Metal-Arc Gas Shielded Welding - (Overhead) Low Carbon Steel — SEG Awards Vocationally-Related Qualification Design and Technology Revision

    This topic covers metal-arc gas shielded welding in the overhead position on low carbon steel. Learners must understand safety, equipment, parameters, and

    Topic Synopsis

    This topic covers metal-arc gas shielded welding in the overhead position on low carbon steel. Learners must understand safety, equipment, parameters, and produce sound welds.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Metal-Arc Gas Shielded Welding - (Overhead) Low Carbon Steel

    SEG AWARDS
    vocational

    This topic covers metal-arc gas shielded welding in the overhead position on low carbon steel. Learners must understand safety, equipment, parameters, and produce sound welds.

    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 vocationally-related qualification designed for students aiming to become proficient welders in industries such as construction, manufacturing, and engineering. This diploma covers advanced 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 joints, selecting appropriate filler materials, and inspecting welds to industry standards like BS EN ISO 9606-1. The course also emphasises health and safety regulations, such as the Control of Substances Hazardous to Health (COSHH) and personal protective equipment (PPE) requirements.

    Mastering welding techniques is crucial for ensuring structural integrity and safety in fabricated products. This diploma not only teaches hands-on skills but also underpins theoretical knowledge of metallurgy, weld defects, and distortion control. By understanding how heat input, travel speed, and electrode angles affect weld quality, students can produce consistent, defect-free welds. The qualification prepares learners for roles as welding technicians, fabricators, or for further study in engineering disciplines.

    Within the wider Design and Technology curriculum, welding is a key manufacturing process that enables the creation of strong, permanent joints in metal structures. This diploma integrates design principles with practical application, allowing students to interpret engineering drawings and produce components that meet precise specifications. It also fosters problem-solving skills, as welders must adapt techniques to different materials and positions, such as flat, horizontal, vertical, and overhead welding.

    Key Concepts

    Core ideas you must understand for this topic

    • →Welding Positions: Understand the four main positions (1G/PA flat, 2G/PC horizontal, 3G/PF vertical, 4G/PE overhead) and how technique adjustments are required for each to ensure proper fusion and penetration.
    • →Heat Affected Zone (HAZ): The area of base metal adjacent to the weld that undergoes microstructural changes due to heat. Controlling HAZ size is critical to prevent brittleness or softening, especially in high-strength steels.
    • →Weld Defects: Common defects include porosity (gas pockets), slag inclusion (non-metallic particles), lack of fusion, undercut, and cracking. Each has specific causes and remedies, such as adjusting travel speed or cleaning the joint.
    • →Welding Symbols: Interpretation of standard symbols on engineering drawings (BS EN ISO 2553) indicating weld type, size, length, and surface finish. Misreading symbols leads to incorrect welds and potential failure.
    • →Distortion Control: Techniques like tack welding, backstepping, and using jigs to minimise thermal distortion. Preheating and post-weld heat treatment may also be required for thick sections.

    Learning Objectives

    What you need to know and understand

    • 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. Identify the power sources used in MAGS welding1.8. Describe the principle of the self-adjusting arc mechanism as applied to MAGS welding1.9. Describe how inductance can regulate the quality of the weld deposit1.10. Identify the modes of metal transfer used in MAGS welding activities, to include:• dip • spray• pulse1.11. Describe the importance of correct storage conditions for electrode wires, to include:• location• ventilation• contamination• labelling 1.12. Identify the use of different types of electrode wire, to include:• non-coated• coated (copper)1.13. Describe the content and use of deoxidising agents added to electrode wires1.14. Describe the effects of using damaged or corroded electrode wires1.15. Identify the range and application of shielding gases and gas mixtures used in MAGS welding1.16. Identify and select the welding parameters to be used when welding low carbon steel in the overhead welding position (PE), to include:• welding voltage• wire feed speed• torch slope and tilt angles• electrode extension• speed of travel• inductance• shielding gas flow rate (LPM)1.17. 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. Identify the causes of distortion in welded joints1.22. Identify methods used to control distortion in welded joints1.23. Describe the significance of residual stress found 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 MAGS welding process on low carbon steel or stainless steel.• tee fillet (PE)• butt (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 test• nick break test1.27. Identify the function of:• weld inspection activities• quality control• quality assurance1.28. Describe the importance of carrying out quality control checks on consumables used in MAGS welding activities1.29. Describe the range and purpose of destructive tests used on welded joints1.30. Identify the use and application of the four main methods of non-destructive testing (NDT), to include:• dye penetrant flaw detection• magnetic particle flaw detection• ultrasonic flaw detection• radiog

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Identifies health and safety roles and procedures.
    • Selects correct welding parameters for overhead position.
    • Sets up and checks welding equipment safely.
    • Produces welds meeting specified quality standards.
    • Performs destructive tests and interprets results.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Practice overhead welding on scrap pieces first.
    • 💡Monitor weld pool constantly.
    • 💡Follow risk assessment and use PPE.
    • 💡Tip 1: Always start with a clean joint. Examiners look for preparation: remove rust, oil, paint, and moisture. Contamination is a leading cause of defects and will lose marks. Use a wire brush or grinder as needed.
    • 💡Tip 2: Demonstrate understanding of welding parameters. In practical assessments, explain why you chose a specific current, voltage, or travel speed. Relate it to material thickness and joint type to show theoretical knowledge.
    • 💡Tip 3: Inspect your own work critically. Before submitting, check for undercut, spatter, and uniform bead profile. Use a weld gauge to measure leg length and throat thickness. Self-correction shows professionalism.

    Common Mistakes

    Common errors to avoid in your coursework

    • Incorrect torch angle leading to poor penetration.
    • Ignoring gas flow rate causing porosity.
    • Failing to clean base metal before welding.
    • Misconception: 'A bigger weld is always stronger.' Correction: Oversized welds can introduce excessive heat input, increasing distortion and HAZ issues. Weld size should match design specifications; a properly sized, defect-free weld is stronger than a large, flawed one.
    • Misconception: 'MIG welding doesn't require as much skill as TIG.' Correction: While MIG is often easier to learn, achieving high-quality MIG welds still requires precise control of wire feed speed, voltage, and gun angle. Both processes demand skill for consistent results.
    • Misconception: 'You can weld any metal with the same settings.' Correction: Different metals (e.g., carbon steel, stainless steel, aluminium) have varying thermal conductivity, melting points, and reactivity. Electrode type, shielding gas, and parameters must be tailored to the material.

    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 in Engineering: Understanding of risk assessments, PPE, and workshop safety procedures is essential before handling welding equipment.
    • •Fundamentals of Engineering Materials: Knowledge of metal properties (e.g., tensile strength, hardness) and how they affect weldability. This includes recognising common metals like mild steel, stainless steel, and aluminium.
    • •Introduction to Fabrication Techniques: Familiarity with cutting, grinding, and measuring tools used in preparing joints. Skills in reading simple engineering drawings are also beneficial.

    Key Terminology

    Essential terms to know

    • 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. Identify the power sources used in MAGS welding1.8. Describe the principle of the self-adjusting arc mechanism as applied to MAGS welding1.9. Describe how inductance can regulate the quality of the weld deposit1.10. Identify the modes of metal transfer used in MAGS welding activities, to include:• dip • spray• pulse1.11. Describe the importance of correct storage conditions for electrode wires, to include:• location• ventilation• contamination• labelling 1.12. Identify the use of different types of electrode wire, to include:• non-coated• coated (copper)1.13. Describe the content and use of deoxidising agents added to electrode wires1.14. Describe the effects of using damaged or corroded electrode wires1.15. Identify the range and application of shielding gases and gas mixtures used in MAGS welding1.16. Identify and select the welding parameters to be used when welding low carbon steel in the overhead welding position (PE), to include:• welding voltage• wire feed speed• torch slope and tilt angles• electrode extension• speed of travel• inductance• shielding gas flow rate (LPM)1.17. 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. Identify the causes of distortion in welded joints1.22. Identify methods used to control distortion in welded joints1.23. Describe the significance of residual stress found 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 MAGS welding process on low carbon steel or stainless steel.• tee fillet (PE)• butt (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 test• nick break test1.27. Identify the function of:• weld inspection activities• quality control• quality assurance1.28. Describe the importance of carrying out quality control checks on consumables used in MAGS welding activities1.29. Describe the range and purpose of destructive tests used on welded joints1.30. Identify the use and application of the four main methods of non-destructive testing (NDT), to include:• dye penetrant flaw detection• magnetic particle flaw detection• ultrasonic flaw detection• radiog

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