0.7 times the material thickness and fusion to both plates.
    • Award credit for tee fillet weld with legs of equal length (within tolerance) and full penetration at the root.
    • Award credit for corner weld showing adequate fusion to both sides without burn-through or excessive concavity.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Practice maintaining a steady arc length.
    • 💡Clean base metal thoroughly before welding.
    • 💡Check gas flow rate before starting.
    • 💡Practise maintaining consistent arc length.
    • 💡Ensure proper cleaning of base metal.
    • 💡Check weld appearance for penetration and fusion.
    • 💡Prior to the assessment, conduct a trial weld on test coupons to confirm machine settings and technique.
    • 💡Always check the welding procedure specification (WPS) if provided; it contains essential parameters and acceptance criteria.
    • 💡Position yourself and the workpiece to allow comfortable torch manipulation and clear visibility of the weld pool.
    • 💡Inspect your welds visually before asking the assessor to evaluate; check for uniformity, cracks, and porosity.
    • 💡When answering questions about health and safety, always refer to specific legislation (e.g., Health and Safety at Work Act) and give practical examples of how it applies in a workshop setting. This shows deeper understanding.
    • 💡For practical assessments, ensure you demonstrate correct tool handling techniques. For instance, when using a hacksaw, maintain a steady rhythm and use the full length of the blade to avoid jamming. Examiners look for safe and efficient working practices.
    • 💡In written exams, pay attention to the command words. 'Describe' requires a detailed explanation, while 'Explain' requires reasons or causes. For example, 'Explain why mild steel is used for car body panels' should include points about its ductility, weldability, and cost-effectiveness.

    Common Mistakes

    Common errors to avoid in your coursework

    • Incorrect tungsten electrode preparation.
    • Poor gas shielding leading to porosity.
    • Inconsistent travel speed affecting weld quality.
    • Incorrect gas flow or tungsten preparation.
    • Poor travel speed leading to uneven beads.
    • Incorrect torch angle or filler rod placement.
    • Tungsten electrode contamination due to contact with the weld pool or filler rod, leading to arc wander.
    • Inadequate gas coverage causing porosity; often a result of incorrect gas flow rate, draughts, or holding the torch at an incorrect angle.
    • Excessive heat input causing distortion, especially on thin gauge materials; failure to use tack welds or back-step technique.
    • Misidentification of filler rod grade, leading to incompatible weld metal properties.
    • Misconception: 'All metals are the same.' Correction: Different metals have distinct properties (e.g., hardness, ductility, corrosion resistance) that affect their suitability for specific applications. For example, mild steel is tough and easy to weld, while aluminium is lightweight and corrosion-resistant.
    • Misconception: 'Safety glasses are optional.' Correction: In engineering workshops, safety glasses are mandatory when using tools or machinery that could produce flying debris. Failure to wear them can result in serious eye injuries.
    • Misconception: 'Measuring once is enough.' Correction: Always measure twice (or more) to avoid errors. A common mistake is misreading a micrometer or steel rule, leading to inaccurate components that may not fit or function correctly.

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Basic numeracy skills for taking measurements and understanding tolerances.
    • •Familiarity with simple tools and materials from Key Stage 3 Design and Technology.
    • •An understanding of basic workshop safety rules (e.g., not running, tying back long hair).

    Key Terminology

    Essential terms to know

    • Know the process and health & safety requirements for tungsten inert gas (TIG) welding, Be able to produce beads on plate in the PA flat position, Be able to produce a lap fillet weld in the PB horizontal/vertical position, Be able to produce a tee fillet weld in the PA flat position, Be able to produce a corner weld in the PA flat position
    • Know the process and health & safety requirements for tungsten inert gas (TIG) welding, Be able to produce beads on plate in the PA flat position, Be able to produce a lap fillet weld in the PB horizontal/vertical position, Be able to produce a tee fillet weld in the PA flat position, Be able to produce a corner weld in the PA flat position
    • TIG Welding Process Fundamentals
    • Health and Safety Practices
    • Bead on Plate Technique (PA)
    • Lap Fillet Weld (PB)
    • Tee Fillet Weld (PA)
    • Corner Weld (PA)

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