INTRODUCTION TO METAL FABRICATION

COURSE DESCRIPTION

Course Description

Introduction to Metal Fabrication is a course that provides students with opportunities to examine safety and technical information in agricultural metal fabrication and to participate in hands-on activities in the laboratory. Topics include career opportunities, safety, identification and selection, metal preparation and finishing, metal cutting, weld quality, and shielded metal arc welding (SMAW). The FFA is an integral, co-curricular component and serves as a means to enhance classroom instruction while helping students develop leadership abilities, expand work-place-readiness skills and broaden opportunities for personal and professional growth.

Prerequisite:

None (Agriscience preferred)

Program:

Agriconstruction

Program Goals:

  1. Identify careers in metal fabrication.
  2. Describe the history of metal fabrication and its impact on the industry.
  3. Demonstrate safety procedures used in the metal fabrication industry.
  4. Explain the use of metal fabrication tools and equipment.
  5. Differentiate between the types of metal used in metal fabrication.
  6. Demonstrate techniques for preparing metal for fabrication.
  7. Prepare oxyacetylene unit for operation.
  8. Use an oxyacetylene torch with a neutral flame to cut and fuse metal.
  9. Demonstrate procedures for using plasma arc cutting equipment.
  10. Analyze weld imperfections to determine corrective measures.
  11. Compare destructive and non-destructive weld test methods.
  12. Explain the SMAW process.
  13. Demonstrate procedures for adjusting and operating the SMAW machine.
  14. Cut threads in metal using a tap.
  15. Cut threads using a die.
  16. Explain the process of marking and cutting sheet metal.
  17. Demonstrate the use of rivets in sheet metal assembly.

Course Goals:

  1. Identify career opportunities.
  2. Discuss education requirements.
  3. Discuss working conditions.
  4. Compare benefits.
  5. Fill out applications.
  6. Write résumé.
  7. Discuss history.
  8. Define terms.
  9. Discuss automated welding systems.
  10. Explain meaning of safety.
  11. Identify hazards.
  12. Demonstrate Personal Protective Equipment.
  13. Demonstrate hand and power tool safety.
  14. Explain safety color coding.
  15. Discuss fire prevention methods.
  16. Demonstrate proper cylinder handling.
  17. Identify proper lens shade.
  18. Identify needed tools.
  19. Demonstrate proper use of hand tools.
  20. Identify welding equipment.
  21. Explain welding with different current types.
  22. Identify terms associated with metals.
  23. Describe metal classifications.
  24. Describe metal characteristics.
  25. Identify metal types.
  26. Prepare metal.
  27. Remove rust and scale.
  28. Discuss proper lens shades.
  29. Identify torch parts.
  30. Change cylinders.
  31. Check for leaks.
  32. Adjust torch valves.
  33. Light and adjust torch flame.
  34. Shut off and bleed lines.
  35. Inspect welds.
  36. Correct flaws.
  37. Explain destructive and non-destructivetesting.
  38. Compare electrodes.
  39. Recognize color and number codes.
  40. Identify welding machines.
  41. Identify weld joints.
  42. Discuss arc striking methods.
  43. Identify weld types.
  44. Demonstrate weld types.
  45. Create weld joints.
  46. Tap threads.
  47. Drill holes.
  48. Mark metal.
  49. File metal.
  50. Bend steel.
  51. Fasten with rivets.

Essential Question:

  1. What are the benefits and requirements of a career in metal fabrication?
  2. What are the legal and social reasons for learning to prevent shop accidents?
  3. What affect does mining minerals have on the environment?
  4. What is the benefit of preparing metal surfaces before welding?
  5. How do students safely cut metal for fabrication?
  6. How are welds tested in the welding industry?
  7. What benefits does a career in the welding field provide?
  8. What are the ways metal can be manipulated for assembly?

Philosophy

This course is designed to provide opportunities for students to develop meaningful skills which will help them in making wise career choices. The students are expected to meet all course goals and apply knowledge through real-life situations. This program has been designed to meet the needs of all students individually and covers all contents standards of the Alabama Course of Study for Metal Fabrication.

Course Outline:

Students enrolled in this course will study:

  1. Career Opportunities
  2. Safety
  3. Identification and Selection
  4. Metal preparation and finishing
  5. Metal cutting
  6. Weld Quality
  7. Shielded metal arc welding
  8. Metal Assembly

Culminating Product(s):

  1. Student will develop career portfolios.
  2. Students will master shop safety by identifying mock safety hazards in the shop and by passing the safety portion of the lesson with a 100 on the shop safety test.
  3. Students will use knowledge learned to select metal used to construct projects.
  4. Students will prepare metal for fabrication in various ways.
  5. Students will safely operate an oxyacetylene torch and plasma cutter.
  6. Students will analyze and test welds to improve weld quality.
  7. Plan and build an FFA display.
  8. Complete a small project utilizing the methods of assembly described in the lesson.

Class fee

The fee for this class is $10.00, which must be paid as soon as possible.

Assessment Procedure:

Student grades will be based upon the following:

Daily grades

Tests

Lab/shop work

Homework

Projects (individual and group)

Task evaluation

Midterm and Final

Grading Scale:

100 points

Credentials:

Postsecondary Degree

Discipline

Students should follow all the rules according to school board policy. Students refusing to follow the rules will be subject to the following consequences:

  1. Warning
  2. Writing assignment/clean shop/after school in class detention
  3. Referred to office

Major offenses/Class 3 will refer to office immediately for discipline.

Student Organization

The Colbert County FFA Chapter is an active organization in which students enrolled in this course are encouraged to participate. The FFA competes on the local, district, state and national level. Students should not miss an opportunity to join this organization. The dues for the FFA are $20.00. This is in addition to the class fee.

Supplies

Safety Glasses (clear and dark tint)

Tape measure

Ear plugs

Dust mask if needed

Notebook

Pens/pencil

Thank you for joining this program and I look forward to working with you this semester. Please feel free to contact me if you have any questions or concerns.

Phone # 446-6576 email-

Thanks again

Jeff McKinney

Instructor CCHS