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Framework
Area and/or Course Introduction to Welding 6
C D
5
Knowledge
Assimilation Adaptation
4 _______ ___X____
Objectives:
The student will be able to (TSWBT). (Oregon Skill Set numbers in parentheses at the
end of the objective statement.)
1. Identify the basics steps incorporated into the arc welding (SMAW) process (AG 10.02.01.04)
2. Select applications for arc welding in real-world settings (CS.EF.02)
3. Explain how the arc forms and demonstrate how to properly set up equipment (EL.HS.RE.08)
4. Demonstrate striking the arc to begin the SMAW process (CS.EF.02)
5. Create arc welds which are consistent with industry standards (PST 04.04.07.c)
http://www.learn-how-to-weld.com/arc-
1. Arc welder
welding/how-to-arc-weld/welding-safety.html
2. Welding helmet
http://www.welding-technology-
3. Welding gloves
machines.info/arc-welding-processes-and-
4. Whiteboard equipments/advantages-disadvantages-and-
applications-of-arc-spot-welding.htm
5. Slag hammer
Anticipatory Set/Introduction/Motivation/Interest Approach:
Pass or Fail
The teacher will review some of the careers students have picked, but more importantly the
teacher will review safety with the students because this will be the first day the students are
actually working in the shop. The review will be called pass or fail because in order to receive
daily participation points, students will have to work in the shop. If they are unsafe or not
dressed appropriately they will not be allowed into the shop. Some examples are provided below:
Not wearing safety glasses in the shop at any time. Pass or Fail?
Wearing flip-flops in the shop; Pass or Fail?
Throwing hot metal across the room; Pass or Fail?
Set:
The teacher will begin the lesson by using a science based statement and safety scare tactic. The
teacher will ask two questions, write down responses on the board, and respond appropriately.
(Q) How many amps does it take to stop the human heart?
(A) of an amp
(Q) How many amps are we working with when we are arc welding?
Safety is an extremely important piece of working in the welding shop. Today we will be
working on reviewing safety, properly setting up the equipment
1. Identify the basics steps incorporated into the arc welding (SMAW) process
2. Select applications for arc welding in real-world settings
3. Explain how the arc forms and demonstrate how to properly set up equipment
4. Demonstrate striking the arc to begin the SMAW process
5. Create arc welds which are consistent with industry standards
Strategy Includes Teacher Subject Matter Outline/Problem and Solution (Application
Activity, Student Activity, Points Lace in Throughout Lesson) (Modeling, Guided
Questions/Answers and Practice, and Content)
Objectives
The teacher will be out in the It will feel like they are sandy and very itchy. Known as flash
shop to demonstrate and show burn.
students safety, travel, speed, Eye safety is very, very important.
and ask/answer questions
about the welding process. Make sure you always use a welding helmet. I use what is
called an "automatic" welding helmet. This type of helmet will
(Q) What is a flashburn? "automatically" dull and filter the welding arc.
(A) Flashburn is an extreme Arc welding preparation, make sure you do it.
sun burn on the eye, and it has
basically no way to reverse the So the basic idea behind welding is a simple electric
effects once it has happened circuit...right. You attach the earth clamp to the bit of metal
being welded, and then when you bring the electrode closer to
(Q) When do we not have to the bit of metal you want to weld, you establish and arc.
wear our safety glasses in the
shop? So you need the earth to touch the work and you need the
electrode to touch the work, thus completing the basic circuit.
(A) NEVER, we always wear
eye protection, even under our This step in the welding process is also very critical if you want
helmets to learn how to stick weld properly. You must always have a
clean, secure and tight earth connection. If you do not, it can
(Q) Why do we double check really affect you welding experience, especially if you are
we have properly connected learning and you don't know what's going on.
our ground clamp, every time
we begin to weld? So when you are doing the first step to successfully make you
first weld by doing "weld preparation" . Make sure you grind
(A) So we make sure the away a small area on the steel to be welded, so that when you
electric circuit is being made clamp your earth to it you will not have any troubles later on in
through the metal, and not our the welding process.
bodies
Because at least when you are welding the heat from the arc
(Q) Why does the metal have will to a certain extent burn away some of the impurities. But
to be clean before we start the where the earth clamp goes, it can't burn away paint or other
welder? surface contaminates can it.
(A) To make a good Make sure you have an excellent welding earth connection
connection
(Q) Has anyone used an arc Advantages Disadvantages and Applications of Arc
welder before? Welding -
Advantages
(A) If students have used an Besides the advantages listed more are as under:
arc welder before, the teacher (1) The process involves less maintenance cost.
will ask them where and what (2) Skill of the operator does not influence the quality of spot
they were welding and most welds obtained by this process.
importantly why they used the (3) The process is normally free from smoke and spatter.
arc welder Limitations
(1) To achieve low cost of construction, the weld production
(Q) What would be some of rate is not very high.
the advantages of using the arc (2) The process proves uneconomical as compared to resistance
welder? spot welding where the latter can be easily employed.
(Q) If there are three ways to There are three ways how to strike an arc.
strike an arc, which one is the
best? 1. Flick up from an edge
(A) The one which works best 2. Strike like a match/ scratch it
for you
3. Tap it straight down, then back up
The teacher will give
demonstrations on striking the Hold the rod as straight up as possible.
arc and ask students to
practice with the welder One of the mistakes people make when arc welding is not
turned off, just to demonstrate holding the rod at the right angle. For now hold it straight up,
the correct angle and motion ie 90deg.
(Q) Is it going to be easier to You should actually hold the rod between 0 and 16 degrees,
practice striking an arc with a with the rod leaning towards the direction of travel. I say keep
longer electrode or shorter? it straight up as you will always as a learner drop your arm,
which will change the angle of the rod.
(A) Shorter rods or electrodes
will not react as dramatically Make sure the ground clamp is connected
to minor hand movements
Yell clear before striking your arc
Once students have shown the Current setting: The correct current, or amperage, setting
teacher how they are going to primarily depends on the diameter and type of electrode
strike the arc, students will selected. For example, a 1/8 in. 6010 rod runs well from 75 to
turn on their machine to the 125 amps, while a 5/32 in. 7018 rod welds at currents up to 220
correct setting, and practice amps.
just keeping an arc for a few
seconds
Objective #5 Arc Welding
Length of arc: The correct arc length varies with each
Students will begin arc electrode and application. As a good starting point, arc length
welding by creating short should not exceed the diameter of the metal portion (core) of
beads and comparing the the electrode. Holding the electrode too closely decreases
welds with industry standard welding voltage. This creates an erratic arc that may extinguish
welds which are posted on the itself or cause the rod to freeze, as well as produces a weld
shop classroom wall. bead with a high crown. Excessively long arcs (too much
voltage) produce spatter, low deposition rates, undercuts and
Students should start to see maybe porosity.
the differences in the welds,
and note the differences on a Angle of travel: Stick welding in the flat, horizontal and
piece of paper. overhead position uses a "drag" or "backhand" welding
technique. Hold the rod perpendicular to the joint and tilt the
At the end of the first day the top of the electrode in the direction of travel approximately 5 to
teacher will ask that the 15 degrees.
students turn in a piece of
paper which describes how Manipulation: Each welder manipulates or weaves the
their welds are different from electrode in a unique style. Develop your own style by
the industry standard SMAW observing others, practicing and creating a method that
welds produces good results for you. Note that on material 1/4 in. and
thinner, weaving the rod typically creates a bead that is wider
(Q) Why do I have you guys than necessary. In many instances, plain, straight-ahead travel
practice just making beads on works fine.
a plate?
To create a wider bead on thicker material, manipulate the
(A) Because welding takes electrode from side to side creating a continuous series of
practice, practice, practice. partially overlapping circles, or in a "Z," semi-circle or stutter-
Running beads is the first step step pattern. Limit side-to-side motion to 2-1/2 times the
to becoming a professional diameter of the electrode core. To cover a wider area, make
multiple passes or "stringer beads."
Closure/Summary/Conclusion (Tie in Objectives)
The only way to improve in arc welding is practice. Good welders work everyday or every
chance they have to make regular beads like you have all practiced today. Welding can be
frustrating, but once those challenges have been over come, it is a very satisfying skill to have.
What have we learned today?
1. Identify the basics steps incorporated into the arc welding (SMAW) process
2. Select applications for arc welding in real-world settings
3. Explain how the arc forms and demonstrate how to properly set up equipment
4. Demonstrate striking the arc to begin the SMAW process
5. Create arc welds which are consistent with industry standards
Visual and verbal checks for understanding will be done by the teacher to ensure the students are
understanding the concepts of arc welding and striking the arc
Self-evaluation
Daily calendar
Industry standard comparison sheet
Lesson Reflection
This lesson was set up with students practicing much of the time when the welder is off. If I
could redo this lesson I would demonstrate with the machine off and on, and then let students
turn on the welder and practice striking the arc. I do not think they really learned anything from
practicing with the electricity off, it is an entirely new ballgame when there is actually a response
from a simple movement of the hand.