Tungsten-Arc Gas Shielded Welding - Aluminium — SEG Awards Vocationally-Related Qualification Design and Technology Revision

    This topic covers TAGS welding of aluminium, including safety, equipment, and techniques. Learners must understand PPE, risks, fire prevention, and how to

    Topic Synopsis

    This topic covers TAGS welding of aluminium, including safety, equipment, and techniques. Learners must understand PPE, risks, fire prevention, and how to produce and test welded joints.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Tungsten-Arc Gas Shielded Welding - Aluminium

    SEG AWARDS
    vocational

    This topic covers TAGS welding of aluminium, including safety, equipment, and techniques. Learners must understand PPE, risks, fire prevention, and how to produce and test welded joints.

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

    Assessment criteria

    SEG Awards Level 2 Award in Welding Techniques and Skills

    Topic Overview

    The SEG Awards Level 2 Award in Welding Techniques and Skills is a vocationally-related qualification that introduces you to the core principles and practices of welding within Design and Technology. This award covers essential welding processes, including Manual Metal Arc (MMA), Metal Inert Gas (MIG), and Tungsten Inert Gas (TIG) welding, focusing on safety, equipment setup, joint preparation, and producing sound welds. You'll learn how to interpret welding symbols, select appropriate materials and consumables, and apply correct techniques to create strong, durable joints in various positions. This qualification is ideal if you're considering a career in engineering, manufacturing, or construction, as it provides a solid foundation for further study or entry-level roles in the welding industry.

    Mastering welding techniques is crucial because welding is a fundamental joining process used across countless industries, from automotive and aerospace to shipbuilding and structural steelwork. This award not only teaches you practical skills but also emphasizes the importance of health and safety, quality control, and problem-solving. You'll develop the ability to assess weld quality, identify defects, and make adjustments to improve your work. By the end of the course, you'll be able to produce welds that meet industry standards, giving you a competitive edge in the job market or progression to higher-level qualifications like the Level 3 Award in Welding.

    Within the broader Design and Technology curriculum, welding connects theoretical knowledge of materials and structures with hands-on fabrication. You'll apply principles of material science, such as how heat affects metal properties, and engineering design, such as joint selection for load-bearing applications. This qualification also complements other DT areas like metalworking, CAD/CAM, and product design, enabling you to create functional prototypes and final products with confidence.

    Key Concepts

    Core ideas you must understand for this topic

    • →Welding processes: Understand the differences between MMA (stick), MIG (wire feed with shielding gas), and TIG (non-consumable tungsten electrode with filler rod) welding, including their applications, advantages, and limitations.
    • →Joint types and positions: Know how to prepare and weld butt, lap, T-joint, and corner joints in flat, horizontal, vertical, and overhead positions, adjusting technique for each.
    • →Safety and PPE: Always use appropriate personal protective equipment (welding helmet with correct shade, flame-resistant gloves, apron, and steel-toed boots) and ensure proper ventilation and fire safety measures.
    • →Weld defects and quality: Identify common defects like porosity, slag inclusion, undercut, and lack of fusion, and understand how to prevent them through correct settings, technique, and cleaning.
    • →Welding symbols and standards: Interpret basic welding symbols on engineering drawings, including weld type, size, length, and finish requirements, according to BS EN ISO standards.

    Learning Objectives

    What you need to know and understand

    • 1.1 Identify the need to use appropriate PPE (personal protective equipment) when carrying out TAGS welding activities1.2 Identify the risks associated when welding with TAGS, to include:• arc radiation burns• arc eye• burns from handling hot materials• welding fumes• dangers of using high frequency systems• electric shocks • fire1.3 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 signs1.1. Identify the functions of the listed equipment when used with TAGS welding activities, to include:• transformer/generators• transformer/rectifiers• welding inverters• high frequency units• cooling systems• welding lead• welding return lead• welding earth• welding torch• welding shrouds1.2. Identify ancillary equipment used when welding with the TAGS welding process1.3. Identify suitable storage conditions for TAGS filler wires1.4. Identify the filler wires in terms of:• size by diameter• alloying additions1.5. Identify the electrode in terms of:• size by electrode diameter• type of electrodes - alloying additions1.6. Identify appropriate safety checks on TAGS welding equipment prior to use1.7. Prepare to carry out the TAGS 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 electrode type/size• select gas type and flow rate• select filler wire type• set the correct welding current• produce suitable tack welds• weld the joint• post welding cleaning1.8. Identify welding parameters to be used when completing welded joints using TAGS welding, to include:• welding current• electrode slope and tilt angles• filler wire slope and tilt angles• gas flow rates• arc length• electrode polarity1.9. Identify suitable safety checks on welding equipment prior to use1.10. Complete welds on low carbon steel, or stainless steel or aluminium 3 mm or greater in thickness using the TAGS 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 position1.11. Describe the limitations of visual inspection on completed welded joints when using the TAGS welding process1.12. Identify and describe typical welding defects that may be found in TAGS welded joints, to include:• undercut • cracks• tungsten inclusions• porosity• arc craters• lack of fusion• lack of penetration 1.13. Check completed welds for:• weld size to cover leg length and throat thickness• weld profile• weld appearance and uniformity• absence of surface defects1.14. Complete the requirements for a report document on welds produced1.15. 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 test1.16. Prepare and carry out destructive tests on a completed single vee butt weld in accordance with the supplied drawing of the welded joint, to include:• face bend test• root bend test• fracture test1.17. 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

    • Identify correct PPE for TAGS welding and associated risks.
    • Describe fire prevention and emergency procedures.
    • Explain functions of TAGS welding equipment and ancillary items.
    • Demonstrate correct preparation and welding of joints in PA/PB positions.
    • Identify welding defects and perform destructive tests.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Memorise typical welding defects and their causes.
    • 💡Practice setting welding parameters for aluminium.
    • 💡Understand the importance of gas flow rate and arc length.
    • 💡Tip 1: In practical assessments, always set up your equipment correctly before starting. Examiners look for methodical preparation: check gas flow (for MIG/TIG), select correct polarity, and adjust wire feed speed and voltage according to material thickness. Rushing into welding without proper setup loses marks.
    • 💡Tip 2: Demonstrate your understanding of weld defects by inspecting your own welds. If you see a defect, explain how you would correct it (e.g., 'I have slag inclusion here because my travel speed was too slow; I need to increase speed and ensure proper cleaning between passes'). This shows analytical thinking.
    • 💡Tip 3: For theory questions, use technical vocabulary precisely. For example, distinguish between 'penetration' (depth of fusion into base metal) and 'reinforcement' (excess weld metal above the base plate). Examiners reward accurate terminology.

    Common Mistakes

    Common errors to avoid in your coursework

    • Confusing electrode polarity for aluminium welding.
    • Overlooking pre-weld cleaning and post-weld cleaning requirements.
    • Misidentifying tungsten inclusions or porosity in welds.
    • Mistake: Thinking that a longer arc length gives better penetration. Correction: A long arc actually reduces penetration and increases spatter; maintain a short arc length (about the diameter of the electrode) for consistent, deep penetration.
    • Mistake: Believing that MIG welding doesn't require cleaning the base metal. Correction: Even with MIG, dirt, rust, oil, or paint can cause porosity and weak welds; always clean the joint area thoroughly before welding.
    • Mistake: Assuming that TIG welding is easier than MMA because it's more controlled. Correction: TIG requires excellent hand-eye coordination and precise control of both torch and filler rod; it's actually one of the most challenging processes to master.

    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 fire safety and safe handling of tools.
    • •Familiarity with different types of metals (e.g., mild steel, stainless steel, aluminium) and their properties, as covered in Key Stage 4 Design and Technology.
    • •Some experience with hand tools and measuring instruments (e.g., files, hammers, tape measures) is helpful but not essential.

    Key Terminology

    Essential terms to know

    • 1.1 Identify the need to use appropriate PPE (personal protective equipment) when carrying out TAGS welding activities1.2 Identify the risks associated when welding with TAGS, to include:• arc radiation burns• arc eye• burns from handling hot materials• welding fumes• dangers of using high frequency systems• electric shocks • fire1.3 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 signs1.1. Identify the functions of the listed equipment when used with TAGS welding activities, to include:• transformer/generators• transformer/rectifiers• welding inverters• high frequency units• cooling systems• welding lead• welding return lead• welding earth• welding torch• welding shrouds1.2. Identify ancillary equipment used when welding with the TAGS welding process1.3. Identify suitable storage conditions for TAGS filler wires1.4. Identify the filler wires in terms of:• size by diameter• alloying additions1.5. Identify the electrode in terms of:• size by electrode diameter• type of electrodes - alloying additions1.6. Identify appropriate safety checks on TAGS welding equipment prior to use1.7. Prepare to carry out the TAGS 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 electrode type/size• select gas type and flow rate• select filler wire type• set the correct welding current• produce suitable tack welds• weld the joint• post welding cleaning1.8. Identify welding parameters to be used when completing welded joints using TAGS welding, to include:• welding current• electrode slope and tilt angles• filler wire slope and tilt angles• gas flow rates• arc length• electrode polarity1.9. Identify suitable safety checks on welding equipment prior to use1.10. Complete welds on low carbon steel, or stainless steel or aluminium 3 mm or greater in thickness using the TAGS 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 position1.11. Describe the limitations of visual inspection on completed welded joints when using the TAGS welding process1.12. Identify and describe typical welding defects that may be found in TAGS welded joints, to include:• undercut • cracks• tungsten inclusions• porosity• arc craters• lack of fusion• lack of penetration 1.13. Check completed welds for:• weld size to cover leg length and throat thickness• weld profile• weld appearance and uniformity• absence of surface defects1.14. Complete the requirements for a report document on welds produced1.15. 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 test1.16. Prepare and carry out destructive tests on a completed single vee butt weld in accordance with the supplied drawing of the welded joint, to include:• face bend test• root bend test• fracture test1.17. Identify appropriate documentation relating to welding activities, to include:• welding procedure specifications (WPS)• weld inspection report

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