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

    Tungsten-Arc Gas Shielded Welding (Overhead) - Aluminium covers health and safety, equipment, welding parameters, and techniques for overhead aluminium wel

    Topic Synopsis

    Tungsten-Arc Gas Shielded Welding (Overhead) - Aluminium covers health and safety, equipment, welding parameters, and techniques for overhead aluminium welding.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Tungsten-Arc Gas Shielded Welding - (Overhead) - Aluminium

    SEG AWARDS
    vocational

    Tungsten-Arc Gas Shielded Welding (Overhead) - Aluminium covers health and safety, equipment, welding parameters, and techniques for overhead aluminium welding.

    1
    Learning Outcomes
    3
    Assessment Guidance
    3
    Key Skills
    1
    Key Terms
    4
    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 an advanced vocational qualification designed for students who have already mastered basic welding and wish to develop professional-level competence in a range of welding processes. This diploma covers manual metal arc (MMA), metal inert gas (MIG), tungsten inert gas (TIG), and flux-cored arc welding (FCAW), along with advanced cutting techniques such as plasma and oxy-fuel cutting. Students learn to interpret complex engineering drawings, select appropriate welding parameters, and produce high-quality welds in various positions (flat, horizontal, vertical, and overhead) on carbon steel, stainless steel, and aluminium.

    This qualification is essential for those aiming to become certified welders in industries such as construction, oil and gas, automotive, and shipbuilding. It emphasises not only practical skills but also theoretical knowledge of metallurgy, weld defects, non-destructive testing (NDT), and health and safety regulations. By completing this diploma, students gain the ability to work independently to industry standards (e.g., BS EN ISO 9606-1) and are prepared for roles such as welding technician, site welder, or fabrication supervisor. The diploma also serves as a stepping stone to higher-level engineering qualifications or specialised welding certifications.

    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 welding in all positions (PA, PB, PC, PD, PE, PF, PG) and techniques like stringer beads and weave beads to achieve consistent penetration and fusion.
    • →Metallurgy and Material Properties: Know how heat input, cooling rates, and alloying elements affect the microstructure and mechanical properties of welded joints, including concepts like heat-affected zone (HAZ) and residual stress.
    • →Weld Defects and Quality Control: Identify common defects (e.g., porosity, slag inclusion, undercut, lack of fusion) and understand how to prevent them through proper parameter selection and technique. Familiarity with non-destructive testing methods (visual inspection, dye penetrant, magnetic particle, ultrasonic) is crucial.
    • →Health, Safety, and Environmental Regulations: Comply with COSHH, PPE requirements, fire prevention, fume extraction, and safe handling of gas cylinders. Understand risk assessments and method statements (RAMS) for welding tasks.

    Learning Objectives

    What you need to know and understand

    • 1.1. Identify the roles of various organisations involved with Health and safety in the workplace, to include:• Health and Safety Executive (HSE)• Environmental Health• Local Authorities1.2. Identify the roles of various individuals involved with Health and Safety in the workplace, to include:• Company safety officers• Company safety representatives• Environmental health officers• HSE inspectors1.3. Identify the purpose and typical contents of an organisations Health and Safety Policy1.4. Describe the purpose of a risk assessment, to include:• who should carry out risk assessments• when to carry out a risk assessment• identification of the 5 steps of risk assessment1.5. Identify the precautions to be taken when working in high risk areas, to include:• risk assessments• permits to work• high/low temperature working conditions• lock off systems• isolation of equipment1.6. Describe the control and safe removal of welding fumes and gases created during the welding process, to include:• natural extraction• local extraction• PPE and specialist breathing equipment1.7. Describe the hazards associated when using the TAG welding process, to include:• arc radiation• using high frequency• production of phosgene gas1.8. Identify the power sources used in TAG welding1.9. Identify the type of welding current (AC/DC) and polarity to be used when welding:• low carbon steel• stainless steel• aluminium1.10. Describe the application and use of equipment used in the TAG welding process, to include:• high frequency unit• current control foot pedal• gas pressure regulator• gas flow meter• gas lens1.11. Describe the importance of correct storage conditions for tungsten electrodes and filler wires, to include:• location• ventilation• contamination• labelling 1.12. Identify the range of different alloying elements added to tungsten electrodes1.13. Identify the electrode (tip) preparation required when using an AC or DC welding current1.14. Identify the content and application of a range of filler wires used in the TAG welding process1.15. Describe the effects of using damaged tungsten electrodes and filler wires1.16. Identify the range and application of shielding gases used in the TAG welding process1.17. Identify and select the welding parameters to be used when welding low carbon steel, stainless steel or aluminium in the overhead welding position (PE), to include:• welding voltage• slope in/slope out control• torch slope and tilt angles• high frequency• speed of travel• pre/post gas flow• shielding gas flow rate (LPM)1.18. Describe the application and function of gas backing /purging1.19. Identify suitable welding preparations for the type of joint and material thickness being welded, to include:• included angle• angle of bevel• root face dimension• root gap dimension1.20. Describe the advantages and limitations of the methods listed that are used to produce suitable welding preparations on materials, to include:• thermal methods• mechanical (chip forming)• shearing• bevelling machines• abrasive methods1.21. Identify the main types of distortion found in completed welded joints, to include:• longitudinal• transverse• angular1.22. Identify the main causes of distortion in welded joints1.23. Identify methods used to control distortion in welded joints1.24. Describe the significance of residual stress found in welded joints1.25. Identify appropriate safety checks on the welding equipment prior to use1.26. Select suitable welding parameters to enable the listed joints to be welded by the TAG welding process on one material type to cover, low carbon steel, stainless steel or aluminium in a thickness range of between 1.6 mm to 3 mm.• tee fillet (PE)• butt (PE)• open outside corner (PE)• lap joint (PE)1.27. Carry out destructive tests on the completed welds and document the results. Tests to include:• face bend• root bend• fracture test• nick break test1.28. Identify the function of:• weld inspection activities• quality control• quality assurance1.29. Des

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Identify health and safety roles and procedures.
    • Select correct equipment and parameters for aluminium.
    • Perform overhead TAG welding on specified joints.
    • Carry out destructive tests and document results.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Practice setting parameters for aluminium.
    • 💡Ensure thorough pre-weld checks.
    • 💡Document test results accurately.
    • 💡Tip 1: Always set up your workstation methodically before starting. Examiners award marks for preparation: correct PPE, clean base metal, proper gas flow, and electrode/filler selection. A rushed setup often leads to defects.
    • 💡Tip 2: In practical assessments, demonstrate consistent travel speed and arc length. Examiners look for uniform bead width and height. Practise maintaining a steady hand and using both hands for support when possible.
    • 💡Tip 3: For theory questions, use technical terminology accurately (e.g., 'dilution', 'penetration', 'heat input'). Show you understand the 'why' behind procedures, not just the 'how'. Link answers to industry standards (e.g., BS EN ISO 9606-1) for higher marks.

    Common Mistakes

    Common errors to avoid in your coursework

    • Incorrect electrode preparation for AC/DC.
    • Poor gas shielding leading to contamination.
    • Ignoring distortion control methods.
    • Misconception: 'MIG welding is always easier than TIG.' Correction: While MIG is faster, TIG offers greater control and is essential for thin materials or aesthetic welds. Each process requires specific skills and is suited to different applications.
    • Misconception: 'A visually good weld is always a strong weld.' Correction: Visual appearance does not guarantee internal soundness. Defects like lack of fusion or porosity may be hidden. That's why NDT and destructive testing are critical for certification.
    • Misconception: 'You can weld any material with the same settings.' Correction: Different materials (e.g., carbon steel vs. aluminium) require different filler metals, shielding gases, and heat inputs. Using incorrect parameters leads to weak or defective welds.

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Completion of a Level 2 welding qualification (e.g., SEG Awards Level 2 Certificate in Welding Skills) or equivalent experience.
    • •Basic understanding of engineering drawings and symbols (e.g., welding symbols, dimensioning, tolerances).
    • •Familiarity with workshop safety practices and basic hand tools.

    Key Terminology

    Essential terms to know

    • 1.1. Identify the roles of various organisations involved with Health and safety in the workplace, to include:• Health and Safety Executive (HSE)• Environmental Health• Local Authorities1.2. Identify the roles of various individuals involved with Health and Safety in the workplace, to include:• Company safety officers• Company safety representatives• Environmental health officers• HSE inspectors1.3. Identify the purpose and typical contents of an organisations Health and Safety Policy1.4. Describe the purpose of a risk assessment, to include:• who should carry out risk assessments• when to carry out a risk assessment• identification of the 5 steps of risk assessment1.5. Identify the precautions to be taken when working in high risk areas, to include:• risk assessments• permits to work• high/low temperature working conditions• lock off systems• isolation of equipment1.6. Describe the control and safe removal of welding fumes and gases created during the welding process, to include:• natural extraction• local extraction• PPE and specialist breathing equipment1.7. Describe the hazards associated when using the TAG welding process, to include:• arc radiation• using high frequency• production of phosgene gas1.8. Identify the power sources used in TAG welding1.9. Identify the type of welding current (AC/DC) and polarity to be used when welding:• low carbon steel• stainless steel• aluminium1.10. Describe the application and use of equipment used in the TAG welding process, to include:• high frequency unit• current control foot pedal• gas pressure regulator• gas flow meter• gas lens1.11. Describe the importance of correct storage conditions for tungsten electrodes and filler wires, to include:• location• ventilation• contamination• labelling 1.12. Identify the range of different alloying elements added to tungsten electrodes1.13. Identify the electrode (tip) preparation required when using an AC or DC welding current1.14. Identify the content and application of a range of filler wires used in the TAG welding process1.15. Describe the effects of using damaged tungsten electrodes and filler wires1.16. Identify the range and application of shielding gases used in the TAG welding process1.17. Identify and select the welding parameters to be used when welding low carbon steel, stainless steel or aluminium in the overhead welding position (PE), to include:• welding voltage• slope in/slope out control• torch slope and tilt angles• high frequency• speed of travel• pre/post gas flow• shielding gas flow rate (LPM)1.18. Describe the application and function of gas backing /purging1.19. Identify suitable welding preparations for the type of joint and material thickness being welded, to include:• included angle• angle of bevel• root face dimension• root gap dimension1.20. Describe the advantages and limitations of the methods listed that are used to produce suitable welding preparations on materials, to include:• thermal methods• mechanical (chip forming)• shearing• bevelling machines• abrasive methods1.21. Identify the main types of distortion found in completed welded joints, to include:• longitudinal• transverse• angular1.22. Identify the main causes of distortion in welded joints1.23. Identify methods used to control distortion in welded joints1.24. Describe the significance of residual stress found in welded joints1.25. Identify appropriate safety checks on the welding equipment prior to use1.26. Select suitable welding parameters to enable the listed joints to be welded by the TAG welding process on one material type to cover, low carbon steel, stainless steel or aluminium in a thickness range of between 1.6 mm to 3 mm.• tee fillet (PE)• butt (PE)• open outside corner (PE)• lap joint (PE)1.27. Carry out destructive tests on the completed welds and document the results. Tests to include:• face bend• root bend• fracture test• nick break test1.28. Identify the function of:• weld inspection activities• quality control• quality assurance1.29. Des

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