What is the difference between MIG and TIG welding?

MIG (Metal Inert Gas) welding uses a continuously fed wire electrode and a shielding gas, making it faster and easier for beginners, especially on thicker materials. TIG (Tungsten Inert Gas) welding uses a non-consumable tungsten electrode and a separate filler rod, offering more control and producing higher quality welds on thinner materials like aluminium and stainless steel. TIG requires more skill and practice.

How do I prepare metal for welding?

First, clean the metal surface to remove rust, paint, oil, or dirt using a wire brush, grinder, or chemical cleaner. Then, bevel or chamfer the edges if the material is thick to ensure full penetration. Finally, ensure the joint fits tightly with no gaps, and clamp the pieces securely to prevent movement during welding.

What are common welding defects and how can I avoid them?

Common defects include porosity (gas pockets), undercut (groove at the weld toe), lack of fusion, and slag inclusion. To avoid them, ensure proper cleaning, use correct welding parameters (current, voltage, travel speed), maintain a consistent arc length, and use the correct technique for the joint position. Practice and inspection are key.

Do I need to wear a respirator when welding?

Yes, especially when welding in confined spaces or with materials that produce toxic fumes (e.g., galvanised steel). Even in well-ventilated areas, welding fumes can be harmful. A respirator with appropriate filters (e.g., P3) is recommended to protect your lungs from metal oxides and gases.

What career options are available after this qualification?

This certificate can lead to roles such as welder, fabricator, sheet metal worker, or maintenance engineer. Many students progress to advanced apprenticeships in industries like automotive, aerospace, construction, or oil and gas. Further study options include Level 3 diplomas in engineering or welding inspection.

How is the SEG Awards Level 2 Certificate assessed?

Assessment is typically through practical tasks and a portfolio of evidence. You will be observed performing welding and fabrication tasks to industry standards, and you may also complete written assignments or online tests covering theory, health and safety, and drawing interpretation. There is no final exam; instead, you are assessed continuously.

Tungsten-Arc Gas Shielded Welding – Low Carbon Steel, Stainless Steel, Aluminium

SEG AWARDS

vocational

This unit covers tungsten-arc gas shielded (TAGS) welding of low carbon steel, stainless steel, and aluminium. It includes equipment, consumables, techniques for butt and fillet welds, and weld inspection, with a strong emphasis on health and safety.

Learning Outcomes

Assessment Guidance

Key Skills

Key Terms

Assessment Criteria

Assessment criteria

SEG Awards Level 2 Certificate in Fabrication and Welding Techniques and Skills

Topic Overview

The SEG Awards Level 2 Certificate in Fabrication and Welding Techniques and Skills is a vocationally-related qualification that introduces students to the core principles and practices of metal fabrication and welding. This course covers essential skills such as interpreting engineering drawings, measuring and marking out materials, cutting and shaping metal, and joining components using various welding techniques including MIG, TIG, and MMA welding. It is designed to provide a solid foundation for those pursuing careers in engineering, manufacturing, or construction, and it aligns with industry standards to ensure students are job-ready.

Understanding fabrication and welding is crucial in modern design and technology because it bridges the gap between theoretical design and practical production. Students learn how to select appropriate materials, plan fabrication sequences, and apply safe working practices. The qualification emphasizes precision, quality control, and problem-solving, which are transferable skills applicable to a wide range of engineering disciplines. By mastering these techniques, students gain the confidence to create functional metal products and structures, from simple brackets to complex assemblies.

This qualification fits into the wider subject of Design and Technology by providing hands-on experience with industrial processes and materials. It complements other areas such as product design, mechanical engineering, and manufacturing technology. Students who complete this certificate often progress to advanced apprenticeships, further education in engineering, or direct employment in welding and fabrication roles. The course also develops an understanding of health and safety regulations, environmental considerations, and the importance of quality assurance in a professional workshop environment.

Key Concepts

Core ideas you must understand for this topic

→Interpretation of engineering drawings and symbols: Students must be able to read and understand technical drawings, including dimensions, tolerances, welding symbols, and material specifications.
→Safe working practices: This includes using personal protective equipment (PPE), proper ventilation, fire safety, and correct handling of tools and equipment to prevent accidents.
→Welding techniques: Proficiency in MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), and MMA (Manual Metal Arc) welding, including setting parameters, striking an arc, and producing sound welds.
→Material preparation and cutting: Skills in measuring, marking out, and cutting metals using hand tools, power tools, and thermal cutting methods like oxy-fuel or plasma cutting.
→Quality control and inspection: Understanding how to check welds for defects (e.g., porosity, undercut, lack of fusion) and using inspection tools like weld gauges and visual inspection criteria.

Learning Objectives

What you need to know and understand

The unit covers the equipment and consumables required for tungsten-arc gas shielded (TAGS) welding and the techniques used to produce welds that meet the quality standard required. Practical weld samples covering butt and fillet welds must be welded in the flat (PA) or horizontal vertical (PB) welding positions. These are rigorously tested to show that the completed welds are structurally sound. Welding inspection techniques are also covered to give the learner the information and skills to carry out weld inspection.Health and safety is an integral part of this unit covering TAGS welding activities. Learners need to be aware of the dangers of fires and the need to wear correct PPE.

Assessment Criteria

Key criteria assessors look for in your portfolio

Select correct equipment and consumables for TAGS welding.
Produce butt and fillet welds in flat or horizontal-vertical positions.
Inspect welds to ensure they meet quality standards.
Follow health and safety procedures, including PPE use.

Assessment Guidance

Guidance for achieving higher grades

💡Practice setting up the TAGS torch and adjusting parameters.
💡Know common weld defects and their causes.
💡Always wear correct PPE and check equipment safety.
💡Always refer to the engineering drawing for dimensions and welding symbols. Examiners look for evidence that you can interpret these correctly, so double-check your measurements and mark them clearly on your work.
💡Demonstrate safe working practices throughout the assessment. This includes wearing correct PPE, maintaining a tidy workspace, and following risk assessments. Safety is a key marking criterion.
💡Practice producing consistent weld beads in different positions (flat, horizontal, vertical, overhead). Examiners award higher marks for welds that are uniform, free from defects, and meet the specified quality standards.

Common Mistakes

Common errors to avoid in your coursework

Incorrect gas flow or tungsten preparation leading to defects.
Poor joint fit-up causing incomplete fusion.
Neglecting to clean base metal before welding.
Misconception: Welding is just about melting metal together. Correction: Successful welding requires proper joint preparation, correct heat input, and control of the weld pool to avoid defects. It's a precise skill that involves understanding metallurgy and technique.
Misconception: Thicker metal always needs more heat. Correction: While thicker metal generally requires more heat, other factors like joint type, welding position, and material composition also affect heat input. Overheating can cause distortion or burn-through.
Misconception: Any filler metal will work for any base metal. Correction: Filler metals must be compatible with the base metal to ensure strength and corrosion resistance. Using the wrong filler can lead to weak joints or cracking.

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.
•Familiarity with measuring tools such as rulers, callipers, and squares.
•Some experience with hand tools (e.g., hammers, files, hacksaws) and power tools (e.g., angle grinders, drills).

Key Terminology

Essential terms to know

The unit covers the equipment and consumables required for tungsten-arc gas shielded (TAGS) welding and the techniques used to produce welds that meet the quality standard required. Practical weld samples covering butt and fillet welds must be welded in the flat (PA) or horizontal vertical (PB) welding positions. These are rigorously tested to show that the completed welds are structurally sound. Welding inspection techniques are also covered to give the learner the information and skills to carry out weld inspection.Health and safety is an integral part of this unit covering TAGS welding activities. Learners need to be aware of the dangers of fires and the need to wear correct PPE.

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Tungsten-Arc Gas Shielded Welding – Low Carbon Steel, Stainless Steel, Aluminium

Assessment criteria

Topic Overview

Key Concepts

Learning Objectives

Assessment Criteria

Assessment Guidance

Common Mistakes

Frequently Asked Questions

Before You Start

Key Terminology

Ready to learn?

Related Topics in SEG AWARDS vocational Design and Technology

12. Advanced Fabrication Processes – Plate (3 mm and Above in Thickness)

6. Fabrication Processes – Sheet Metal

Advanced Fabrication Processes – Sheet Metal (below 3 mm in Thickness)

Engineering Drawing

Topic Synopsis

Key Concepts & Core Principles

Exam Tips & Revision Strategies

Common Misconceptions & Mistakes to Avoid

Examiner Marking Points

Tungsten-Arc Gas Shielded Welding – Low Carbon Steel, Stainless Steel, Aluminium

Assessment criteria

Topic Overview

Key Concepts

Learning Objectives

Assessment Criteria

Assessment Guidance

Common Mistakes

Frequently Asked Questions

What is the difference between MIG and TIG welding?

How do I prepare metal for welding?

What are common welding defects and how can I avoid them?

Do I need to wear a respirator when welding?

What career options are available after this qualification?

How is the SEG Awards Level 2 Certificate assessed?

Before You Start

Key Terminology

Ready to learn?

Related Topics in SEG AWARDS vocational Design and Technology

12. Advanced Fabrication Processes – Plate (3 mm and Above in Thickness)

6. Fabrication Processes – Sheet Metal

Advanced Fabrication Processes – Sheet Metal (below 3 mm in Thickness)

Engineering Drawing