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

    This topic covers manual metal-arc welding of stainless steel in the vertical position, including health and safety, equipment, electrode selection, weldin

    Topic Synopsis

    This topic covers manual metal-arc welding of stainless steel in the vertical position, including health and safety, equipment, electrode selection, welding parameters, joint preparation, distortion control, and weld testing.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Manual Metal-Arc Welding (Vertical) - Stainless Steel

    SEG AWARDS
    vocational

    This topic covers manual metal-arc welding of stainless steel in the vertical position, including health and safety, equipment, electrode selection, welding parameters, joint preparation, distortion control, and weld testing.

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

    Assessment criteria

    SEG Awards Level 3 Diploma in Welding Techniques and Skills

    Topic Overview

    The SEG Awards Level 3 Diploma in Welding Techniques and Skills is a comprehensive vocational qualification designed for students aiming to become proficient welders in industries such as construction, manufacturing, and engineering. This diploma covers a wide range of welding processes, including Manual Metal Arc (MMA), Metal Inert Gas (MIG), Tungsten Inert Gas (TIG), and Flux-Cored Arc Welding (FCAW). Students develop practical skills in preparing materials, setting up equipment, and producing high-quality welds to industry standards. The course also emphasizes health and safety, quality control, and interpretation of engineering drawings, ensuring graduates are job-ready.

    This qualification is part of the SEG Awards Vocationally-Related Qualification framework, which focuses on applied learning and real-world competencies. It is ideal for students who prefer hands-on learning and wish to pursue careers as welding technicians, fabricators, or inspectors. The diploma not only teaches technical skills but also fosters problem-solving, attention to detail, and teamwork—attributes highly valued by employers. By mastering welding techniques, students contribute to the creation of safe and durable structures, from bridges to pipelines, making this qualification vital for the UK's engineering and construction sectors.

    Within the broader Design and Technology curriculum, welding is a key manufacturing process that transforms raw materials into functional products. This diploma bridges the gap between design concepts and practical realization, enabling students to understand material properties, joint design, and structural integrity. It also aligns with modern industry standards such as ISO 9606 and EN 287, preparing students for certification and career progression. Mastery of welding techniques opens doors to apprenticeships, higher-level engineering courses, and specialized roles in aerospace, automotive, and offshore industries.

    Key Concepts

    Core ideas you must understand for this topic

    • →Welding processes: Understand the principles, advantages, and limitations of MMA, MIG, TIG, and FCAW, including appropriate applications for each.
    • →Joint configurations and positions: Master butt, lap, T-joint, and corner joints in flat, horizontal, vertical, and overhead positions as per BS EN ISO 6947.
    • →Weld defects and quality control: Identify common defects like porosity, slag inclusion, undercut, and lack of fusion; learn non-destructive testing (NDT) methods such as visual inspection and dye penetrant testing.
    • →Material preparation and safety: Correctly clean, bevel, and fit materials; follow COSHH regulations, use PPE (e.g., welding helmet, gloves, fire-resistant clothing), and ensure adequate ventilation.
    • →Interpretation of welding symbols and drawings: Read engineering drawings to determine weld size, type, and position according to BS EN ISO 2553.

    Learning Objectives

    What you need to know and understand

    • 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 MMA welding process, to include working:• in a confined space1.5. Describe the function of the equipment used in MMA welding, to include:• transformer• generator• rectifier• invertors• welding lead cable• welding return cable• secondary earth and connector• electrode holder• cable clamp• low voltage safety devices (LVSD)1.6. 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 electrodes that are used for the MMA welding process, to include:• general purpose • low hydrogen (basic)• positional1.9. State the function of the flux coating on electrodes1.10. Describe the effects of incorrect storage of electrodes1.11. State the effect of using damaged electrodes when carrying out welding activities1.12. Identify and select the welding parameters to be used when welding materials in the vertical welding position (PF/PG), to include:• welding current• OCV (open circuit voltage)• electrode slope and tilt angles• arc length• speed of travel• electrode polarity1.13. Identify suitable welding preparations for the type of joint and material thickness being welded1.14. Identify terms associated with welding preparations, to include:• included angle• angle of bevel• root face dimension• root gap dimension 1.15. Describe the application of distortion control techniques, to include: • pre-setting • restraint• joint geometry 1.16. Be able to follow instructions given on a WPS (Welding Procedure Sheet)1.17. Identify appropriate safety checks on the welding equipment prior to use1.18. Select suitable welding parameters to enable the listed joints to be welded by the MMA 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)1.19. Carry out visual inspection of completed welds1.20. Prepare and carry out nick break tests on the completed fillet welds1.21. Prepare and carry out destructive tests on completed butt welds, to include:• face bend • root bend• fracture test 1.22. Record the results of the weld examination as detailed in 7.1, 7.2 and 7.31.23. Identify and describe typical defects found in MMA welded joints, to include:• cracks• inclusions (slag)• undercut• arc craters• porosity• lack of penetration1.24. Identify possible causes of the defects listed in 8.1

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Applies health and safety legislation and risk assessment procedures.
    • Selects correct electrodes and welding parameters for vertical welding.
    • Prepares joints correctly and controls distortion.
    • Produces welds that meet visual and destructive test criteria.
    • Identifies and explains causes of common weld defects.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Practise vertical welding techniques to maintain consistent arc length.
    • 💡Refer to WPS for exact parameters and joint preparation.
    • 💡Perform visual inspection before destructive testing.
    • 💡Always refer to the welding procedure specification (WPS) during practical assessments. Examiners look for adherence to parameters like current, voltage, travel speed, and preheat temperature. Deviating from the WPS can result in immediate failure.
    • 💡In written exams, use correct terminology (e.g., 'arc length' not 'gap', 'slag inclusion' not 'dirt'). Show your working for calculations like heat input or filler wire consumption. This demonstrates depth of understanding.
    • 💡For practical tests, practice in all positions (flat, horizontal, vertical, overhead) until consistent. Examiners award marks for uniform weld bead profile, minimal spatter, and proper fusion at the toes. Clean your workpiece thoroughly before inspection.

    Common Mistakes

    Common errors to avoid in your coursework

    • Using incorrect electrode angle or travel speed for vertical position.
    • Inadequate pre-weld cleaning causing porosity or slag inclusion.
    • Failing to control heat input, leading to distortion or burn-through.
    • Misconception: 'All welding processes are the same—just pick one.' Correction: Each process has specific uses; MMA is versatile for outdoor work, MIG is fast for thin materials, TIG is precise for critical joints, and FCAW is ideal for thick sections. Choosing the wrong process can lead to weak welds.
    • Misconception: 'If the weld looks good on the surface, it's fine.' Correction: Surface appearance doesn't guarantee internal quality. Defects like lack of fusion or porosity can be hidden. Always follow welding procedure specifications (WPS) and perform NDT when required.
    • Misconception: 'Safety is just about wearing a helmet.' Correction: Welding involves multiple hazards: UV radiation, fumes, electric shock, fire, and noise. Proper ventilation, fire extinguishers, ear protection, and electrical safety are equally critical.

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Basic understanding of material properties (e.g., carbon steel, stainless steel, aluminium) and how heat affects them.
    • •Familiarity with workshop safety practices, including use of PPE and emergency procedures.
    • •Ability to read simple engineering drawings and interpret dimensions and symbols.

    Key Terminology

    Essential terms to know

    • 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 MMA welding process, to include working:• in a confined space1.5. Describe the function of the equipment used in MMA welding, to include:• transformer• generator• rectifier• invertors• welding lead cable• welding return cable• secondary earth and connector• electrode holder• cable clamp• low voltage safety devices (LVSD)1.6. 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 electrodes that are used for the MMA welding process, to include:• general purpose • low hydrogen (basic)• positional1.9. State the function of the flux coating on electrodes1.10. Describe the effects of incorrect storage of electrodes1.11. State the effect of using damaged electrodes when carrying out welding activities1.12. Identify and select the welding parameters to be used when welding materials in the vertical welding position (PF/PG), to include:• welding current• OCV (open circuit voltage)• electrode slope and tilt angles• arc length• speed of travel• electrode polarity1.13. Identify suitable welding preparations for the type of joint and material thickness being welded1.14. Identify terms associated with welding preparations, to include:• included angle• angle of bevel• root face dimension• root gap dimension 1.15. Describe the application of distortion control techniques, to include: • pre-setting • restraint• joint geometry 1.16. Be able to follow instructions given on a WPS (Welding Procedure Sheet)1.17. Identify appropriate safety checks on the welding equipment prior to use1.18. Select suitable welding parameters to enable the listed joints to be welded by the MMA 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)1.19. Carry out visual inspection of completed welds1.20. Prepare and carry out nick break tests on the completed fillet welds1.21. Prepare and carry out destructive tests on completed butt welds, to include:• face bend • root bend• fracture test 1.22. Record the results of the weld examination as detailed in 7.1, 7.2 and 7.31.23. Identify and describe typical defects found in MMA welded joints, to include:• cracks• inclusions (slag)• undercut• arc craters• porosity• lack of penetration1.24. Identify possible causes of the defects listed in 8.1

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