Development of arc welding defects for NDT certification in zimbabwe using design of experiments

This study explores the development of representative arc welding defects for Non-Destructive Testing (NDT) certification programs in Zimbabwe, employing Design of Experiments (DoE) methodologies to optimize defect creation and detection. Recognizing that welding defects can compromise product quality and impact business performance, this work addresses the need for skilled NDT personnel capable of identifying and characterizing various weld imperfections. Traditional NDT training in Zimbabwe lacks access to realistic weld defects, hindering the development of practical skills essential for effective quality control. This study aims to bridge this gap by systematically creating and characterizing common arc welding defects such as porosity, cracks, lack of fusion, and slag inclusions using controlled welding parameters and DoE techniques. Collaborative efforts with local industries and educational institutions support the development of a comprehensive set of representative weld defect samples. These samples are intended to enhance NDT training programs, aligning them with industry needs and international standards. Methodologically, this study integrates experimental welding, non-destructive testing, and statistical analysis. DoE is used to optimize welding parameters for creating specific defect types, while various NDT methods such as ultrasonic testing, radiographic testing, and magnetic particle inspection characterize and quantify the resulting defects. The effectiveness of these defects for training purposes is evaluated through surveys and practical assessments involving NDT trainees and certified inspectors. Expected outcomes include a well-characterized set of arc welding defect samples, optimized NDT procedures for defect detection, and recommendations for integrating these resources into NDT certification programs in Zimbabwe. By promoting practical, hands-on training, this investigation aims to contribute to workforce development and enhance the reliability of welding processes in Zimbabwe's industrial sector.