Lesson Plan
Course Title: Advanced Welding
Session Title: GTAW Safety
Performance Objective:
Upon completion of this assignment, the student will be able to safely prepare for using
the Gas Tungsten Arc Welding (GTAW) machine.
Specific Objectives:




Understand definitions/terms
Describe safety steps/measures
Discuss why safety measures are in place
Demonstrate safety steps
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.
Advanced Welding:

130.324(c)(2)(F)
…apply knowledge and skills related to health and safety in the workplace, as
specified by appropriate government regulations.

130.324(c)(13)(A)(B)(C)(D)(E)
…use safe operating practices;
…perform fillet welds;
…perform groove welds;
…perform welds in all appropriate positions according to accepted welding
standards; and
…perform welds on metals such as carbon steel, stainless steel, pipe, and
aluminum.
Interdisciplinary Correlations:
English:
110.42(6) – Reading/word identification/vocabulary development
 110.42(6)(A)
…expand vocabulary development through wide reading, listening, and discussing;
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Instructor/Trainer
References:
GTAW Student Material booklet Mid-America Vocational Curriculum Consortium
(1984)
AirCo Safety Video (1988)
Lincoln Electric Safety Power Point
Modern Welding (2004)
Welding Principles and Applications (1999)
Instructional Aids:
1.
2.
3.
4.
5.
Golden Rules Handout
Definitions Worksheet Handout
Checklist
Safety Quiz
Safety Quiz Answer Key
Materials Needed:
Safety Glasses
Protective hood and lenses
Protective clothing
Lincoln Power Point on safety
Sample MSDS sheet (not provided; use one specific to shop/lab)
Equipment Needed:
GTAW machine
Example tools
Demonstration table
Learner
The student should provide writing instrument for note-taking.
Introduction
Introduction (LSI Quadrant I):
Safety in the welding shop/lab is crucial for the well-being of all people in the shop at
any given time. All safety rules and measures must be followed at all times to
ensure that no accidents occur.
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The instructor should be the model for this behavior. Any injuries or hazardous
situations should be reported immediately. All instructions should be followed the
first time without fail. There is no room for error on safety. Never hesitate to ask
questions before doing something in the shop if it will prevent an accident from
occurring.
Outline
Outline (LSI Quadrant II):
I. First Aid locations
II. Emergency exits
III. Protective clothing
A. Cotton shirt
B. Loose fitting jeans or work pants (no cuffs)
C. Boots
D. Gloves
IV. Protective eyewear
A. Importance
B. Types of protection
C. Usage problems
D. Usage areas
E. Usage times
V. Protective hood
A. Types of hoods
B. Types of lenses
VI. Work area
A. Cleanliness
B. Fire prevention
1. Extinguisher location
2. Rags/oil
VII. Electricity
A. Proper cord handling
B. Frayed cords
C. All wires treated as hot
D. No working on electricity inside or outside machines
E. No wet hands
VIII. Tools
A. Necessity of proper use for safety
B. Wrench use
C. Grinder use
IX. Equipment/Materials
A. Necessity of proper use for safety
B. Transporting/lifting
X. Handling bottles
XI. Handling consumable
A. Proper referencing
B. Tungsten
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C. Cup
D. Gases
XII. Fume dissipation
XIII. MSDS sheets
XIV. Show Lincoln Power Point
Application
Guided Practice (LSI Quadrant III):
Students will work with helmets to practice checking and covering procedure.
Students will work with electrical cords to practice proper cord handling.
Students will work with the grinder to practice proper tool handling.
Students will work with a specified piece of equipment to practice proper lifting of
equipment.
Independent Practice (LSI Quadrant III):
Students will utilize “Getting Started” checklist to complete specified safety procedure.
Summary
Review (LSI Quadrants I and IV):
Review checklist and reasons for safety measures.
Evaluation
Informal Assessment (LSI Quadrant III):
Discuss which safety practices apply to general shop safety procedures.
Discuss which safety practices are applicable only to GTAW as opposed to those that
cross over to other forms of welding.
Formal Assessment (LSI Quadrant III, IV):
Administer the safety test. Each student must score a 100% on the test in order for that
student to proceed to the next shop/lab experience. Anything less than a 100%
indicates a potential safety breech. If a 100% is not scored, the student will attend a reteach/review session with the instructor to cover the material missed on the test. A
retest will then occur. If a special education student requires accommodation, the
modifications can be made by reading the material to the student. The student must still
be able to demonstrate hands-on mastery of 100% of the safety procedures before
being allowed to use the equipment or participate in shop/lab activities.
Extension/Enrichment (LSI Quadrant IV):
For those 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.
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Checklist
Clothing
__Boots
__Pants (heavy cotton/denim; no cuffs; loose, but good fit; no
frays/holes)
__Shirt (long sleeve, heavy cotton)
__Cap (optional)
__Welding helmet with proper lens
Health
__Over-the-Counter and prescription drugs (check with the instructor)
__General physical condition
Work Area
__Clean
__Free from possible electrical shock
__Gas cylinder properly secured and adjusted
__Fire protection available
Machinery
__Grinder ready for use
__Cables in good condition
**Any time someone strikes an arc, the welder should say, “Cover.”
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Definitions for GTAW
Non-consumables – materials that are not used up in the GTAW process
Flash burn – when harmful rays burn eyes
ANSI – American National Standards Institute
IR – Infrared Rays – Harmful rays emitted by welding
UV – Ultra Violet Rays – Harmful rays emitted by welding
MSDS Material Safety Data Sheets – papers that are shipped with all
chemicals
Inert Gas – does not react with metal to form oxides
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Golden Rules
If you open it, close it.
If you turn it on, turn it off.
If you unlock it, lock it.
If you break it, repair it.
If you can’t fix it, call someone who can.
If you borrow it, return it.
If you use it, take care of it.
If you make a mess, clean it up.
If you move it, put it back.
If you don’t know how to operate it, leave it alone.
If it doesn’t concern you, mind your own business.
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GTAW Safety Test
1. List 8 items recommended as protective equipment in the text.
a.
b.
c.
d.
e.
f.
g.
h.
2. What shaded lens is recommended for GTAW
________________________________________________________
3. The light is brighter with GTAW. Why?
a. ________________________________________
b. ________________________________________
4. What does the Golden Rule of Welding attempt to convey?
________________________________________________________
5. Describe how to lift an object sitting low to the ground.
a. _________________________
b. _________________________
6. What jewelry is acceptable in the shop area
________________________________________________________
7. Report ________ (all, most, some) accidents to the instructor.
8. Never use ______ (oil, water, cutting fluid) to loosen cylinder fittings.
9. Never attempt to _______ (repair, clean) any part of a cylinder, valves or gauges.
10. Always keep cylinders _______ (closed, open) when not in use.
11. What should be done to all equipment to help insure against electrical shock.
_________________________________________________________
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Select true statements concerning safety for GTAW by placing an “X” in the appropriate
blanks.
12. _____ Welders flashburn occurs when a worker gets an eyeful of the dangerous
and harmful rays.
13. _____ Always wear ANSI safety glasses with your welding helmet.
14. _____ Exposed skin can be damaged by sound waves that can cause cancer.
15. _____ Flame-retardant treated cotton or leather, should be worn.
16. ______ When cables are worn or frazzled splice or use duct-tape to repair.
17. _____ All cylinders in the work area shall be secured.
18. _____ Use approved leak detector solution.
19. _____ The higher the current the greater the potential for creating harmful gases
and fumes.
20. _____ A welding helmet is checked for cracks by looking in the directions of the sun.
21. What is the best practice in preventing accidents?
______________________________________________________________
22. What types of material should not be worn in the shop?
a.
b.
c.
23. When should the tool rest be re-adjusted?
________________________________________________________
24. What type of material should be placed on the inside and outside of the shaded
lens?
________________________________________________________
25. Why should a fan or vacuum be placed in the welding area?
___________________________________________________________
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GTAW Safety Test- ANSWERS
1. List 8 items recommended as protective equipment in the text.
a. Helmet
b. Cap/hat
c. Safety glasses
d. Leather jacket
e. Gloves
f. Apron
g. Flame resistant shirt and pants (no cuffs)
h. High-top safety shoes or boots
2. What shaded lens is recommended for GTAW
a. #10 (9-14 is acceptable)
3. The light is brighter with GTAW. Why?
a. Due to the type of arc produced
b. Reflections of the light
4. What does the Golden Rule of Welding attempt to convey?
a. Responsibility
5. Describe how to lift an object low to the ground.
a. Back straight
b. Lift with your knees
6. What jewelry is acceptable in the shop area
a. None
7. Report ________ (all) accidents to the instructor.
8. Never use ______ (oil) to loosen cylinder fittings.
9. Never attempt to _______ (repair) any part of a cylinder, valves or gauges.
10. Always keep cylinders _______ (closed) when not in use.
11. What should be done to all equipment to help insure against electrical shock.
a. Should be earth grounded
Select true statements concerning safety for GTAW by placing an “X” in the appropriate
blanks.
12. __X__ Welders flashburn occurs when a worker gets an eyeful of the dangerous
and harmful rays.
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13. __X__ Always wear ANSI safety glasses with your welding helmet.
14. _____ Exposed skin can be damaged by sound waves that can cause cancer.
15. __X__ Flame-retardant treated cotton or leather, should be worn.
16. ______ When cables are worn or frazzled splice or use duct-tape to repair.
17. __X__ All cylinders in the work area shall be secured.
18. __X__ Use approved leak detector solution.
19. __X__ The higher the current the greater the potential for creating harmful gases
and fumes.
20. __X__ A welding helmet is checked for cracks by looking in the directions of the
sun.
21. What is the best practice in preventing accidents?
a. To continually review safety practices and job dangers
22. What types of material should not be worn in the shop?
a. Nylon
b. Rayon
c. Polyester
23. When should the tool rest be re-adjusted?
a. When the grinder wheel is greater than 1/6 inch away from the tool rest.
24. What type of material should be placed on the inside and outside of the shaded
lens?
a. Plastic
25. Why should a fan or vacuum be placed in the welding area?
a. So fumes can be displaced from the area
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