Design and Technology SEG Awards Vocationally-Related Qualification Revision
Complete topic breakdowns, revision notes, exam practice questions, and adaptive quizzes for the SEG Awards Vocationally-Related Qualification Design and Technology specification.
Specification Topics
- Engineering Drawing
- Materials, Science and Calculations for Fabrication and Welding Practice
- Manual Metal-Arc - (Overhead) - Stainless Steel
- Materials for Fabrication and Welding Techniques and Skills
- Manual Metal-Arc Welding – (Overhead) Low Carbon Steel, Stainless Steel
- 12. Advanced Fabrication Processes – Plate (3 mm and Above in Thickness)
- Fabrication Processes – Sheet Metal (Below 3 mm in Thickness)
- Tungsten-Arc Gas Shielded Welding - (Vertical) Low Carbon Steel
- Tungsten-Arc Gas Shielded Welding - (Overhead) - Stainless Steel
- Manual Metal-Arc Welding – (Vertical) Low Carbon Steel, Stainless Steel or Aluminium
- Manual Metal-Arc Welding - (Vertical) - Low Carbon Steel
- Manual Metal-Arc Welding - (Overhead) - Low Carbon Steel
- Metal-Arc Gas Shielded Welding - (Overhead) Low Carbon Steel
- Manual Metal-Arc Welding – Low Carbon Steel, Stainless Steel, Aluminium
- Fabrication Processes – Plate
- Metal-Arc Gas Shielded Welding – (Overhead) Low Carbon Steel, Stainless Steel, Aluminium
- Advanced Fabrication Processes – Sheet Metal (below 3 mm in Thickness)
- Manual Metal-Arc Welding - Stainless Steel
- Tungsten-Arc Gas Shielded Welding - (Overhead) - Aluminium
- Pipe Welding using Tungsten-Arc Gas Shielded Welding
- Metal-Arc Gas Shielded Welding – (Vertical) Low Carbon Steel, Stainless Steel or Aluminium
- Manual Metal-Arc Welding (Vertical) - Stainless Steel
- Metal-Arc Gas Shielded Welding - (overhead) - Stainless Steel
- Metal-Arc Gas Shielded Welding – Low Carbon Steel, Stainless Steel, Aluminium
- Pipe Welding using Manual Metal-Arc Welding, Metal-Arc Gas Shielded Welding or Tungsten-Arc Gas Shielded Welding
- 6. Fabrication Processes – Sheet Metal
- Tungsten-Arc Gas Shielded Welding – (Overhead) Low Carbon Steel, Stainless Steel, Aluminium
- Metal-Arc Gas Shielded Welding - Low Carbon Steel
- Tungsten-Arc Gas Shielded Welding - Low Carbon Steel
- Pipe Welding Using Manual Metal-Arc Welding
- Engineering Drawing using Manual and CAD Techniques
- Welding Processes (Manual Metal-Arc and Metal-Arc Gas Shielded))
- Manual Metal-Arc Welding - Low Carbon Steel
- Tungsten-Arc Gas Shielded Welding – (Vertical) Low Carbon Steel, Stainless Steel or Aluminium
- Metal-Arc Gas Shielded Welding- (vetical) Low Carbon Steel
- Metal-Arc Gas Shielded Weldiing - (Overhead) - Aluminium
- Tungsten-Arc Gas Shielded Welding – Low Carbon Steel, Stainless Steel, Aluminium
- Engineering Drawing Using Manual and CAD Techniques
- Health and Safety in a Fabrication and Welding Environment
- Metal-Arc Gas Shielded Welding - Stainless Steel
- Tungsten-Arc Gas Shielded Welding - Stainless Steel
- Pipe Welding using Metal-Arc Gas Shielded Welding
- Fabrication Processes (Sheet Metal and Plate)
- Fabrication Processes – Plate (3 mm and Above in Thickness)
- Thick Plate Welding using Flux Cored Metal-Arc Gas Shielded Welding
- Metal-Arc Gas Shielded Welding - (Vertical) - Aluminium
- Metal-Arc Gas Shielded Welding - (Vertical) Stainless Steel
- Tungsten-Arc Gas Shielded Welding - (Vertical) - Stainless steel
- Metal-Arc Gas Shielded Welding - Aluminium
- Tungsten-Arc Gas Shielded Welding - Aluminium
- Tungsten-Arc Gas Shielded Welding - (Vertical) - Aluminium
- Tungsten-Arc Gas Shielded Welding - (Overhead) - Low Carbon Steel
Top Exam Tips
- Practice drawing simple parts freehand first.
- Learn common CAD shortcuts to save time.
- Double-check title block information.
- Revise material classification and common tests.
- Practice calculations for area, volume, and force.
- Understand symbols and abbreviations used in welding.
- Practice calculations with real-world welding parameters.
- Revise material property tables and their applications.
- Focus on understanding, not just memorising, quality control processes.
- Revise key formulas for heat input and deposition rates.
Common Mistakes to Avoid
- Inconsistent line weights or styles.
- Missing or incorrect dimensions.
- Poor layout causing confusion.
- Confusing tensile strength with hardness.
- Miscalculating angles for bevels or bends.
- Overlooking heat-affected zone effects.
- Errors in unit conversions for heat input calculations.
- Misidentifying weld symbols on drawings.
Key Terminology & Definitions
- Using various drawing instruments and/or computer-aided design (CAD) systems, learners will know how to produce engineering drawings that will meet current industry standards.
- This is a mandatory unit which will be assessed by a 40 question on-line multi-choice question (MCQ) assessment. Learners will gain an understanding of various topics associated with the related aspects of welding and fabrication.The main areas or key focus points are materials, science, calculations and quality control of welding and fabrication operations.There is no practical requirement for this unit, however, observation of demonstrations concerning various aspects of the assessment criteria carried out in the workshop or laboratory is to be encouraged.
- 1.1. Identify the roles of various organisations involved with safety in the workplace, to include:• Health and Safety Executive (HSE)• Environmental Health• Local Authorities1.2. Identify the roles of various individuals involved with health and safety in the workplace, to include:• Company safety officers• Company safety representatives• Environmental health officers• HSE inspectors1.3. Identify the purpose for and typical contents of an organisations’ Health and Safety Policy1.4. Describe the purpose of a risk assessment, to include:• who should carry out risk assessments• when to carry out a risk assessment• identification of the 5 steps of risk assessment1.5. Identify the precautions to be taken when working in high risk areas, to include:• risk assessments• permits to work• high/low temperature working conditions• lock off systems• isolation of equipment1.6. Describe the control and safe removal of welding fumes and gases created during the welding process, to include:• natural extraction• local extraction• PPE and specialist breathing equipment1.7. Identify the different power sources used in MMA welding, to include:• transformer• generator• rectifier• invertor1.8. Describe features of the power sources as listed in 2.1, to include:• type of current produced (AC/DC) • maintenance requirements• portability• suitable applications 1.9. Identify the advantages and limitations of using both alternating current (AC) and direct current (DC)1.10. Describe how the electrical features listed affect the MMA welding process:• change of polarity when using direct current (DC)• current control (tapped, moving core and moving coil)• duty cycle of the power source • drooping characteristic feature1.11. Describe the importance of correct storage conditions for electrodes, to include:• location• ventilation• contamination• labelling1.12. Identify the use of different types of electrodes, to include:• cellulosic• rutile• basic (low hydrogen)1.13. Describe the reasons why basic (low hydrogen) electrodes require special conditions when being stored prior to use1.14. Describe the effects of using damaged or damp electrodes1.15. Identify the functions of:• flux coating on the electrode• slag covering on the weld deposit1.16. Identify and select the welding parameters to be used when welding low carbon steel in the overhead welding position (PE), to include:• welding current• OCV (open circuit voltage)• electrode slope and tilt angles• arc length• speed of travel• electrode polarity1.17. Identify which parameters may need a different selection when welding stainless steel or aluminium in the overhead position (PE)1.18. Identify suitable welding preparations for the type of joint and material thickness being welded, to include:• included angle• angle of bevel• root face dimension• root gap dimension1.19. Describe the advantages and limitations of the methods listed that are used to produce suitable welding preparations on materials, to include:• thermal methods• mechanical (chip forming)• shearing• bevelling machines• abrasive methods1.20. Identify the main types of distortion found in completed welded joints, to include:• longitudinal• transverse• angular1.21. Describe the significance of residual stress found in welded joint1.22. Identify the main causes of distortion in welded joints1.23. Identify methods used to control distortion in welded joints1.24. Identify appropriate safety checks on the welding equipment prior to use1.25. Select suitable welding parameters to enable the listed joints to be welded by the MMA welding process on low carbon steel or stainless steel.• tee fillet (PE)• butt weld(PE)• open outside corner (PE)• lap joint (PE)1.26. Carry out destructive tests on the completed welds and document the results. Tests to include:• face bend• root bend• fracture test1.27. Identify defects and imperfections that may be found in welds completed in the overhead position (PE) by the MMA welding process1.28. Identify the use of aids whe
- 1.1 For mixtures of metals, describe the terms• solubility• solid solutions2.1 Describe the effect of gain structure on annealing, normalising and hardening techniques with reference to temperatures and cooling rates. 2.2 Define• hardenability• weldability to British Standards• work hardening2.3 Define the critical cooling velocity with reference to • changes in microstructure• changes in mechanical properties• influence of mass/section of welded structures• hard zone cracking2.4 Describe the effects of alloying elements used to produce Alloy steels2.5 Calculate carbon equivalents to current British Standards2.6 Describe hot and cold cracking in terms of• cooling rate• hydrogeninfluence of impurities3.1 Describe the behaviour of a material subject to a tensile force in terms of • stress, strain and elasticity• yield strength• tensile strength• percentage elongation• percentage reduction in area• stiffness (without proof of Young’s modulus)• proof stress3.2 State Hooke’s Law3.3 Describe in simple terms the effects of compressive force and shear stress on common materials3.4 Describe the following mechanical testing methods• hardness testing (Brinell, Vickers and Rockwell)• fatigue testing• charpy impact test3.5 Describe how mechanical properties can affect the testing of metals 3.6 Describe in simple terms the mechanism by which creep occurs3.7 Describe the mechanism by which the following types of corrosion (stress, galvanic, rusting) occurs 3.8 Give examples of where the methods (mechanical barriers, inhibitors and sacrificial anodes) are used to overcome the effects caused by the types of corrosion described above
- Learners will understand differences in various metals, the way in which they are identified and the properties each have which will allow them to be used for certain applications and how materials are supplied to industry in different forms, sizes and profiles. Introductions to the application and use of welding terms and symbols are covered relating to fillet and butt welded joints. Simple applications of science are covered to enable the learner to understand how materials behave during the application of heat. This unit also covers the basic application of mathematics related to welding and fabrication activities and at a level that the learner should be able to understand and use confidently. This unit is assessed by a 30 question externally set MCQ (multiple choice question) examination.
- Learners will develop a high standard of practical skills to enable them to produce acceptable welded joints in the overhead (PE) welding position. This Diploma level qualification requires the learner to have a good understanding of health and safety, welding equipment, consumables, joint preparation and the quality assurance required to conform to relevant standards applicable to the welding industry.The learner has a choice of materials to weld by the manual metal-arc (MMA) welding process, these being low carbon steel or stainless steel.
- The practical content of this unit requires the learner to demonstrate skills in reading complex drawings, marking out, cutting, forming and assembling parts of a fabricated assembly that meet the required dimensional accuracy and tolerance in low carbon steel greater than 3 mm in thickness.The theoretical aspects of this unit covers the features of fabrication work that enable the practical work to be carried out safely and understanding the various processes involved which are required to produce complex assemblies.
- The practical content of this unit requires the learner to manufacture a fabricated assembly in sheet metal (below 3 mm in thickness) to given dimensions and within a specified tolerance.Understanding safe working practices when carrying out sheet metal fabrication activities is an important criterion in all aspects of this unit. Other areas include working from fabrication drawings, marking out, cutting, forming and assembly.
- 1.1. Identify the responsibilities of both the employer and the employee when complying with the Health and Safety at Work Act 19741.2. Identify the use of current legislation, to include:• COSHH (Control of Substances Hazardous to Health)• PUWER (Provision and Use of Work Equipment)• RIDDOR (Reporting of Injuries, Diseases, and Dangerous Occurrences Regulations)1.3. Identify the use of a risk assessment procedure1.4. Identify safe working practices when using the TAG welding process, to include working:• in a confined space• at an height above 2 metres • with containers that have held chemicals or flammable liquids • in damp or wet conditions• with hazards from using high frequency units1.5. Describe the function of the equipment used in the TAG welding process, to include:• rectifier• inverter• high frequency units• welding lead cable and clamp• welding return cable and clamp• secondary earth and connector• torch• tungsten• collet• shroud• cooling system• gas supply, regulator and flow meter1.6. Identify suitable maintenance checks that would be required on the items listed in 2.11.7. State the procedures to be followed for the safe storage of welding equipment when the welding activity has been completed1.8. Identify a range of tungsten electrodes that are used for the TAG welding process, to include:• types used• size (diameter)• alloying additions• preparation of electrode tip (shape/dimensions)1.9. Identify a range of filler wires that are used for the TAG welding process, to include:• types used• size (diameter)• alloying additions1.10. Describe the effects of incorrect storage of tungsten electrode and filler wires1.11. State the effect of using damaged tungsten electrode and filler wires when carrying out welding activities1.12. Identify the shielding gas/es used in TAG welding1.13. Identify the function of the shielding gas used in TAG welding1.14. Identify and select the welding parameters to be used when welding in the vertical welding position (PF/PG):• welding current• torch slope and tilt angles• filler wire slope and tilt angles• shielding gas flow rate• arc length• speed of travel1.15. Identify the use of autogenous techniques when using the TAG welding process1.16. Identify suitable welding preparations for the type of joint and material thickness being welded1.17. Identify terms associated with welding preparations, to include:• included angle• angle of bevel• root face dimension• root gap dimension 1.18. Describe the application of distortion control techniques, to include: • pre-setting • restraint• joint geometry • chills• weld sequence1.19. Be able to follow instructions given on a WPS (Welding Procedure Sheet)1.20. Identify appropriate safety checks on the welding equipment prior to use1.21. Select suitable welding parameters to enable the listed joints to be welded by the TAG welding process on low carbon steel or stainless steel or aluminium• tee fillet (PF)• butt (PF)• open outside corner (PF or PG)• lap joint (PF or PG)1.22. Carry out visual inspection of completed welds1.23. Prepare and carry out nick break tests on completed fillet welds1.24. Prepare and carry out destructive tests on completed butt welds, to include:• face bend • root bend• fracture test 1.25. Record the results of the weld examination as detailed in 7.1, 7.2 and 7.31.26. Identify and describe typical defects found in the TAG welding process joints, to include:• cracks• inclusions• undercut• lack of fusion• arc craters• porosity• lack of penetration1.27. Identify possible causes of the defects listed in 8.1
- 1.1. Identify the roles of various organisations involved with Health and safety in the workplace, to include:• Health and Safety Executive (HSE)• Environmental Health• Local Authorities1.2. Identify the roles of various individuals involved with Health and Safety in the workplace, to include:• Company safety officers• Company safety representatives• Environmental health officers• HSE inspectors1.3. Identify the purpose and typical contents of an organisations Health and Safety Policy1.4. Describe the purpose of a risk assessment, to include:• who should carry out risk assessments• when to carry out a risk assessment• identification of the 5 steps of risk assessment1.5. Identify the precautions to be taken when working in high risk areas, to include:• risk assessments• permits to work• high/low temperature working conditions• lock off systems• isolation of equipment1.6. Describe the control and safe removal of welding fumes and gases created during the welding process, to include:• natural extraction• local extraction• PPE and specialist breathing equipment1.7. Describe the hazards associated when using the TAG welding process, to include:• arc radiation• using high frequency• production of phosgene gas1.8. Identify the power sources used in TAG welding1.9. Identify the type of welding current (AC/DC) and polarity to be used when welding:• low carbon steel• stainless steel• aluminium1.10. Describe the application and use of equipment used in the TAG welding process, to include:• high frequency unit• current control foot pedal• gas pressure regulator• gas flow meter• gas lens1.11. Describe the importance of correct storage conditions for tungsten electrodes and filler wires, to include:• location• ventilation• contamination• labelling 1.12. Identify the range of different alloying elements added to tungsten electrodes1.13. Identify the electrode (tip) preparation required when using an AC or DC welding current1.14. Identify the content and application of a range of filler wires used in the TAG welding process1.15. Describe the effects of using damaged tungsten electrodes and filler wires1.16. Identify the range and application of shielding gases used in the TAG welding process1.17. Identify and select the welding parameters to be used when welding low carbon steel, stainless steel or aluminium in the overhead welding position (PE), to include:• welding voltage• slope in/slope out control• torch slope and tilt angles• high frequency• speed of travel• pre/post gas flow• shielding gas flow rate (LPM)1.18. Describe the application and function of gas backing /purging1.19. Identify suitable welding preparations for the type of joint and material thickness being welded, to include:• included angle• angle of bevel• root face dimension• root gap dimension1.20. Describe the advantages and limitations of the methods listed that are used to produce suitable welding preparations on materials, to include:• thermal methods• mechanical (chip forming)• shearing• bevelling machines• abrasive methods1.21. Identify the main types of distortion found in completed welded joints, to include:• longitudinal• transverse• angular1.22. Identify the main causes of distortion in welded joints1.23. Identify methods used to control distortion in welded joints1.24. Describe the significance of residual stress found in welded joints1.25. Identify appropriate safety checks on the welding equipment prior to use1.26. Select suitable welding parameters to enable the listed joints to be welded by the TAG welding process on one material type to cover, low carbon steel, stainless steel or aluminium in a thickness range of between 1.6 mm to 3 mm.• tee fillet (PE)• butt (PE)• open outside corner (PE)• lap joint (PE)1.27. Carry out destructive tests on the completed welds and document the results. Tests to include:• face bend• root bend• fracture test• nick break test1.28. Identify the function of:• weld inspection activities• quality control• quality assurance1.29. Des
- This unit covering manual metal-arc (MMA) welding is designed to further the skills of the learner who has satisfactorily completed and achieved a level 2 qualification in fabrication and welding practice. Learners will further develop skills in the theory of safe working practice and the theoretical aspects of technology associated with this particular welding process.For this qualification all welding is to be carried out in the vertical welding position (PF/PG) covering a range of welded joints. Both the fillet weld and butt joint will be tested to ensure that they are structurally sound.
- Health & Safety Legislation and Risk Assessment
- MMA Welding Equipment and Maintenance
- Electrode Classification and Storage
- Vertical Welding Parameters and Technique