Development of a New Welding Product Quality Control and Management System Model for China

The Chinese welding industry is growing every year due to rapid development of the Chinese economy. Increasingly, companies around the world are looking to use Chinese enterprises as their cooperation partners. However, the Chinese welding industry also has its weaknesses, such as relatively low quality and weak management. A modern, advanced welding management system appropriate for local socio-economic conditions is required to enable Chinese enterprises to enhance further their business development. The thesis researches the design and implementation of a new welding quality management system for China. This new system is called ‗welding production quality control management model in China‘ (WQMC). Constructed on the basis of analysis of a survey and in-company interviews, the welding management system comprises the following different elements and perspectives: a ‗Localized congenital existing problem resolution strategies‘ (LCEPRS) database, a ‗human factor designed training system‘ (HFDT) training strategy, the theory of modular design, ISO 3834 requirements, total welding management (TWM), and lean manufacturing (LEAN) theory. The methods used in the research are literature review, questionnaires, interviews, and the author‘s model design experiences and observations, i.e. the approach is primarily qualitative and phenomenological. The thesis describes the design and implementation of a HFDT strategy in Chinese welding companies. Such training is an effective way to increase employees‘ awareness of quality and issues associated with quality assurance. The study identified widely existing problems in the Chinese welding industry and constructed a LCEPRS database that can be used in efforts to mitigate and avoid common problems. The work uses the theory of modular design, TWM and LEAN as tools for the implementation of the WQMC system.

Controlling full penetration in MAG welding by the application of infrared thermography and neural network

In this study, an infrared thermography based sensor was studied with regard to usability and the accuracy of sensor data as a weld penetration signal in gas metal arc welding. The object of the study was to evaluate a specific sensor type which measures thermography from solidified weld surface. The purpose of the study was to provide expert data for developing a sensor system in adaptive metal active gas (MAG) welding. Welding experiments with considered process variables and recorded thermal profiles were saved to a database for further analysis. To perform the analysis within a reasonable amount of experiments, the process parameter variables were gradually altered by at least 10 %. Later, the effects of process variables on weld penetration and thermography itself were considered. SFS-EN ISO 5817 standard (2014) was applied for classifying the quality of the experiments. As a final step, a neural network was taught based on the experiments. The experiments show that the studied thermography sensor and the neural network can be used for controlling full penetration though they have minor limitations, which are presented in results and discussion. The results are consistent with previous studies and experiments found in the literature.

Possibilities of advanced MAG-welding processes in shipbuilding

In shipbuilding industry welding of primer coated and tack welded steel products cause different issues. Primer coated steel products are commonly used at shipyards to ensure corrosion free storage of products in outdoor conditions. However usage of primer can cause imperfections to welds. To prevent porosity primed steel products are usually welded with tubular welding wires. Tack welds cause commonly interferences in mechanized welding when over welded, which increases costs related to welding due to increased need of preparing and repairing. The aim of this study is to research possibilities of advanced solid wire MAG-welding processes to deal with these two previously mentioned problems. This study concentrates to examine possibilities of MAG-welding, pulse MAG-welding, double pulse MAG-welding, RapidArc and ForceArc processes. Large amount of experiments were made to find out the produced porosity and the ability to over weld tack welds with each process in different circumstances. In welding of primed steel products porosity is caused mainly by hydrogen, CO, CO2, nitrous gases and zinc fumes. It was found in experiments that porosity of MAG-welding can be greatly decreased by using pulse MAG-welding instead. Also reduction of welding speed, usage of air gap and usage of solid wire product with higher amount of alloying elements reduces porosity. Researched advanced MAG-welding processes did not have an improvement into over welding of tack welds. With studied throat thicknesses and welding positions conventional MAG-welding managed better over welding of tack welds than the four studied advanced MAG-welding processes. Studied solid wire MAG-welding processes would be best suited at shipyard for mechanized welding in welding position PB. In welding positions PD and PG tubular welding wires are clearly more productive.

Comparison of EN & ASME welding and its allied processes standards

This thesis is made in cooperation with Wärtsilä and Sandvik. The main purpose of the thesis is to clarify the best suitable American standards for European standards used in Wärtsilä’s investigation checklist and to make wide and easily readable tables for Wärtsilä and their subcontractors. One of the most important issues is to make clear if the compared American standards are demanding enough for Wärtsilä’s needs. The research is done by comparing EN standards mentioned in Wärtsilä’s investigation checklist to corresponding ASME, AWS, ASNT and ASTM standards. The research shows that there is visible lack of requirements in American standards compared to European ones. Some areas of American standards are more demanding than European standards but in larger scale EN standards are much wider and more demanding than American standards. Because of these reasons, usage of European standards should be recommended for Wärtsilä’s subcontractors to ensure the quality and reliability of production.

Front end development for building automation systems using JavaScript Frameworks

Automation technologies are widely acclaimed to have the potential to significantly reduce energy consumption and energy-related costs in buildings. However, despite the abundance of commercially available technologies, automation in domestic environments keep on meeting commercial failures. The main reason for this is the development process that is used to build the automation applications, which tend to focus more on technical aspects rather than on the needs and limitations of the users. An instance of this problem is the complex and poorly designed home automation front-ends that deter customers from investing in a home automation product. On the other hand, developing a usable and interactive interface is a complicated task for developers due to the multidisciplinary challenges that need to be identified and solved. In this context, the current research work investigates the different design problems associated with developing a home automation interface as well as the existing design solutions that are applied to these problems. The Qualitative Data Analysis approach was used for collecting data from research papers and the open coding process was used to cluster the findings. From the analysis of the data collected, requirements for designing the interface were derived. A home energy management functionality for a Web-based home automation front-end was developed as a proof-of-concept and a user evaluation was used to assess the usability of the interface. The results of the evaluation showed that this holistic approach to designing interfaces improved its usability which increases the chances of its commercial success.