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

    This topic covers MAGS welding of low carbon steel in the vertical position, including safety, equipment, parameters, and defect identification. Students p

    Topic Synopsis

    This topic covers MAGS welding of low carbon steel in the vertical position, including safety, equipment, parameters, and defect identification. Students perform welds and tests.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

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

    SEG AWARDS
    vocational

    This topic covers MAGS welding of low carbon steel in the vertical position, including safety, equipment, parameters, and defect identification. Students perform welds and tests.

    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 advanced 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 materials and consumables, and perform welds to industry standards like BS EN ISO 9606-1. The course emphasises health and safety, quality control, and practical competence, preparing learners for roles as skilled welders or further study in welding engineering.

    This diploma builds on foundational welding skills and introduces complex techniques such as welding in all positions (flat, horizontal, vertical, and overhead) and on various joint types (butt, fillet, T-joint, and lap joints). Students develop an understanding of weld defects, their causes, and how to prevent them through proper technique and parameter adjustment. The qualification also covers non-destructive testing (NDT) methods like visual inspection and dye penetrant testing, ensuring welds meet stringent quality criteria. By the end of the course, students can produce sound welds on carbon steel, stainless steel, and aluminium, following written welding procedures (WPS).

    Mastering welding techniques is crucial for career progression in sectors like oil and gas, automotive, and structural steelwork. This diploma not only provides hands-on skills but also develops problem-solving abilities, attention to detail, and adherence to safety protocols. It aligns with national occupational standards and can lead to certifications such as the CSWIP 3.0 Welding Inspector or progression to a Level 4 qualification in welding engineering. Students who complete this diploma are well-equipped to enter the workforce as competent welders or pursue apprenticeships in specialised welding fields.

    Key Concepts

    Core ideas you must understand for this topic

    • →Welding Positions and Joint Types: Understand the four main welding positions (1G/PA flat, 2G/PC horizontal, 3G/PF vertical, 4G/PE overhead) and common joint configurations (butt, fillet, T-joint, lap). Each requires specific technique and parameter adjustments to achieve full penetration and sound fusion.
    • →Welding Parameters and Their Effects: Mastery of current (amperage), voltage, travel speed, and wire feed speed (for MIG/FCAW) is essential. Incorrect settings lead to defects like lack of fusion, porosity, or excessive spatter. For example, too high amperage in MMA can cause undercut, while too low results in slag inclusion.
    • →Weld Defects and Prevention: Common defects include porosity (gas entrapment), slag inclusion (in MMA/FCAW), lack of fusion, undercut, and distortion. Prevention involves proper cleaning, correct electrode angle, appropriate heat input, and using the right shielding gas (e.g., CO2 or Ar/CO2 mix for MIG).
    • →Material Selection and Preparation: Know the properties of carbon steel, stainless steel, and aluminium. Pre-weld cleaning removes oil, rust, and paint. For aluminium, remove oxide layer with a stainless steel brush. Post-weld heat treatment may be needed for certain alloys to relieve stress.
    • →Health and Safety in Welding: Always use PPE (welding helmet with correct shade, flame-resistant clothing, gloves, and safety boots). Ensure adequate ventilation to avoid fume inhalation. Follow fire safety protocols and use screens to protect others from arc eye.

    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

    • Identify health and safety responsibilities.
    • Describe MAGS welding equipment and its function.
    • Select correct welding parameters for vertical welding.
    • Perform welds and carry out visual and destructive tests.
    • Identify and explain common welding defects.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Memorise typical parameters for vertical MAGS welding.
    • 💡Practice setting up the welding machine correctly.
    • 💡Learn defect causes and remedies.
    • 💡Tip 1: Always set up your welding parameters according to the WPS and check them before starting. Examiners look for methodical preparation, including correct gas flow rate (e.g., 15-20 L/min for MIG) and electrode selection. A well-prepared workstation demonstrates professionalism and reduces errors.
    • 💡Tip 2: Focus on maintaining a consistent travel speed and arc length. In MMA, keep the arc length equal to the electrode diameter. In MIG, maintain a stick-out of 10-15 mm. Inconsistent technique leads to uneven bead appearance and potential defects. Practice on scrap metal to develop muscle memory.
    • 💡Tip 3: After welding, clean the weld thoroughly (e.g., using a wire brush or chipping hammer for slag) and inspect for defects. Examiners award marks for post-weld inspection and the ability to identify and explain any imperfections. Use a weld gauge to check fillet weld leg length and throat thickness.

    Common Mistakes

    Common errors to avoid in your coursework

    • Using incorrect travel speed for vertical welding.
    • Neglecting to check gas flow rate.
    • Confusing face bend and root bend tests.
    • Misconception: 'More amperage always means a stronger weld.' Correction: Excessive amperage can cause burn-through, excessive spatter, and weaken the heat-affected zone (HAZ). The correct amperage depends on material thickness, joint type, and electrode size. Always follow the Welding Procedure Specification (WPS).
    • Misconception: 'MIG welding doesn't require as much skill as TIG.' Correction: While MIG is often easier to learn, producing high-quality MIG welds requires precise control of travel speed, gun angle, and wire stick-out. Poor technique leads to defects like lack of fusion or cold lapping, especially in vertical or overhead positions.
    • Misconception: 'You can weld without cleaning the metal if you use a flux-cored wire.' Correction: Flux-cored wires are more tolerant of surface contaminants than solid wires, but they still require clean metal for optimal results. Rust, oil, or paint can cause porosity and slag inclusions, compromising weld integrity.

    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 materials (e.g., carbon steel, stainless steel, aluminium) and their properties.
    • •Completion of a Level 2 welding qualification or equivalent experience in basic welding techniques (e.g., MMA or MIG in flat position).
    • •Familiarity with reading engineering drawings and symbols, including weld symbols as per BS EN ISO 2553.

    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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