Date of Award:

5-2013

Document Type:

Thesis

Degree Name:

Master of Science (MS)

Department:

Applied Sciences, Technology, and Education

Department name when degree awarded

Agriculture Systems Technology and Education

Committee Chair(s)

Michael L. Pate

Committee

Michael L. Pate

Committee

Brian K. Warnick

Committee

Rebecca G. Lawver

Committee

Julie P. Wheeler

Abstract

The purpose of this study was to determine if having fewer operator-controlled variables during welding will improve secondary students' ability to meet weld quality standards for an AWS 1F test. Two different welding processes, Gas Metal Arc Welding and Shielded Metal Arc welding, were used in the research. The population of this study (N = 71), participants were randomly assigned into one of four treatment groups. The study was conducted over six class periods. Participants completed a welding pretest, taught safety procedures followed by welding instruction of both GMAW and SMAW process. Practice sessions were given for each welding process and completed in a specific order or operation. Each participant had one day (60 minutes of practice for each process. Participants then performed AWS 1F (flat-position fillet) welds which were scored according to four grading criteria as follows: a) presence of cracks or porosity, b) complete fusion, c) fillet leg size is specified minimum, and d) undercut – not to exceed 1/32 inches. Welds were created on 3/16"X 4" flat carbon steel using Lincoln Power MIG 255 MIG welders using ER70-S electrode with 100 percent carbon dioxide shielding gas and Lincoln Invertec V275-S stick welders with E7018, 3/32" electrodes. The study indicated that students produce welds that meet AWS quality standards when using the GMAW process; however, results were not statistically significant. Test results suggest that the majority of students were able to produce welds that met AWS quality standards with the GMAW process. This may suggest that less time is needed for practicing and testing students with the GMAW process, allowing for more time to be spent on processes more difficult for students to learn and grasp, like SMAW. We recommend extending practice sessions essential for skills to be developed and improved upon. Educational programs should allow ample time for students to practice performing skills as required by program guidelines and regulations. Mastering any technique takes time and practice. Educators should be considerate of each student and assess their individual needs and requirements.

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