Welding Sheet Metal
Flexible Manufacturing
Lesson Plan
Performance Objective
At the end of the lesson, students will demonstrate how to select electrodes, use different welding processes,
and produce welds on two sheet metal projects, to match the criteria in the Welding Project Rubric.
Specific Objectives
 Explain how sheet metal is formed
 Explain the different types of welding used in manufacturing companies and the classroom lab
 Explain the different electrodes used in welding processes
 Demonstrate how to weld sheet metal using different welding processes
 Demonstrate how to weld scrap metal to make a project
Terms
 Ingot- a bar of cast metal
 Hot rolled- sheet metal formed while hot; not uniform in thickness; surface can be scaly; less expensive
than hot rolled
 Cold rolled- sheet metal formed when cold; uniform in thickness; surface is smooth; costs more than
hot rolled; surface can be grained or textured
 Sheet stock- sheet metal used in a flexible manufacturing lab will be different gauges and could include
copper, aluminum, and brass materials
 Oxy-fuel process- a process achieved by heating the edges of the metal and adding a filler rod into the
weld pool
 Welding electrode- provides the path for the current to flow to the metal to be welded
 Flux- substance to aid in fusion (as in soldering)
 Shielded metal arc welding (SMAW)- (or stick welding) uses a metal rod electrode coated with a flux;
has a number system which describes the rods, tensile, strength, coating, welding current, and
direction
 Gas metal arc welding (GMAW)- (or MIG welding) uses a thin wire electrode loaded into the machine’s
feeder; the wire is sized by diameter
 Gas tungsten arc welding (GTAW)- (or TIG welding) uses a tungsten rod as the electrode
 Oxygen acetylene welding (OAW)- uses a metal filler rod in the welding process
Time
It should take approximately 55-65 minutes to teach the lesson and 55-65 minutes for each of 10 lab sessions.
Preparation
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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.
Flexible Manufacturing
 130.327 (c)
o (4) The student differentiates the technical concepts that form the knowledge and skills of
metal trades. The student is expected to:
(B) examine the theory of shielded metal arc-welding and gas metal arc-welding.

130.327 (c)
o (7) The student applies the technical concepts and skills of the welding industry to simulated
and actual work situations. The student is expected to:
(B) explore the use of the common types of electrodes; and
(C) use various welding machines to weld multiple joints.

130.327 (c)
o (9) The student differentiates the concepts that form the technical knowledge and skills of
sheet metal manufacturing. The student is expected to:
(A) analyze the types, sizes, and properties of sheet metal materials;
(B) analyze the fundamentals of oxy-fuel processes as related to sheet metal.
Interdisciplinary Correlations
Geometry
 111.41 (c)
o (1) Mathematical process standards. The student uses mathematical processes to acquire and
demonstrate mathematical understanding. The student is expected to:
(A) apply mathematics to problems arising in everyday life, society, and the workplace;
(B) use a problem-solving model that incorporates analyzing given information,
formulating a plan or strategy, determining a solution, justifying the solution, and
evaluating the problem-solving process and the reasonableness of the solution; and
(C) select tools, including real objects, manipulatives, paper and pencil, and technology
as appropriate, and techniques, including mental math, estimation, and number sense
as appropriate, to solve problems.
Occupational Correlation (O*Net – www.onetonline.org/)
Job Title: Welders, Cutters, and Welder Fitters
O*Net Number: 51-4121.06
Reported Job Titles: Aluminum Welder, Fabrication Welder, Fabricator, Fitter/Welder, Maintenance Welder,
Mig Welder, Sub Arc Operator, Welder, Welder-Fitter, Welder/Fabricator
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Tasks
 Weld components in flat, vertical, or overhead positions.
 Operate safety equipment and use safe work habits.
 Lay out, position, align, and secure parts and assemblies prior to assembly, using straightedges,
combination squares, calipers, and rulers.
 Examine work pieces for defects and measure work pieces with straightedges or templates to ensure
conformance with specifications.
 Recognize, set up, and operate hand and power tools common to the welding trade, such as shielded
metal arc and gas metal arc welding equipment.
 Weld separately or in combination, using aluminum, stainless steel, cast iron, and other alloys.
 Select and install torches, torch tips, filler rods, and flux, according to welding chart specifications or
types and thicknesses of metals.
Soft Skills
 Critical Thinking
 Operation and Control
 Monitoring
 Reading Comprehension
Accommodations for Learning Differences
It is important that lessons accommodate the needs of every learner. These lessons may be modified to
accommodate your students with learning differences by referring to the files found on the Special
Populations page of this website.
Preparation
o Research the Internet for welding associations and organizations as resources.
o Review and become familiar with the terminology and proper welding techniques.
o Have materials and websites ready prior to the start of the lesson.
o Have a copy of the welding rubrics for each student.
o Have welding projects for students to choose from.
References
 Althouse, Turnquist, Bowditch, Bowditch, and Bowditch. (2013). Modern welding. Tinley Park, Illinois:
Goodheart-Willcox Company.
 The American Century Dictionary (1995) Oxford University Press, Inc. New York: New York.
Instructional Aids
 Welding Sheet Metal slide presentation
 Welding Projects Rubric
 Websites on welding
 Textbook
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Introduction
The purposes of this lesson are to help students
 understand about types of sheet metal used in the lab and how they are manufactured;
 explain about types of electrodes and filler material used in welding processes;
 use information about welding electrodes while completing two projects; and
 safely use welding equipment in the lab.
 Show
o Types of sheet metal used in the flexible manufacturing lab
 Ask
o Have you ever wondered how sheet metal is manufactured?
 Show
o Types of welding electrodes used in the flexible manufacturing lab
 Say
o The coding and meaning of 6013 and 7011 electrodes was explained earlier.
 Ask
o What type electrodes are used for arc, TIG, MIG, and oxygen acetylene welding?
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Outline
MI
OUTLINE
I.
Introduction of welding sheet metal
A. Types for applications
B. History
C. Hot rolled vs. cold rolled
D. Sheet stock
II.
Welding sheet metal
A. Oxy-fuel process
B. Welding coated metal
C. Shielded metal arc welding (SMAW)
D. Gas metal arc welding (GMAW)
III.
Common types of welding electrodes
A. SMAW
B. GMAW or MIG
C. Gas tungsten arc-welding (GTAW) or TIG
D. Oxygen acetylene (OAW)
NOTES TO TEACHER
Show Welding Sheet
Metal slide presentation
and welding projects
that you have for the
students to choose
from.
After presentation, have
students practice
welding and producing
their projects. Grade
welds using the Welding
Project Rubric.
IV. Welded project
A. Choose welding project
B. Practice welding beads
C. Practice on different thicknesses
D. Produce project
E. Grade welds
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Multiple Intelligences Guide
Existentialist
Interpersonal
Intrapersonal
Kinesthetic/
Bodily
Logical/
Mathematical
Musical/Rhythmic
Naturalist
Verbal/Linguistic
Visual/Spatial
Application
Guided Practice
The students will practice welding beads on different thicknesses of metal.
Independent Practice
The students will develop a simple welded project of their choice.
Summary
Review
The students will be able to explain the different types of welding used in a manufacturing company and in the
lab.
Evaluation
Informal Assessment
The teacher will observe students welding their two projects.
Formal Assessment
The students’ welds are graded using the Welding Project Rubric.
Enrichment
Extension
The students will research welding information from association and organization websites.
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Name ________________________________________Date_______________________ Period ___________
Welding Project Rubric
3 X 3 Flat Plate Assignment
Number of beads welded ______ X 10 points
_________
Uniformity of beads (max 10 points)
_________
Penetration of weld (max 10 points)
_________
Overall appearance (max 10 points)
_________
Weld splatter (max 5 points)
_________
Grade: _________
Joint Project Assignment
Number of joints welded ______ X 15 points
_________
Uniformity of beads (max 20 points)
_________
Penetration of weld (max 20 points)
_________
Overall appearance (max 10 points)
_________
Weld splatter (max 5 points)
_________
Grade: _________
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