Lesson Plan. Time The lesson should take approximately four (45 minute) class periods to teach and complete the activities.

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1 Basic Metals Welding Lesson Plan Performance Objective Upon completion of this lesson, students will be able to demonstrate how to differentiate between various types of metals and metal shapes, by mastering at least 70% of the Basic Metals Test. Specific Objectives Define ferrous and non-ferrous, alloy and alloy steels Identify various metals Identify standard metal shapes Determine characteristics and uses of various metals Evaluate information from a spark test Terms Alloy - metal formed by melting, fusing, or mixing two or more metals together Alloy steel - steel with one or more other metals added to give the steel certain characteristics or properties (always ferrous) Appendage - a subordinate part connected to the main part Carbon - main hardening agent in steel Conductor - a material that allows electricity or heat to pass through it Ductile - capable of being drawn out into wire Ferrous - metal that contains iron as a major element Galvanize - to produce a coating of zinc to prevent rusting Lustrous - reflecting light evenly Malleable - capable of being stretched or bent Metallurgy - the science of separating metals from their ores and then smelting, or refining them for use Non-Ferrous - metal that contains no iron or extremely small amounts of iron Sprigs - a small shoot Weldment - assembly of two or more metal parts with welding Time The lesson should take approximately four (45 minute) class periods to teach and complete the activities. Preparation TEKS Correlations This lesson, as published, correlates to the following TEKS. Any changes/alterations to the activities may result in the elimination of any or all of the TEKS listed. 1

2 Welding (c) o (4) The student knows the function and application of the tools, equipment, technologies, and materials used in welding. The student is expected to: (A) use welding equipment according to safety standards; (B) properly dispose of environmentally hazardous materials used in welding; and (C) use appropriate personal protective equipment as needed to follow safety measures. Interdisciplinary Correlations English Language Arts and Reading, English I (b) o (1) Reading/Vocabulary Development. Students understand new vocabulary and use it when reading and writing. Students are expected to: (A) determine the meaning of grade-level technical academic English words in multiple content areas (e.g., science, mathematics, social studies, the arts) derived from Latin, Greek, or other linguistic roots and affixes (b) o (9) Reading/Comprehension of Informational Text/Expository Text. Students analyze, make inferences and draw conclusions about expository text and provide evidence from text to support their understanding. Students are expected to: (D) synthesize and make logical connections between ideas and details in several texts selected to reflect a range of viewpoints on the same topic and support those findings with textual evidence (b) o (11) Reading/Comprehension of Informational Text/Procedural Texts. Students understand how to glean and use information in procedural texts and documents. Students are expected to: (B) analyze factual, quantitative, or technical data presented in multiple graphical sources. Occupational Correlation (O*Net Job Title: Welders, Cutters, and Welder Fitters O*Net Number: Reported Job Titles: Aluminum Welder, Fabrication Welder, Fabricator, Fitter/Welder, Maintenance Welder, Mig Welder, Sub Arc Operator, Welder, Welder-Fitter, Welder/Fabricator Tasks Weld components in flat, vertical, or overhead positions. Operate safety equipment and use safe work habits. 2

3 Soft Skills Critical Thinking Operation and Control Monitoring Reading Comprehension Accommodations for Learning Differences These lessons accommodate the needs of every learner. Modify the lessons to accommodate your students with learning differences by referring to the files found on the Special Populations page of this website. Preparation Materials Needed o Sample pieces of flat metal o Sample pieces of various shaped metals (at least 15) Equipment Needed o Computer and projector o Grinder o Safety goggles Learner Preparation o The student should provide writing instrument and paper for note-taking. References Fortney, C. & Fulkerson, D. & Gregory, M. (1984). Gas tungsten arc welding. Stillwater, OK: Mid- America Vocational Curriculum Consortium. Althouse, A. D. & Bowditch, W. A. & Bowditch, K. E. & Bowditch, K. & Bowditch, M. A. (2004). Modern welding. Tinley Park, IL: Goodheart-Willcox. Jeffus, L. F. (1999). Welding principles and applications. (4 th ed.) Independence, KY: Cengage Learning. Instructional Aids Types of Metals slide presentation (Slides 1-28) o Characteristics and Uses of Metals handout o Surface Color of Common Metals handout Basic Metal Shapes slide presentation (Slides 29-33) o Basic Metal Shapes Handout 1 o Basic Metal Shapes Handout 2 o Basic Metal Shapes Handouts 1 and 2 Answer Key Spark Test Characteristics slide presentation (Slides 34-39) o Basic Metals and Metallurgy Job Sheet handout o Spark Test Record Sheet handout Basic Metals Test 3

4 Introduction The purpose of this lesson is to help students be able to differentiate between various types of metals and metal shapes. Say o In welding, many different types of materials are joined together. The school welding shop is limited in the types of materials, but it is necessary to know the most commonly used metals in the field of welding. Ask o Why is it necessary to know the most commonly used metals in the field of welding? Say o Knowledge of the materials will help you make better choices concerning filler metals and uses of the fabrication. Show o Any array of types of metal pieces o Metal pieces (round bar, half-round bar, oval bar, half-oval bar, square bar, hexagon bar, flat bar, H-beam, I-beam, channel, angle, flat plate, tubing and pipe) Outline MI OUTLINE NOTES TO TEACHER I. Terms A. Alloy B. Alloy Steel C. Appendage D. Conductor E. Ductile F. Ferrous G. Galvanize H. Lustrous I. Malleable J. Metallurgy K. Non-ferrous L. Sprigs M. Weldment Review the terms for this lesson. 4

5 MI OUTLINE Outline II. Types of Metals A. Show Types of Metals slide presentation B. Students take notes and fill in Characteristics and Uses of Metals handout during presentation. C. Teacher may choose to present an example of the following metal pieces. i. Nickel steel ii. Chromium steel iii. Stainless steel iv. Plain carbon steel v. Low-alloy steel vi. Chrome-nickel steel vii. Manganese steel viii. Molybdenum steel ix. Tungsten steel x. Magnet steel xi. Tungsten carbide xii. Vanadium steel xiii. Stellite xiv. High-speed steel xv. Wrought iron xvi. Gray cast iron xvii. White cast iron xviii. Malleable cast iron xix. Aluminum xx. Copper xxi. Zinc xxii. Magnesium xxiii. Nickel xxiv. Titanium xxv. Lead xxvi. Tin D. Review Surface Color of Common Metals handout NOTES TO TEACHER Begin Types of Metals slide presentation. (Slides 1-28) Distribute Characteristics and Uses of Metals Chart handout. Multiple copies of the handout may be needed to accommodate the number of examples shown (by teacher). Have students work independently to take notes during the presentation. Students will use these notes during their assessment. On Plain Carbon Steels (Slide 6), be sure to note that the numbers listed start at 35/100 of 1%. Make a distinction between lead and the carbon that students use in a pencil. Distribute Surface Color of Common Metals handout. Discuss the chart as a reference tool to show the differences in types of metals. 5

6 MI Outline OUTLINE III. Basic Metal Shapes A. Show Basic Metal Shapes slide presentation. B. Students take notes on Basic Metal Shapes Handout 1 OR Handout 2 during slide presentation. C. Teacher should pass around examples of metal shapes. i. Round bar ii. Half-round bar iii. Oval bar iv. Half-oval bar v. Square bar vi. Hexagon bar vii. Flat bar viii. H-beam ix. I-beam x. Channel xi. Angle xii. Flat plate xiii. Tubing and pipe IV. Spark Tests A. Teacher demonstrates a spark test checking with the students at each step to make sure they understand the procedure. B. Show the Spark Test Characteristics slide presentation. C. Teacher divides the class into small groups. D. Send each group separately to the grinder station. E. At the grinder station, each group will test the sample metal piece provided by the teacher. F. After all groups have tested the metal, have the class discuss the results and determine the type of metal. G. Change the metal type and repeat the test process several times. (Each time, have students discuss the results before testing a new metal.) H. Each student will use the Spark Test Record Sheet to record the results and findings. NOTES TO TEACHER Begin Basic Metal Shapes slide presentation (Slides 29-33). Distribute Basic Metal Shapes Handout 1 and Handout 2. There are two versions so the teacher can differentiate which one is appropriate for various students. This activity will serve as an independent practice activity; notes will be used during assessment. Grade handouts with Basic Metal Shapes Handout key. Begin the Spark Test Characteristics slide presentation (Slides 34-39). Distribute Basic Metals and Metallurgy Job Sheet and Spark Test Record Sheet. Guide the spark test activity. Ensure students wear safety goggles. Have students record the results and discuss the metal type based on notes. 6

7 MI OUTLINE Outline NOTES TO TEACHER V. Review VI. Assessment A. Teacher will set up stations with a piece of metal at each station. Students will identify the specific shape. B. Students are required to master at least 70% of the Basic Metals Test covering metal types and metal shapes. Teacher needs to provide 15 metal shapes for students to identify on the Basic Metals Test. Multiple Intelligences Guide Existentialist Interpersonal Intrapersonal Kinesthetic/ Bodily Logical/ Mathematical Musical/Rhythmic Naturalist Verbal/Linguistic Visual/Spatial Application Guided Practice Guide the spark test and follow up discussion to evaluate metal types. Students may use their notes. Independent Practice During the Types of Metals slide presentation, students will take notes and complete the Characteristics and Uses of Metals handout. During the Basic Metal Shapes slide presentation, students will take notes on the Basic Metal Shapes Handouts 1 and 2. Summary Review Check for mastery/understanding by orally reviewing students on the information. Ask individual students to identify pieces of metal or metal shapes. 7

8 Evaluation Informal Assessment The teacher will monitor students understanding throughout the lesson. If further explanation is needed on a given topic, the teacher should elaborate or re-teach that portion of the lesson. During review time, check each student for general mastery level. Formal Assessment Mastery of at least 70% on the Basic Metals Test over types of metals and metal shapes will be required. Enrichment Extension For students who need remediation, a re-teach and review session will reinforce the topics of concern. The remediation will need to be tailored to the individual needs of the student. 8

9 Name Date Class Characteristics and Uses of Metals Metal Characteristics Typical Uses 9

10 Surface Color of Common Metals Metal Color of Unfinished, Unbroken Surface Color and Structure of Newly Color of Freshly Filed Surface Fractured Surface White cast iron Dull gray Silvery white; crystalline Silvery white Gray cast iron Dull gray Dark silvery; crystalline Light silvery gray Malleable iron Dull gray Dark gray; finely crystalline Light silvery gray Wrought iron Light gray Bright gray Light silvery gray Low-carbon and cast steel Dark gray Bright gray Bright silvery gray High-carbon steel Dark gray Light gray Bright silvery gray Stainless steel Dark gray Medium gray Bright silvery gray Copper Reddish brown to green Bright red Bright copper color Brass and bronze Reddish yellow, yellow-green, or brown Red to yellow Reddish yellow to yellowish white Aluminum Light gray White; finely crystalline White Nickel Dark gray Off-white Bright silvery white Lead White to gray Light gray; crystalline White Copper-Nickel (70-30) Gray Light gray Bright silvery white 10

11 Name Date Class Basic Metal Shapes Handout 1 Directions Draw a picture of each of the following basic metal shapes. 1. Round Bar 2. Half-Round Bar 3. Oval Bar 4. Half-Oval Bar 5. Square Bar 6. Hexagon Bar 11

12 7. Flat Bar 8. H-Beam 9. I-Beam 10. Channel 11. Angle 12. Flat Plate 13. Pipe 14. Tubing 12

13 Name Date Class Basic Metal Shapes Handout 2 Directions Write the correct name beside each of the following basic metal shapes

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16 Basic Metal Shapes Handout 1 and 2 Answer Key 1. Round Bar 2. Half-Round Bar 3. Oval Bar 4. Half-Oval Bar 16

17 5. Square Bar 6. Hexagon Bar 7. Flat Bar 8. H-Beam 9. I-Beam 17

18 10. Channel 11. Angle 12. Flat Plate 13. Pipe 14. Tubing 15. Tubing 18

19 Basic Metals and Metallurgy Job Sheet Handout Directions Conduct Spark Tests to identify common metals used for welding. I. Tools and Materials A. Safety glasses B. Face shield C. Locking pliers D. Pedestal grinder E. Metal samples selected by teacher II. Procedure A. Check the work area for safe working conditions B. Provide as dark a back-drop as possible to assist with better spark recognition C. Check grinder for proper working order D. Check grinding wheel to make sure it has been dressed E. Turn off light on grinder (if there is one) F. Put on face shield G. Lock pliers onto first metal sample H. Turn on grinder and allow it to reach maximum rpm I. Position yourself at the grinder so that all sparks will be free of obstructions and easy to observe J. Place metal sample on tool rest, hold pliers lightly, and move metal into grinding wheel until it makes light contact K. Grind metal sample long enough to produce a stable spark pattern L. Observe color close to wheel and color of sparks at the dying end of the spark stream M. Observe the shape of the spark pattern or stream pattern N. Observe the volume and length of spark stream 19

20 Metal Sample Spark Test Record Sheet Color Pattern Shape Volume Length in Inches Name of Metal 1 At Wheel End Stream 2 At Wheel End Stream 3 At Wheel End Stream 4 At Wheel End Stream 5 At Wheel End Stream 20

21 Name Date Class Basic Metals Test Identify Metal Shapes Used for Welding Directions Identify the shape of each piece of metal. Shape #1 Shape #2 Shape #3 Shape #4 Shape #5 Shape #6 Shape #7 Shape #8 Shape #9 Shape #10 Shape #11 Shape #12 Shape #13 Shape #14 Shape #15 21