Welding Processes (Manual Metal-Arc and Metal-Arc Gas Shielded)) — SEG Awards Vocationally-Related Qualification Design and Technology Revision

    This topic covers safe working practices and correct procedures for manual metal-arc (MMA) and metal-arc gas shielded (MAGS) welding. Learners must produce

    Topic Synopsis

    This topic covers safe working practices and correct procedures for manual metal-arc (MMA) and metal-arc gas shielded (MAGS) welding. Learners must produce a welded joint to an acceptable standard.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Welding Processes (Manual Metal-Arc and Metal-Arc Gas Shielded))

    SEG AWARDS
    vocational

    This topic covers safe working practices and correct procedures for manual metal-arc (MMA) and metal-arc gas shielded (MAGS) welding. Learners must produce a welded joint to an acceptable standard.

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

    Assessment criteria

    SEG Awards Level 1 Certificate in Fabrication and Welding Techniques and Skills

    Topic Overview

    The SEG Awards Level 1 Certificate in Fabrication and Welding Techniques and Skills introduces you to the fundamental processes used in metal fabrication and welding. This qualification covers essential skills such as measuring, marking out, cutting, and joining metals using common welding techniques like MIG (Metal Inert Gas) and MMA (Manual Metal Arc). You will learn how to interpret simple engineering drawings, select appropriate materials and equipment, and apply safe working practices in a workshop environment. This certificate is ideal if you are considering a career in engineering, manufacturing, or construction, as it provides a solid foundation for further study or entry-level roles.

    In this course, you will develop practical competence in preparing and assembling metal components. You will practice setting up welding equipment, controlling weld parameters, and inspecting your work for quality. The qualification also emphasises health and safety regulations, including the use of personal protective equipment (PPE) and proper ventilation. By the end of the certificate, you should be able to produce basic welded joints in the flat position and understand the principles of distortion control. This hands-on experience is directly relevant to real-world fabrication tasks and helps build confidence in using workshop tools and machinery.

    The SEG Awards Level 1 Certificate is a vocationally-related qualification, meaning it focuses on practical skills and knowledge that are directly applicable to the workplace. It fits within the broader Design and Technology curriculum by linking design concepts with material processing and manufacturing techniques. Understanding fabrication and welding is essential for careers in metalworking, automotive repair, and structural engineering. This qualification also prepares you for progression to Level 2 courses, where you will tackle more complex joints and welding positions.

    Key Concepts

    Core ideas you must understand for this topic

    • →Health and safety: Always wear appropriate PPE (welding helmet, gloves, apron), ensure good ventilation, and follow workshop safety rules to prevent burns, electric shock, and inhalation of fumes.
    • →Measuring and marking out: Use tools like steel rules, scribers, and squares to accurately measure and mark metal before cutting. Precision is critical to ensure components fit together correctly.
    • →MIG welding: A semi-automatic process using a continuous wire electrode and shielding gas (usually argon/CO2 mix). It is ideal for thin to medium thickness steel and produces clean welds with minimal spatter.
    • →MMA welding: Also known as stick welding, this process uses a consumable electrode coated in flux. It is versatile and works well on thicker materials and in outdoor conditions, but requires more skill to control the arc and slag removal.
    • →Distortion and its control: Heat from welding causes metal to expand and contract, leading to distortion. Techniques like tack welding, using jigs, and welding in sequence help minimise movement.

    Learning Objectives

    What you need to know and understand

    • Learners will know about the safe working practice and the correct procedures required when carrying out manual metal-arc (MMA) and metal-arc gas shielded (MAGS) welding activities. It will also be required for the learner to produce a welded joint to an acceptable standard.

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Follows safe working practices throughout welding activities.
    • Sets up equipment correctly for MMA and MAGS welding.
    • Produces a welded joint with acceptable appearance and strength.
    • Identifies common welding defects and their causes.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Practise setting up both MMA and MAGS equipment.
    • 💡Check your welds for porosity, slag inclusion, and penetration.
    • 💡Always inspect equipment before use for safety.
    • 💡Always set up your welding parameters according to the manufacturer's recommendations and the material thickness. Examiners look for correct voltage, wire feed speed (for MIG), or amperage (for MMA) settings. Practice adjusting these to achieve a stable arc and good penetration.
    • 💡Focus on weld appearance and consistency. A good weld should have uniform ripples, no undercut, and minimal spatter. Clean your workpiece thoroughly before welding and remove slag between passes. Examiners award marks for neat, defect-free welds.
    • 💡Demonstrate safe working practices throughout your assessment. This includes correctly storing and handling gas cylinders, using fire-resistant screens, and inspecting cables for damage. Safety is a key assessment criterion, so make it visible in your work habits.

    Common Mistakes

    Common errors to avoid in your coursework

    • Incorrect electrode or wire selection for the material.
    • Poor joint preparation leading to weak welds.
    • Neglecting personal protective equipment (PPE).
    • Misconception: MIG welding does not require any skill because it is automatic. Correction: While MIG is easier to learn, you still need to control travel speed, gun angle, and wire feed speed to produce a sound weld. Poor technique can lead to lack of fusion or porosity.
    • Misconception: You can weld any metal with the same settings. Correction: Different metals (e.g., mild steel, stainless steel, aluminium) require different filler wires, shielding gases, and heat settings. Using incorrect parameters can result in weak or contaminated welds.
    • Misconception: Safety glasses are enough protection for welding. Correction: Welding arcs produce intense ultraviolet (UV) light that can cause 'arc eye' (photokeratitis). You must use a welding helmet with the correct shade filter (e.g., shade 10-13 for MMA) to protect your eyes.

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Basic workshop safety awareness: Understanding of common hazards and PPE requirements in a metalworking environment.
    • •Simple measurement skills: Ability to read a ruler or tape measure and perform basic arithmetic for marking out.
    • •Familiarity with hand tools: Experience using hammers, files, and clamps is helpful but not essential.

    Key Terminology

    Essential terms to know

    • Learners will know about the safe working practice and the correct procedures required when carrying out manual metal-arc (MMA) and metal-arc gas shielded (MAGS) welding activities. It will also be required for the learner to produce a welded joint to an acceptable standard.

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