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

    This topic covers MAGS welding of stainless steel in the vertical position, including safety legislation, equipment, parameters, joint preparation, and def

    Topic Synopsis

    This topic covers MAGS welding of stainless steel in the vertical position, including safety legislation, equipment, parameters, joint preparation, and defect identification. Practical skills include welding, inspection, and destructive testing.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Metal-Arc Gas Shielded Welding - (Vertical) Stainless Steel

    SEG AWARDS
    vocational

    This topic covers MAGS welding of stainless steel in the vertical position, including safety legislation, equipment, parameters, joint preparation, and defect identification. Practical skills include welding, inspection, and destructive 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 vocationally-related qualification designed for students who want to develop advanced practical welding skills and theoretical knowledge. This diploma covers a range of welding processes including Manual Metal Arc (MMA), Metal Inert Gas (MIG), Tungsten Inert Gas (TIG), and Flux-Cored Arc Welding (FCAW). Students learn to interpret engineering drawings, select appropriate welding parameters, and produce high-quality welds in various positions (flat, horizontal, vertical, and overhead). The qualification also emphasises health and safety regulations, quality control, and non-destructive testing methods, preparing students for careers in fabrication, construction, and manufacturing industries.

    This diploma is part of the wider Design and Technology curriculum, bridging the gap between theoretical design principles and practical manufacturing. It equips students with the skills to work with ferrous and non-ferrous metals, understand metallurgy, and apply welding codes and standards such as BS EN ISO 9606. By mastering these techniques, students can progress to higher-level qualifications or directly into employment as welding technicians, fabricators, or inspectors. The course also develops problem-solving and attention to detail, which are essential for producing structurally sound and aesthetically pleasing welds.

    Mastering welding techniques is crucial for ensuring the integrity of metal structures in industries like automotive, aerospace, and construction. This diploma provides a solid foundation for students to specialise in areas such as pipe welding, robotic welding, or welding inspection. With a strong emphasis on practical assessments and portfolio building, students gain hands-on experience that directly translates to workplace demands, making them highly employable in the engineering sector.

    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.
    • →Welding positions and techniques: Master flat, horizontal, vertical, and overhead welding, and know how to adjust parameters like current, voltage, and travel speed for each position.
    • →Metallurgy and material preparation: Learn how heat affects metal properties, the importance of cleaning and beveling edges, and how to select filler materials for different base metals.
    • →Quality control and inspection: Understand visual inspection criteria, common defects (e.g., porosity, undercut, lack of fusion), and non-destructive testing methods like dye penetrant and ultrasonic testing.
    • →Health and safety: Comply with COSHH regulations, use personal protective equipment (PPE) correctly, and manage risks such as fume inhalation, electric shock, and fire.

    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 MAGS 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 conditions1.5. Describe the function of the equipment used in the MAGS welding process, to include:• rectifier• welding lead cable and clamp• welding return cable and clamp• secondary earth and connector• torch• contact tip• shroud/nozzle• wire feed mechanism • 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 electrode wires that are used for the MAGS welding process, to include:• non-coated• copper coated1.9. Describe the effects of incorrect storage of electrode wires1.10. Recognise the effect of using damaged electrode wires when carrying out welding activities1.11. Identify the shielding gas/es used in MAGS welding1.12. Identify the function of the shielding gas used in MAGS welding1.13. Recognise the different modes of metal transfer used in MAGS welding1.14. Identify and select the welding parameters to be used when welding materials greater than 6 mm in thickness in the vertical welding position (PF/PG).• mode of metal transfer• welding current• arc voltage• torch slope and tilt angles• shielding gas flow rate• wire speed• speed of travel1.15. Identify suitable welding preparations for the type of joint and material thickness being welded1.16. Identify terms associated with welding preparations, to include:• included angle• angle of bevel• root face dimension• root gap dimension 1.17. Describe the application of distortion control techniques, to include: • pre-setting • restraint• joint geometry 1.18. Be able to follow instructions given on a WPS (Welding Procedure Sheet)1.19. Identify appropriate safety checks on the welding equipment prior to use1.20. Select suitable welding parameters to enable the listed joints to be welded by the MAGS 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)1.21. Carry out visual inspection of completed welds1.22. Prepare and carry out nick break tests on completed fillet welds1.23. Prepare and carry out destructive tests on completed butt welds, to include:• face bend • root bend• fracture test 1.24. Record the results of the weld examination as detailed in 7.1, 7.2 and 7.31.25. Identify and describe typical defects found in the MAGS welding process joints, to include:• cracks• inclusions• undercut• lack of fusion• arc craters• porosity• lack of penetration1.26. Identify possible causes of the defects listed in 8.1

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Identifies health and safety responsibilities and legislation.
    • Describes function of MAGS welding equipment and maintenance.
    • Selects appropriate welding parameters for vertical welding.
    • Produces welds to specification on various joints.
    • Carries out visual and destructive tests and records results.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Memorise key legislation and their purposes.
    • 💡Practice setting parameters for different thicknesses.
    • 💡Learn to identify defects and their causes.
    • 💡Tip 1: In practical assessments, focus on consistency. Examiners look for uniform weld beads with even ripples and minimal spatter. Practice maintaining a steady travel speed and arc length to achieve this.
    • 💡Tip 2: When answering theory questions, use specific terminology from the welding standards (e.g., BS EN ISO 9606). For example, refer to 'qualification range' and 'thickness range' when discussing welder certification.
    • 💡Tip 3: Always link your answers to real-world applications. If asked about a welding defect, explain not only its cause but also how it affects structural integrity and how to prevent it. This shows deeper understanding.

    Common Mistakes

    Common errors to avoid in your coursework

    • Incorrect parameter selection leading to defects.
    • Poor joint preparation causing lack of fusion.
    • Neglecting safety checks before welding.
    • Misconception: 'MIG welding is always easier than TIG.' Correction: While MIG is faster, TIG offers greater control for thin materials and critical joints. Each process has its own challenges; for example, TIG requires precise hand-eye coordination and foot pedal control.
    • Misconception: 'A bigger weld is always stronger.' Correction: Oversized welds can introduce excessive heat distortion and residual stress. Proper weld size and profile, as specified by engineering drawings, ensure strength without compromising the base material.
    • Misconception: 'You don't need to clean the metal if you're using a shielding gas.' Correction: Contaminants like rust, oil, or paint can cause porosity and weak welds. Always clean the joint area thoroughly, regardless of the welding process.

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Basic understanding of engineering drawings and symbols, including weld symbols as per BS EN ISO 2553.
    • •Knowledge of health and safety practices in a workshop environment, including fire safety and PPE usage.
    • •Familiarity with basic hand tools and measuring instruments like calipers and micrometers.

    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 MAGS 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 conditions1.5. Describe the function of the equipment used in the MAGS welding process, to include:• rectifier• welding lead cable and clamp• welding return cable and clamp• secondary earth and connector• torch• contact tip• shroud/nozzle• wire feed mechanism • 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 electrode wires that are used for the MAGS welding process, to include:• non-coated• copper coated1.9. Describe the effects of incorrect storage of electrode wires1.10. Recognise the effect of using damaged electrode wires when carrying out welding activities1.11. Identify the shielding gas/es used in MAGS welding1.12. Identify the function of the shielding gas used in MAGS welding1.13. Recognise the different modes of metal transfer used in MAGS welding1.14. Identify and select the welding parameters to be used when welding materials greater than 6 mm in thickness in the vertical welding position (PF/PG).• mode of metal transfer• welding current• arc voltage• torch slope and tilt angles• shielding gas flow rate• wire speed• speed of travel1.15. Identify suitable welding preparations for the type of joint and material thickness being welded1.16. Identify terms associated with welding preparations, to include:• included angle• angle of bevel• root face dimension• root gap dimension 1.17. Describe the application of distortion control techniques, to include: • pre-setting • restraint• joint geometry 1.18. Be able to follow instructions given on a WPS (Welding Procedure Sheet)1.19. Identify appropriate safety checks on the welding equipment prior to use1.20. Select suitable welding parameters to enable the listed joints to be welded by the MAGS 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)1.21. Carry out visual inspection of completed welds1.22. Prepare and carry out nick break tests on completed fillet welds1.23. Prepare and carry out destructive tests on completed butt welds, to include:• face bend • root bend• fracture test 1.24. Record the results of the weld examination as detailed in 7.1, 7.2 and 7.31.25. Identify and describe typical defects found in the MAGS welding process joints, to include:• cracks• inclusions• undercut• lack of fusion• arc craters• porosity• lack of penetration1.26. Identify possible causes of the defects listed in 8.1

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