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

    This unit covers the safe and effective use of Tungsten-Arc Gas Shielded (TAGS) welding for stainless steel. Learners will understand equipment, safety pro

    Topic Synopsis

    This unit covers the safe and effective use of Tungsten-Arc Gas Shielded (TAGS) welding for stainless steel. Learners will understand equipment, safety procedures, and welding parameters, and produce welded joints in various positions while inspecting for defects.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Tungsten-Arc Gas Shielded Welding - Stainless Steel

    SEG AWARDS
    vocational

    This unit covers the safe and effective use of Tungsten-Arc Gas Shielded (TAGS) welding for stainless steel. Learners will understand equipment, safety procedures, and welding parameters, and produce welded joints in various positions while inspecting for defects.

    1
    Learning Outcomes
    3
    Assessment Guidance
    3
    Key Skills
    1
    Key Terms
    4
    Assessment Criteria

    Assessment criteria

    SEG Awards Level 2 Certificate in Welding Techniques and Skills

    Topic Overview

    The SEG Awards Level 2 Certificate in Welding Techniques and Skills is a vocationally-related qualification that introduces students to the fundamental principles and practices of welding within the context of Design and Technology. This qualification covers essential welding processes, including Manual Metal Arc (MMA), Metal Inert Gas (MIG), and Tungsten Inert Gas (TIG) welding, along with health and safety regulations, material preparation, and quality control. Students develop practical skills in setting up welding equipment, selecting appropriate consumables, and producing sound welds on various joint configurations.

    This qualification is crucial for students pursuing careers in engineering, manufacturing, construction, or automotive industries, as welding is a core skill in these fields. It also provides a strong foundation for further study, such as Level 3 qualifications or apprenticeships. By mastering welding techniques, students learn to apply theoretical knowledge to real-world tasks, enhancing their problem-solving abilities and attention to detail. The hands-on nature of the course ensures that students gain confidence in using industry-standard equipment and following safe working practices.

    Within the wider Design and Technology curriculum, welding techniques complement topics such as material properties, structural integrity, and manufacturing processes. Students who complete this certificate will be able to design and fabricate metal components, understand the limitations of different welding methods, and evaluate the quality of their work. This qualification not only prepares students for vocational pathways but also develops transferable skills like precision, teamwork, and adherence to specifications.

    Key Concepts

    Core ideas you must understand for this topic

    • →Welding processes: Understand the differences between MMA, MIG, and TIG welding, including their applications, advantages, and limitations. For example, MIG is ideal for thin materials and high productivity, while TIG offers precision for critical joints.
    • →Health and safety: Always follow COSHH regulations, use appropriate PPE (e.g., welding helmet, gloves, fire-resistant clothing), and ensure proper ventilation to avoid fume inhalation. Never weld near flammable materials.
    • →Joint types and positions: Know the five basic joint types (butt, lap, T-joint, corner, edge) and welding positions (flat, horizontal, vertical, overhead). Each requires specific technique adjustments.
    • →Weld defects and quality control: Identify common defects like porosity, undercut, slag inclusion, and lack of fusion. Use visual inspection and destructive/non-destructive testing to assess weld integrity.
    • →Material preparation: Clean surfaces thoroughly to remove rust, oil, or paint. Proper edge preparation (e.g., beveling for thick plates) ensures full penetration and strong welds.

    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

    • Identifies correct PPE and safety risks associated with TAGS welding.
    • Selects appropriate electrode, filler wire, gas type, and welding parameters.
    • Produces welded joints (lap, open corner, single vee butt, tee fillet) in PA or PB positions.
    • Conducts visual inspection and destructive tests (nick break, bend, fracture) on welds.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Memorise the colour coding for different tungsten electrodes and filler wires.
    • 💡Practice setting up the welding machine and adjusting parameters for stainless steel.
    • 💡Learn to identify common defects from visual inspection alone.
    • 💡Tip 1: Always set up your welding parameters (current, voltage, wire feed speed) according to the material thickness and joint type. Examiners look for correct machine settings as evidence of understanding.
    • 💡Tip 2: Practice maintaining a steady travel speed and consistent arc length. Use a mirror or ask a peer to observe your technique. Smooth, uniform beads indicate control and skill.
    • 💡Tip 3: After welding, clean the weld area and inspect for defects. In exams, you may be asked to evaluate your own work—be honest and identify areas for improvement to show reflective practice.

    Common Mistakes

    Common errors to avoid in your coursework

    • Using incorrect electrode polarity or gas flow rate.
    • Failing to clean the workpiece before welding, leading to contamination.
    • Incorrect torch angle causing lack of fusion or tungsten inclusions.
    • Misconception: 'MIG welding doesn't require cleaning the base metal.' Correction: Even MIG welding requires clean surfaces; dirt or oil can cause porosity and weak welds. Always grind or degrease before welding.
    • Misconception: 'A longer arc length gives better penetration.' Correction: A long arc reduces penetration and increases spatter. Maintain a consistent short arc length (about 3mm for MMA) for optimal control.
    • Misconception: 'Welding speed doesn't affect quality.' Correction: Travel speed directly impacts bead shape and penetration. Too fast leads to undercut; too slow causes excessive buildup and burn-through.

    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 PPE use.
    • •Familiarity with hand tools and measuring instruments (e.g., tape measure, square, file) as used in Design and Technology.
    • •Knowledge of material properties, especially metals (e.g., mild steel, aluminium), from prior D&T studies.

    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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