LESSON PLAN

Teacher: Sherwin Faisal P. Melegrito

Specialization: Shielded Metal Arc Welding

Lesson Title: Principles of Arc Welding

No. Periods: 1 (2-hour period)

Objectives:

1. Students will understand the basics of striking and maintaining an arc

2. Students will be able to practice arc welding proficiency by creating arc beads

Materials, Equipment, Audio-Visual Aids: References:

1. Arc welder http://www.learn-how-to-weld.com/arc-

welding/how-to-arc-weld/welding-safety.html
2. Welding helmet
http://www.welding-technology-
3. Welding gloves machines.info/arc-welding-processes-and-
equipments/advantages-disadvantages-and-
4. Whiteboard applications-of-arc-spot-welding.html

5. Slag hammer

Anticipatory Set/Introduction/Motivation/Interest Approach:

Review Yesterday’s Lesson:

“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 slippers in the shop; Pass or Fail?

Throwing hot metal across the room; Pass or Fail?

Set:

“Stop your Heart”

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) ¼ of an amp

(Q) How many amps are we working with when we are arc welding?

(A) 75-120 amps

Transition (Use Objective):

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 Practice,
Questions/Answers and and Content)
Objectives

Safety Review

In order for the students to hear

and see how to arc weld more
than once, the teacher will begin
with showing the students how
the arc process works, while
reviewing safety.
The teacher will mention that
arc welding is also commonly
referred to as Shielded Metal Arc
Welding or SMAW
The welding process can and, will injure you, unless you take
welding safety seriously. Items such as, gloves, clothing and
even welding screens all play a role in your personal safety
when welding.
You don't wear a welding helmet for fashion, or to look good.
Although you can get some pretty sweet looking helmets
these days! That bright blue welding arc will cook your
eyeballs if you do not protect them.
If you look at the welding arc with the naked eye too many
times, or catch too many flashes. Your eyes will get really
sore.

It will feel like they are sandy and very itchy. Known as flash burn.
The teacher will be out in the
shop to demonstrate and show
Eye safety is very, very important.
students safety, travel, speed,
and ask/answer questions about
Make sure you always use a welding helmet. I use what is
the welding process.
called an "automatic" welding helmet. This type of helmet
will "automatically" dull and filter the welding arc.
(Q) What is a flashburn?
(A) Flashburn is an extreme sun
burn on the eye, and it has
basically no way to reverse the
effects once it has happened
(Q) When do we not have to
wear our safety glasses in the
shop?
(A) NEVER, we always wear eye
protection, even under our
helmets
(Q) Why do we double check we
have properly connected our
ground clamp, every time we
begin to weld?
(A) So we make sure the electric
circuit is being made through
the metal, and not our bodies
(Q) Why does the metal have to
be clean before we start the
welder?
(A) To make a good connection
(Q) Where should our cords be
located when we are setting up
our station?
(A) Behind us and out of the way
of other students so they do not
trip over the cords
(Q) Has anyone used an arc
welder before?
Arc welding preparation, make sure you do it.
So the basic idea behind welding is a simple electric
circuit...right. You attach the earth clamp to the bit of metal
being welded, and then when you bring the electrode closer
to the bit of metal you want to weld, you establish and arc.
So you need the earth to touch the work and you need the
electrode to touch the work, thus completing the basic circuit.
This step in the welding process is also very critical if you
want to learn how to stick weld properly. You must always
have a clean, secure and tight earth connection. If you do not,
it can really affect you welding experience, especially if you
are learning and you don't know what's going on.
So when you are doing the first step to successfully make you
first weld by doing "weld preparation" . Make sure you grind
away a small area on the steel to be welded, so that when you
clamp your earth to it you will not have any troubles later on
in the welding process.
Because at least when you are welding the heat from the arc
will to a certain extent burn away some of the impurities. But
where the earth clamp goes, it can't burn away paint or other
surface contaminates can it.
Make sure you have an excellent welding earth connection
Applications for Arc Welding
Advantages Disadvantages and Applications of Arc Welding -
Advantages
Besides the advantages listed more are as under:
(1) The process involves less maintenance cost.
(2) Skill of the operator does not influence the quality of spot
(A) If students have used an arc
welder before, the teacher will
ask them where and what they
were welding and most
importantly why they used the
arc welder
(Q) What would be some of the
advantages of using the arc
welder?
(A) Lower maintenance costs,
easy to maneuver around
(Q) What are some of the
disadvantages to this set up?
(A) Welds do not always look as
nice as MIG welds or O/A welds
(Q) Why do we have you
practice and learn the arc
welding process in this class?
(A) Arc welding is usually more
affordable for at home use, and
industry still uses it for certain
applications
(Q) If there are three ways to
strike an arc, which one is the
best?
(A) The one which works best
for you
The teacher will give
demonstrations on striking the
arc and ask students to practice
You should actually hold the rod between 0 and 16 degrees,
with the welder turned off, just
with the rod leaning towards the direction of travel. I say
to demonstrate the correct angle
and motion
welds obtained by this process.
(3) The process is normally free from smoke and spatter.
Limitations
(1) To achieve low cost of construction, the weld production rate
is not very high.
(2) The process proves uneconomical as compared to resistance
spot welding where the latter can be easily employed.
Applications
The use of manually operated arc spot welding gun is a common
thing in various industries. Arc spot welding is especially
applicable for situations where resistance spots welding needs
high pressure, high currents, does not have easy access and thus
fails to weld.
Arc spot welding torch can also be employed to make holes in
plates up to 3 mm thick or so. After the arc has impinged on the
plate for a definite time, high pressure inert gas blows away the
molten metal leaving a hole in the plate. Other applications of, the
process are in :
1. Automobile industry.
2. Fabrication of sheet metal products.
3. Assembling sheet metal to steel structures.
4. Fabrication of pulleys.
5. Joining killed carbon steel, low alloy steel, high alloy steel,
titanium, etc.
Striking the Arc
There are three ways how to strike an arc.
 1. Flick up from an edge
 2. Strike like a match/ scratch it
 3. Tap it straight down, then back up
Hold the rod as straight up as possible.
One of the mistakes people make when arc welding is not
holding the rod at the right angle. For now, hold it straight up,
i.e. 90deg.

(Q) Is it going to be easier to
practice striking an arc with a
longer electrode or shorter?
(A) Shorter rods or electrodes
will not react as dramatically to
minor hand movements
Students will each practice
setting up an arc welder, but
demonstrating with the machine
off first before moving to
actually practice striking the arc.
Once students have shown the
teacher how they are going to
strike the arc, students will turn
on their machine to the correct
setting, and practice just
keeping an arc for a few seconds
Students will begin arc welding
by creating short beads and
comparing the welds with
industry standard welds which
are posted on the shop
classroom wall.
Students should start to see the
differences in the welds, and
note the differences on a piece
of paper.
At the end of the first day the
teacher will ask that the
students turn in a piece of paper
which describes how their welds
are different from the industry
standard SMAW welds
keep it straight up as you will always as a learner drop your
arm, which will change the angle of the rod.
Make sure the ground clamp is connected
Yell clear before striking your arc
Demonstration of Striking the Arc
Now that you're ready to weld, remember CLAMS. Bringing
all these points together in one moment of welding may seem
like a lot to think about, but it becomes second nature with
practice. And don't get discouraged! Stick welding got its
name not because the electrode looks like a stick, but because
EVERYONE sticks the rod to the work piece when learning
how to weld.
Current setting: The correct current, or amperage, setting
primarily depends on the diameter and type of electrode
selected. For example, a 1/8 in. 6010 rod runs well from 75 to
125 amps, while a 5/32 in. 7018 rod welds at currents up to
220 amps.
Arc Welding
Length of arc: The correct arc length varies with each
electrode and application. As a good starting point, arc length
should not exceed the diameter of the metal portion (core) of
the electrode. Holding the electrode too closely decreases
welding voltage. This creates an erratic arc that may
extinguish itself or cause the rod to freeze, as well as
produces a weld bead with a high crown. Excessively long
arcs (too much voltage) produce spatter, low deposition rates,
undercuts and maybe porosity.
Angle of travel: Stick welding in the flat, horizontal and
overhead position uses a "drag" or "backhand" welding
technique. Hold the rod perpendicular to the joint and tilt the
top of the electrode in the direction of travel approximately 5
to 15 degrees.
Manipulation: Each welder manipulates or weaves the
electrode in a unique style. Develop your own style by
observing others, practicing and creating a method that
produces good results for you. Note that on material 1/4 in.
and thinner, weaving the rod typically creates a bead that is
wider than necessary. In many instances, plain, straight-ahead
travel works fine.
To create a wider bead on thicker material, manipulate the
electrode from side to side creating a continuous series of
(Q) Why do I have you guys partially overlapping circles, or in a "Z," semi-circle or
practice just making beads on a stutter-step pattern. Limit side-to-side motion to 2-1/2 times
plate? the diameter of the electrode core. To cover a wider area,
make multiple passes or "stringer beads."

(A) Because welding takes

practice, practice, practice.
Running beads is the first step to
becoming a professional

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 overcome, 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

Evaluation: (Authentic forms of Evaluation, Quizzes, or Written Exam)

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

Assignments: (Student Activities Involved in Lesson/Designed to Meet Objectives)

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 scenario when there is actually a response from a simple
movement of the hand.