Arc Welding Lesson Plan

This material is based upon work supported by the National Science Foundation under Grant Number 1104095

Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s)
and do not necessarily reflect the views of the National Science Foundation
 Lesson Plan

Time Allotment: 10 Hours

Prepared By: SnoCAMP Instructors

LESSON DESCRIPTION
This module provides students with beginning knowledge and skills relating to the safety,
equipment, and procedures necessary to Arc Welding.

LESSON OBJECTIVE
After completing this module, students should be able to describe the required qualifications,
safety, equipment, procedures, and work environment associated with Arc Welding.

MANUFACTURING SKILL STANDARDS INTRODUCTED (MSSC)

P1 Production Tools and Equipment, E: Skill in operating production equipment.
P3. Personal Safety, C: Knowledge of housekeeping needed to maintain a safe work
environment.
P3 Personal Safety, D: Skill in determining if all safety guards are in place prior to machine
operation.

PERFORMANCE CRITERIA
 Before starting a machining operation, the student will be able to determine the safety
and fitness of tools and materials and report defects and malfunctions to appropriate
personnel.
 The student will be able to safely operate, use, and maintain the tool and perform the
tasks according to manufacturer’s guidelines.
 The student will be able to demonstrate the operation, use, and maintenance according to
manufacturer’s guidelines.
 The student will be able to state and demonstrate both the manufacturer’s safety
procedures and the shop’s safety procedures with 100% accuracy.
 The student will be able to state and demonstrate safe movement and the use of personal
protective equipment such as safety shoes, goggles, and hard hats, and the shop’s safety
procedures with 100% accuracy and consistency.
 The student will be able to identify all safety features of the machine, discuss
characteristic tool wear and failure, and state how this information can protect the user
and others in the shop.
  The student will be able to identify the safety features and demonstrate the safe use of all
available shop hand tools according to manufacturers’ guidelines.
 The student will be able to lay out a part to within . .015” of drawing specifications.
 Given an assembly drawing, the student will be able to use number symbols to match
part descriptions on the parts list with the detail of that part on the drawing.

SEQUENCING
Introduction
Basic rules for the shop
Tour of the shop
Arc Welding Safety
Hand Tools
Basic shop hand tools
Layout skills
Hand tool project
Machine Tools
Introduction to Oxy-Fuel Cutting and Welding
Interpretation of Project Plans
Project Construction

EQUIPMENT AND SUPPLIES NEEDED

This module assumes the school has a metalworking shop. At a minimum, it requires a
metal shop with, metal cutting tools, grinders, and oxy-fuel welding capabilities.

RECOMMENDED STUDENT PREREQUISITES

Completed the following modules:
Safety in Manufacturing
Hazardous Materials
Precision Measurement
Materials Science - Metals
Lean Manufacturing
5S System Lesson Packet
 Class Curriculum
Activity Instructor Notes
Introduction Teacher gives a brief personal introduction.
Preview Module Objective: After completing this module, you
should be able to demonstrate knowledge and skills in shop safety
and in the use of Arc Welding Equipment
Preview Skill Checks: You will demonstrate these skills through a
variety of shop projects that use each of these tools, and in a final
exercise that uses a combination of these skills.
Basic Rules for the Shop Before we go out on the shop floor, we need to agree on some
basic rules about what is safe and what is unsafe – given the fact
that power tools are powerful and potentially dangerous.
Distribute Handout 4 : Arc Welding Fundamentals
Handout 4
Distribute Handout 2 : Health and Safety in Welding
Handout 2
 Review each item. Add whatever additional shop rules
that are needed in your shop.
60 minutes
 Let students know what will happen if they break the rules
– in some schools, this would put them out of the program.
 Let students know that before they use any machine they
will have to pass a skill check on setting it up correctly
and using it safely.
Have each student sign to indicate their agreement.
Tour of the Arc Welding Review all the basic equipment in the Oxygen-Fuel Welding area
Area  Describe what each machine is used for, the safety
requirements for the machine, and how to use it properly.
10 minutes  If possible – have an assistant who demonstrates how to
use the machine as you describe how to do it.
 Review what they will be tested on and what skill check
they will have to pass to be certified to operate that
machine.
Arc Welding Hand Tools Before we start using the Arc Welding equipment, we are going
Basic hand tools watch a presentation and cover hand tools used in the Arc
Welding process
Presentation on Arc  Arc Welding Basics – Lincoln Welding Company
Welding
Handout 3  Distribute Handout 3: Arc Welding Hand Tools
 Review the information in the handout.
10 minutes
Hand tools available for
student inspection
Using the Equipment Review what the equipment does – how it works, how to adjust
the gas flow, what kind of material can be welded, conditions
created during the welding process, including the need for the
10 minutes
fume exhaust system, handling of hot metals (including how to
mark as “hot”).
 Show good and damaged tools.
 Identification of the equipment and tools
Have students come up to the table and identify which are good
tools and which the dull or damaged ones.

Demonstrate how to adjust the welder and how to properly create

a weld with the welder.
 Adjusting the gas flow (MIG Welding)
 Adjusting the settings

Student Tasks
Completion of Beginning Utilizing the Arc Welded Bookend Project Packet, students are to
Welding Project create the selected project to established specifications in a safe
and appropriate manner.