Lesson Plan
Course Title: Welding
Session Title: Filling the Gap
Lesson Duration: 3 Days ( depending on size of class)
Performance Objective:
Upon completion of this assignment, the student will be able to successfully fill
the end of a 1”inch piece of square tubing with an arc weld.
[Lesson length is subjective and will vary from instructor to instructor]
Specific Objectives:





Identify all materials needed for this exercise
Identify all safety procedures needed
Demonstrate the ability to fill the end of 1’ piece of square tubing
Utilize an angle grinder to smooth the welds
Demonstrate the integrity of the welds by filling the remaining end of tuning with
water
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.
Welding:


130.323(c)(2)(A)(B)(C)(D)(E)(F)
…explore academic knowledge and skills required for postsecondary
education;
…identify employers' expectations to foster positive customer satisfaction;
…demonstrate the skills required in the workplace such as interviewing
skills, flexibility, willingness to learn new skills and acquire
knowledge, self-discipline, self-worth, positive attitude, and integrity
in a work situation;
…evaluate personal career goals;
…communicate effectively with others in the workplace to clarify
objectives; and
…demonstrate skills related to health and safety in the workplace, as
specified by appropriate government regulations.
130.323(c)(3)(A)(B)(C)(D)(E)(F)(G)(H)(I)(J)
Copyright © Texas Education Agency, 2012. All rights reserved.
1
…demonstrate effective communication skills with individuals from varied
cultures such as fellow workers, management, and customers;
…demonstrate mathematical skills to estimate costs;
…demonstrate technical writing skills related to work orders;
…apply accurate readings of measuring devices, both U.S. customary and
metric;
…accurately use an appropriate tool to make measurements;
…compute measurements such as area, surface area, volume, and
perimeter;
…determine how changes in dimension affect geometric figures;
…calculate problems using whole numbers, fractions, mixed numbers,
and decimals;
…use a calculator to perform computations;
…perform conversions between fractions and decimals;

130.323(c)(4)(A)
…use welding equipment according to safety standards;

130.323(c)(5)(D)(E)
…analyze types of welding joints;
…analyze positions of welding; and

130.323(c)(6)(B)(D)
…work independently to fabricate a welded project with minimal
assistance;
…troubleshoot equipment.

130.323(c)(7)(A)(B)
…evaluate weld inspection processes; and
…analyze welding codes.
Interdisciplinary Correlations:
English:
110.42(6) – Reading/vocabulary development
 110.42(6)(A)(B)
…expand vocabulary development through wide reading, listening, and discussing;
…rely on context to determine meanings of words and phrases such as figurative
language, idioms, multiple meaning of words, and technical vocabulary;
Instructor/Trainer
References:
Copyright © Texas Education Agency, 2012. All rights reserved.
2
Instructional Aids:
1. Filling the Gap PowerPoint
2. Filling the Gap Outline
3. Quiz
Materials Needed:
6 inch piece of 1 inch square tubing
Equipment Needed:
•
•
•
•
•
•
Chop saw
Arc-welder
6011 welding rods
Gloves
Welding hood
Angle grinder
Learner
•
•
Prior knowledge of welding and cutting techniques and procedures
Prior practice
Introduction
Introduction (LSI Quadrant I):
Any welder can weld a bead. Sometimes a bead is not all that is needed. It never
fails, no matter how good you are, there is always a gap/hole that will need to be
filled. Now Lead into the lesson. (Some students will have a harder time with this
lesson than others).
Outline
Outline (LSI Quadrant II):
1. Each students need to have a refresher on safety
procedures involving welding and grinding
2. Have each student cut 6 inches off a stick of 1 inch
square tubing
3. Have the students weld flat beads (on top of each
other) until the gap is filled
4. Grind the welds flush with the end of the tubing
5. Add water at the open end to test for integrity
The following steps should be completed (see
PowerPoint):
Step 1:
Instructor Notes:
1. Welding the beads
can take a while
depending on
ability
2. Be careful not to
over-heat the initial
welds or the walls
of the tubing will
melt as well
3. The beads will not
be perfect due to
the distance of the
weld.
Copyright © Texas Education Agency, 2012. All rights reserved.
3
•
•
Pick end of the tubing
Weld a small bead across the width of the
tubing
• Care should be taken not to burn through
the wall of the tubing
Step 2:
• Weld an overlapping bead across the
original pass
• Repeat this process until the gap is
completely enclosed
Step 3:
• Grind off the weld flush with the end of the
tubing
Step 4:
• Add water to the open end of your piece of
tubing
• Watch for water penetrating through the
welding end
• If water is visible, repeat the process
4. The idea is not to
achieve beauty, but
rather to fill in the
hole and grind
smooth
5. If water leaks
through the weld,
have the students
repeat the lesson
Application
Guided Practice (LSI Quadrant III):
Teacher works through problems/activity as students observe/follow along and
record process/solution and/or take notes.
Independent Practice (LSI Quadrant III):
Students work independently or collaboratively (pairs, small groups, large
groups, teams, etc.) to complete a new assignment similar to the guided practice
assignment and related to the lesson objective.
Review (LSI Quadrants I and IV):
•
Ask specific questions of learners (be sure to list the questions to be asked
and provide the correct/desired answers).
•
Ask learners if they have any questions
Copyright © Texas Education Agency, 2012. All rights reserved.
4
•
Have each student state one fact that he/she learned during the lesson.
•
Restate lesson objectives or have students recall lesson objectives
Informal Assessment (LSI Quadrant III):
•
Teacher will monitor student progress during independent practice/application
and provide independent reteach/redirection as needed.
•
Students will complete “XYZ assignment” as a classwork grade.
•
Teacher will conduct periodic progress checks as class work grades and
provide students with feedback in the form of an objective and/or subjective
checklist based on project/assignment criteria (be sure to include a copy of
the suggested instrument to be used and align criteria with formal
assessment).
Formal Assessment (LSI Quadrant III, IV):
Demonstration of process or experiment – be sure to include printed directions for
students as well as an evaluation checklist to be used to evaluate the demonstration.
Extension/Enrichment (LSI Quadrant IV): Suggest ways student learning from the
lesson can be extended individually in new or novel situations.
•
Applying learning/content to personal life (work or home) or other classes
(academic or elective).
•
Applying learning to future lessons/coursework.
Copyright © Texas Education Agency, 2012. All rights reserved.
5
Filling the Gap
Outline
Materials







6” piece of 1 inch square tubing
Arc-welder
6011 rods
Welding hood
Welding gloves
Angle grinder
Water access




Step 1
Pick end of the tubing
Weld a small bead across the width of the tubing
Care should be taken not to burn through the wall of the tubing



Step 2
Weld an overlapping bead across the original pass
Repeat this process until the gap is completely enclosed


Step 3
Grind off the weld flush with the end of the tubing




Step 4: THE TEST
Add water to the open end of your piece of tubing
Watch for water penetrating through the welding end
If water is visible, repeat the process
Copyright © Texas Education Agency, 2012. All rights reserved.
6
Filling the Gap Quiz
Name:__________________________
1.
True or False
Care should be taken not to burn through the wall of the tubing.
2.
True or False
Complete this process until there is just a small hole in the gap.
3.
True or False
Weld an overlapping bead across the original pass.
4.
True or False
You should grind off the weld with an overlap at the end of the
tubing.
5.
True or False
Add oil to the open end of your piece of tubing.
Copyright © Texas Education Agency, 2012. All rights reserved.
7
Filling the Gap Quiz Key
Name:__________________________
1. True or False
Care should be taken not to burn through the wall of the tubing.
2. True or False
Weld an overlapping bead across the original pass.
3. True or False
Complete this process until there is just a small hole in the gap.
4. True or False
You should grind off the weld with an overlap at the end of the
tubing.
5. True or False
Add oil to the open end of your piece of tubing.
Copyright © Texas Education Agency, 2012. All rights reserved.
8