Manual Metal-Arc Welding - Stainless Steel — SEG Awards Vocationally-Related Qualification Design and Technology Revision

    Manual Metal-Arc (MMA) welding on stainless steel requires correct PPE, risk awareness, and proper equipment setup. Learners must produce welded joints in

    Topic Synopsis

    Manual Metal-Arc (MMA) welding on stainless steel requires correct PPE, risk awareness, and proper equipment setup. Learners must produce welded joints in PA/PB positions, inspect for defects, and perform destructive tests.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Manual Metal-Arc Welding - Stainless Steel

    SEG AWARDS
    vocational

    Manual Metal-Arc (MMA) welding on stainless steel requires correct PPE, risk awareness, and proper equipment setup. Learners must produce welded joints in PA/PB positions, inspect for defects, and perform destructive tests.

    1
    Learning Outcomes
    3
    Assessment Guidance
    3
    Key Skills
    1
    Key Terms
    5
    Assessment Criteria

    Assessment criteria

    SEG Awards Level 2 Award in Welding Techniques and Skills

    Topic Overview

    The SEG Awards Level 2 Award in Welding Techniques and Skills introduces you to the core principles and practical methods of welding, focusing on the most common industrial processes: Manual Metal Arc (MMA), Metal Inert Gas (MIG), and Tungsten Inert Gas (TIG). You'll learn how to prepare materials, set up equipment, and produce sound welds in various positions (flat, horizontal, vertical, and overhead). This qualification is essential for careers in construction, manufacturing, automotive, and engineering, as welding is a fundamental joining technique used across these industries.

    Safety is paramount in welding. The course covers personal protective equipment (PPE), ventilation, fire prevention, and safe handling of gases and electrical equipment. You'll also study weld defects, their causes, and how to avoid them—knowledge that directly impacts the quality and integrity of your work. By the end, you'll be able to interpret welding symbols, select appropriate parameters, and produce welds that meet industry standards (e.g., BS EN ISO 5817).

    This award sits within the wider Design and Technology curriculum by linking practical skills with material science and engineering principles. It prepares you for further study (e.g., Level 3 qualifications) or direct entry into apprenticeships. Mastering welding techniques not only builds technical competence but also develops problem-solving, attention to detail, and manual dexterity—transferable skills valued in many technical roles.

    Key Concepts

    Core ideas you must understand for this topic

    • →Welding processes: Understand the differences between MMA (stick welding), MIG (wire feed with shielding gas), and TIG (non-consumable tungsten electrode with filler rod). Each has specific applications, advantages, and limitations.
    • →Weld positions: Flat (PA), horizontal-vertical (PB), vertical (PF), and overhead (PE). You must be able to set up and weld in each position, adjusting technique to control molten metal flow.
    • →Weld defects: Common defects include porosity (gas pockets), slag inclusion, lack of fusion, undercut, and cracking. Know their causes (e.g., incorrect travel speed, contaminated filler) and how to prevent them.
    • →Safety procedures: Correct use of PPE (welding helmet with appropriate shade, gloves, apron, boots), fume extraction, fire watch, and safe storage of gas cylinders. Never weld without proper ventilation or near flammable materials.
    • →Welding symbols and standards: Interpret basic welding symbols on engineering drawings (e.g., fillet weld size, length, pitch). Understand quality levels according to BS EN ISO 5817 (B, C, D).

    Learning Objectives

    What you need to know and understand

    • 1.1 Identify the need to use appropriate PPE (personal protective equipment) when carrying out manual metal welding activities1.2 Identify associated risks when welding with MMA, to include:• arc radiation burns• arc eye• burns from handling hot materials• welding fumes• electric shocks • fire• sparks1.3 Identify fire prevention and emergency procedures required in the workplace, to include:• causes of fire• types of fire extinguisher used• evacuation procedures1.4 Identify the main groups of safety signs, to include:• warning• prohibition• mandatory• information signs1.5 Identify the function of the listed equipment when used with MMA welding activities:• transformer/generators• transformer/rectifiers• welding lead• welding return lead• welding earth• electrode holders1.6 Identify ancillary equipment used when welding with the MMA welding process1.7 Identify suitable storage conditions for manual metal welding electrodes1.8 Identify the electrode in terms of:• size by electrode diameter• flux coating type1.9 Identify appropriate safety checks on MMA welding equipment prior to use1.10 Prepare to carry out MMA welding to produce welded joints in the PA or PB positions, to include:• production of the correct welding preparation• identify distortion control methods to be used• select the correct electrode type/size• set the correct welding current• produce suitable tack welds• weld the joint• post weld cleaning1.11 Identify welding parameters to be used when completing welded joints using MMA welding, to include:• welding current• electrode slope and tilt angles• arc length• electrode polarity1.12 Identify suitable safety checks on welding equipment prior to use1.13 Complete a weld on:• low carbon steel greater than 6 mm in thickness or• stainless steel in materials greater than 3mm in thickness or • aluminium in materials greater than 3mm in thicknessusing the MMA welding process, to include as a minimum:• lap joint • open outside corner • single vee butt joint• tee fillet weldWelds to be completed in the PA or PB position1.14 Describe the limitations of visual inspection on completed welded joints using the MMA welding process1.15 Identify and describe typical welding defects that may be found in MMA welded joints, to include:• undercut • cracks• slag inclusions• porosity• arc craters• lack of penetration 1.16 Check completed welds for:• weld size to include leg length and throat thickness• weld profile• weld appearance and uniformity• absence of surface defects1.17 Complete the requirements for a report document on welds produced1.18 Prepare and carry out a destructive test on a fillet weld in accordance with the supplied drawing of the welded joint, to include:• nick break test1.19 Prepare and carry out destructive tests on a completed single vee butt weld in accordance with the supplied drawing of the welded joint, to include:• face bend test• root bend test• fracture test1.20 Identify appropriate documentation relating to welding activities, to include:• welding procedure specifications (WPS)• weld inspection report

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Identify correct PPE and associated risks.
    • Set up welding equipment with correct parameters.
    • Produce sound welds (lap, corner, butt, tee) in PA/PB.
    • Identify and describe common welding defects.
    • Perform destructive tests (nick break, bend, fracture).

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Memorise safety signs and fire extinguisher types.
    • 💡Practice setting welding current for different thicknesses.
    • 💡Review common defects: undercut, porosity, slag inclusion.
    • 💡Tip 1: In practical assessments, always perform a visual inspection of your weld before submitting. Check for uniform bead width, consistent ripples, and no obvious defects. A clean, neat appearance often correlates with good internal quality.
    • 💡Tip 2: When answering theory questions, use correct terminology (e.g., 'arc length', 'travel speed', 'included angle') and refer to relevant standards. For example, 'This defect is classified as lack of fusion according to BS EN ISO 5817 quality level C.' This shows depth of knowledge.
    • 💡Tip 3: Practice setting up equipment quickly and safely. In timed assessments, efficient preparation (e.g., selecting correct electrode, adjusting wire feed speed) saves time for the actual welding. Know your machine settings for each process.

    Common Mistakes

    Common errors to avoid in your coursework

    • Incorrect electrode selection or current setting.
    • Poor joint preparation leading to defects.
    • Failing to clean welds before inspection.
    • Mistake: Believing that a longer arc length gives better penetration. Correction: A long arc reduces heat concentration, leading to poor fusion and increased spatter. Keep the arc short (about the diameter of the electrode) for MMA and TIG; for MIG, maintain a consistent stick-out of 10–15 mm.
    • Mistake: Thinking that welding in the vertical position is the same as flat, just tilted. Correction: Gravity pulls molten metal downward, so you must adjust travel speed and angle. For vertical-up welding, use a slight upward angle and weave technique to control the puddle; for vertical-down, move faster with a drag angle.
    • Mistake: Assuming that more shielding gas always gives better protection. Correction: Excessive gas flow can cause turbulence, drawing in air and causing porosity. Follow manufacturer recommendations (typically 10–15 L/min for MIG, 8–12 L/min for TIG).

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Basic health and safety awareness in a workshop environment (e.g., understanding of COSHH, risk assessments).
    • •Fundamental knowledge of materials: properties of common metals (mild steel, stainless steel, aluminium) and how heat affects them (expansion, distortion).
    • •Ability to read simple engineering drawings and identify basic symbols (e.g., weld symbols, dimensions).

    Key Terminology

    Essential terms to know

    • 1.1 Identify the need to use appropriate PPE (personal protective equipment) when carrying out manual metal welding activities1.2 Identify associated risks when welding with MMA, to include:• arc radiation burns• arc eye• burns from handling hot materials• welding fumes• electric shocks • fire• sparks1.3 Identify fire prevention and emergency procedures required in the workplace, to include:• causes of fire• types of fire extinguisher used• evacuation procedures1.4 Identify the main groups of safety signs, to include:• warning• prohibition• mandatory• information signs1.5 Identify the function of the listed equipment when used with MMA welding activities:• transformer/generators• transformer/rectifiers• welding lead• welding return lead• welding earth• electrode holders1.6 Identify ancillary equipment used when welding with the MMA welding process1.7 Identify suitable storage conditions for manual metal welding electrodes1.8 Identify the electrode in terms of:• size by electrode diameter• flux coating type1.9 Identify appropriate safety checks on MMA welding equipment prior to use1.10 Prepare to carry out MMA welding to produce welded joints in the PA or PB positions, to include:• production of the correct welding preparation• identify distortion control methods to be used• select the correct electrode type/size• set the correct welding current• produce suitable tack welds• weld the joint• post weld cleaning1.11 Identify welding parameters to be used when completing welded joints using MMA welding, to include:• welding current• electrode slope and tilt angles• arc length• electrode polarity1.12 Identify suitable safety checks on welding equipment prior to use1.13 Complete a weld on:• low carbon steel greater than 6 mm in thickness or• stainless steel in materials greater than 3mm in thickness or • aluminium in materials greater than 3mm in thicknessusing the MMA welding process, to include as a minimum:• lap joint • open outside corner • single vee butt joint• tee fillet weldWelds to be completed in the PA or PB position1.14 Describe the limitations of visual inspection on completed welded joints using the MMA welding process1.15 Identify and describe typical welding defects that may be found in MMA welded joints, to include:• undercut • cracks• slag inclusions• porosity• arc craters• lack of penetration 1.16 Check completed welds for:• weld size to include leg length and throat thickness• weld profile• weld appearance and uniformity• absence of surface defects1.17 Complete the requirements for a report document on welds produced1.18 Prepare and carry out a destructive test on a fillet weld in accordance with the supplied drawing of the welded joint, to include:• nick break test1.19 Prepare and carry out destructive tests on a completed single vee butt weld in accordance with the supplied drawing of the welded joint, to include:• face bend test• root bend test• fracture test1.20 Identify appropriate documentation relating to welding activities, to include:• welding procedure specifications (WPS)• weld inspection report

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