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

    This unit covers metal-arc gas shielded welding of stainless steel, including safety, equipment, techniques, and inspection. Learners produce welded joints

    Topic Synopsis

    This unit covers metal-arc gas shielded welding of stainless steel, including safety, equipment, techniques, and inspection. Learners produce welded joints and carry out destructive tests.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Metal-Arc Gas Shielded Welding - Stainless Steel

    SEG AWARDS
    vocational

    This unit covers metal-arc gas shielded welding of stainless steel, including safety, equipment, techniques, and inspection. Learners produce welded joints and carry out destructive tests.

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

    Assessment criteria

    SEG Awards Level 2 Certificate in Welding Techniques and Skills

    Topic Overview

    The SEG Awards Level 2 Certificate in Welding Techniques and Skills provides a comprehensive introduction to the core welding processes used in engineering and manufacturing. This qualification covers manual metal arc (MMA), metal inert gas (MIG), and tungsten inert gas (TIG) welding, along with essential health and safety practices. Students will learn to prepare materials, set up equipment, and produce welded joints to industry standards, making this certificate a vital stepping stone for careers in fabrication, construction, and automotive industries.

    This vocationally-related qualification is designed to develop both theoretical knowledge and practical competence. You will study welding symbols, joint configurations, and material properties, while also gaining hands-on experience in a workshop environment. The course emphasizes quality control and defect identification, ensuring you can produce sound welds that meet specified criteria. Mastery of these techniques is highly valued by employers and can lead to advanced apprenticeships or further study in engineering.

    Within the broader Design and Technology curriculum, welding is a key manufacturing process that enables the creation of strong, permanent joints in metal structures. Understanding welding techniques allows you to design and fabricate functional products, from simple brackets to complex frameworks. This certificate not only builds technical skills but also fosters problem-solving, attention to detail, and adherence to safety protocols—competencies that are transferable across many engineering disciplines.

    Key Concepts

    Core ideas you must understand for this topic

    • →Welding processes: Understand the principles, advantages, and limitations of MMA, MIG, and TIG welding, including appropriate applications for each.
    • →Joint configurations and welding positions: Recognize butt, lap, T-joint, and corner joints, and be able to weld in flat, horizontal, vertical, and overhead positions.
    • →Welding defects and quality control: Identify common defects such as porosity, slag inclusion, undercut, and lack of fusion, and know how to prevent them through correct technique and parameter settings.
    • →Health and safety: Follow safe working practices including use of PPE (welding helmet, gloves, apron), fume extraction, fire prevention, and proper handling of gas cylinders and electrical equipment.
    • →Material preparation and post-weld treatment: Clean and bevel edges, select appropriate filler materials, and apply post-weld heat treatment or grinding as required.

    Learning Objectives

    What you need to know and understand

    • 1.1 Identify the need to use appropriate PPE (personal protective equipment) when carrying out MAGS welding activities1.2 Identify the risks associated when welding with MAGS, 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 MAGS welding activities:• power source unit• welding lead• welding return lead• welding earth• welding torch• wire feed unit• shielding gas supply, regulator and flow meter1.6 Identify ancillary equipment used when welding with the MAGS welding process1.7 Identify suitable storage conditions for MAGS welding wires1.8 Identify the electrode wires in terms of:• size by electrode diameter• weight of spool• copper coated type1.9 Identify appropriate safety checks on MAGS welding equipment prior to use1.10 Prepare to carry out the MAGS welding process 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 wire size• select correct gas flow rates• set the correct welding current• produce suitable tack welds• weld the joint• post welding cleaning1.11 Identify welding parameters to be used when completing welded joints using MAGS welding, to include:• welding current• gas type and flow rates• welding torch slope and tilt angle1.12 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 MAGS 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 inspections on completed welded joints when using the MAGS welding process1.15 Identify and describe typical welding defects that may be found in MAGS welded joints, to include:• undercut • cracks• inclusions• porosity• arc craters• lack of fusion• lack of penetration 1.16 Check completed welds for:• weld size to cover 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 joints, 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

    • Identifies and uses appropriate PPE and safety procedures.
    • Sets up MAGS welding equipment correctly and safely.
    • Produces welded joints (lap, corner, butt, tee) to specification.
    • Inspects welds visually and identifies defects.
    • Carries out destructive tests (nick break, bend, fracture) correctly.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Always check equipment before use.
    • 💡Practice setting parameters for different joint types.
    • 💡Learn to identify common weld defects.
    • 💡Always set up your welding parameters (current, voltage, wire feed speed) according to the material thickness and joint type. Examiners look for correct machine settings as evidence of understanding.
    • 💡Practice maintaining a consistent travel speed and arc length. Uneven welds often result from inconsistent technique; use a steady hand and watch the weld pool, not the arc.
    • 💡In written answers, use correct terminology (e.g., 'slag inclusion' not 'dirt in the weld') and reference relevant British Standards (e.g., BS EN ISO 9606 for welder approval). This shows depth of knowledge.

    Common Mistakes

    Common errors to avoid in your coursework

    • Incorrect gas flow or wire feed settings.
    • Poor weld preparation leading to defects.
    • Not cleaning welds after completion.
    • Misconception: 'MIG welding is always easier than MMA.' Correction: While MIG is often more forgiving on thin materials, MMA can be more versatile outdoors and on rusty surfaces. Each process requires specific skill sets and is suited to different conditions.
    • Misconception: 'A visually good-looking weld is always a strong weld.' Correction: Appearance can be deceiving; internal defects like lack of fusion or porosity may not be visible. Proper destructive or non-destructive testing is needed to confirm weld integrity.
    • Misconception: 'You can weld any metal with any process.' Correction: Different metals (e.g., aluminium, stainless steel, carbon steel) require specific processes, filler materials, and techniques. For example, TIG is preferred for aluminium due to its precise heat control.

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Basic understanding of health and safety in a workshop environment, including COSHH and risk assessment.
    • •Familiarity with common engineering materials (mild steel, stainless steel, aluminium) and their properties.
    • •Elementary knowledge of hand tools and measuring instruments (e.g., calipers, rulers) used in metalwork.

    Key Terminology

    Essential terms to know

    • 1.1 Identify the need to use appropriate PPE (personal protective equipment) when carrying out MAGS welding activities1.2 Identify the risks associated when welding with MAGS, 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 MAGS welding activities:• power source unit• welding lead• welding return lead• welding earth• welding torch• wire feed unit• shielding gas supply, regulator and flow meter1.6 Identify ancillary equipment used when welding with the MAGS welding process1.7 Identify suitable storage conditions for MAGS welding wires1.8 Identify the electrode wires in terms of:• size by electrode diameter• weight of spool• copper coated type1.9 Identify appropriate safety checks on MAGS welding equipment prior to use1.10 Prepare to carry out the MAGS welding process 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 wire size• select correct gas flow rates• set the correct welding current• produce suitable tack welds• weld the joint• post welding cleaning1.11 Identify welding parameters to be used when completing welded joints using MAGS welding, to include:• welding current• gas type and flow rates• welding torch slope and tilt angle1.12 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 MAGS 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 inspections on completed welded joints when using the MAGS welding process1.15 Identify and describe typical welding defects that may be found in MAGS welded joints, to include:• undercut • cracks• inclusions• porosity• arc craters• lack of fusion• lack of penetration 1.16 Check completed welds for:• weld size to cover 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 joints, 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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