A Systematic Review of Design of Experiments for Arc Welding Defect Development in NDT Training for Zimbabwe

Stephen Kasukusa*, Oscar Gwatidzo**, Godfrey Tigere***, Rindai Pasipaipa Mahoso****, Tafadzwa Mukodi*****
*-***** Harare Institute of Technology, Harare, Zimbabwe.
Periodicity:January - March'2025
DOI : https://doi.org/10.26634/jme.15.1.21716

Abstract

This work critically examines existing literature on the application of Design of Experiments (DoE) methodologies in the development, characterization, and utilization of arc welding defects for Non-Destructive Testing (NDT) training programs, with a specific focus on addressing challenges and opportunities in Zimbabwe. It recognizes the critical need for skilled NDT personnel capable of accurately identifying and characterizing weld imperfections, emphasizing the limitations of traditional training approaches due to the scarcity of standardized, representative defect samples. The paper explores past methods for creating standard defects such as trial-and-error welding, machining artificial flaws, and using defective welds from service and highlights the benefits of a DoE-driven approach, including reproducible defect creation and optimized welding parameters for specific defect types. It also analyzes the effectiveness of various NDT methods, e.g., ultrasonic testing, radiographic testing, and magnetic particle inspection, in characterizing and quantifying defects while examining the challenges of simulating real-world conditions in laboratory settings. Drawing upon insights from over 20 authors, the work provides a comparative analysis of current practices, identifies key areas for improvement, and offers evidence-based recommendations for aligning training programs with industry needs and international standards, ultimately aiming to inform workforce development and enhance the reliability of welding processes in Zimbabwe's expanding industrial sector.

Keywords

Arc Welding Defects, NDT Training, NDT Certification, Zimbabwe, Quality Control, Standardized Defect Samples.

How to Cite this Article?

Kasukusa, S., Gwatidzo, O., Tigere, G., Mahoso, R. P., and Mukodi, T. (2025). A Systematic Review of Design of Experiments for Arc Welding Defect Development in NDT Training for Zimbabwe. i-manager’s Journal on Mechanical Engineering, 15(1), 19-27. https://doi.org/10.26634/jme.15.1.21716

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