Mission-Oriented Dust Control and Surface Improvement Processes for Unpaved Roads, HR-194, 1981

Six subject areas prompted the broad field of inquiry of this mission-oriented dust control and surface improvement project for unpaved roads: • DUST--Hundreds of thousands of tons of dust are created annually by vehicles on Iowa's 70,000 miles of unpaved roads and streets. Such dust is often regarded as a nuisance by Iowa's highway engineers. • REGULATIONS--Establishment of "fugitive dust" regulations by the Iowa DEQ in 1971 has created debates, conferences, legal opinions, financial responsibilities, and limited compromises regarding "reasonable precaution" and "ordinary travel," both terms being undefined judgment factors. • THE PUBLIC--Increased awareness by the public that regulations regarding dust do in fact exist creates a discord of telephone calls, petitions, and increasing numbers of legal citations. Both engineers and politicians are frustrated into allowing either the courts or regulatory agencies to resolve what is basically a professional engineering responsibility. • COST--Economics seldom appear as a tenet of regulatory strategies, and in the case of "fugitive dust," four-way struggles often occur between the highway professions, political bodies, regulatory agencies, and the general public as to who is responsible, what can be done, how much it will cost, or why it wasn't done yesterday. • CONFUSION--The engineer lacks authority, and guidelines and specifications to design and construct a low-cost surf acing system are nebulous, i.e., construct something between the present crushed stone/gravel surface and a high-type pavement. • SOLUTION--The engineer must demonstrate that dust control and surface improvement may be engineered at a reasonable cost to the public, so that a higher degree of regulatory responsibility can be vested in engineering solutions.

High pressure induced changes in beef muscle proteome: correlation with quality parameters

The relationship between pressure induced changes on individual proteins and selected quality parameters in bovine longissimus thoracis et lumborum (LTL) muscle was studied. Pressures ranging from 200 to 600 MPa at 20 °C were used. High pressure processing (HPP) at pressures above 200 MPa induced strong modifications of protein solubility, meat colour and water holding capacity (WHC). The protein profiles of non-treated and pressure treated meat were observed using two dimensional electrophoresis. Proteins showing significant differences in abundance among treatments were identified by mass spectrometry. Pressure levels above 200 MPa strongly modified bovine LTL proteome with main effects being insolubilisation of sarcoplasmic proteins and solubilisation of myofibrillar proteins. Sarcoplasmic proteins were more susceptible to HPP effects than myofibrillar. Individual protein changes were significantly correlated with protein solubility, L*, b* and WHC, providing further insights into the mechanistic processes underlying HPP influence on quality and providing the basis for the future development of protein markers to assess the quality of processed meats.

Wind Loads on Dynamic Message Cabinets and Behavior of Supporting Trusses, TR-612, 2013

Large Dynamic Message Signs (DMSs) have been increasingly used on freeways, expressways and major arterials to better manage the traffic flow by providing accurate and timely information to drivers. Overhead truss structures are typically employed to support those DMSs allowing them to provide wider display to more lanes. In recent years, there is increasing evidence that the truss structures supporting these large and heavy signs are subjected to much more complex loadings than are typically accounted for in the codified design procedures. Consequently, some of these structures have required frequent inspections, retrofitting, and even premature replacement. Two manufacturing processes are primarily utilized on truss structures - welding and bolting. Recently, cracks at welding toes were reported for the structures employed in some states. Extremely large loads (e.g., due to high winds) could cause brittle fractures, and cyclic vibration (e.g., due to diurnal variation in temperature or due to oscillations in the wind force induced by vortex shedding behind the DMS) may lead to fatigue damage, as these are two major failures for the metallic material. Wind and strain resulting from temperature changes are the main loads that affect the structures during their lifetime. The American Association of State Highway and Transportation Officials (AASHTO) Specification defines the limit loads in dead load, wind load, ice load, and fatigue design for natural wind gust and truck-induced gust. The objectives of this study are to investigate wind and thermal effects in the bridge type overhead DMS truss structures and improve the current design specifications (e.g., for thermal design). In order to accomplish the objective, it is necessary to study structural behavior and detailed strain-stress of the truss structures caused by wind load on the DMS cabinet and thermal load on the truss supporting the DMS cabinet. The study is divided into two parts. The Computational Fluid Dynamics (CFD) component and part of the structural analysis component of the study were conducted at the University of Iowa while the field study and related structural analysis computations were conducted at the Iowa State University. The CFD simulations were used to determine the air-induced forces (wind loads) on the DMS cabinets and the finite element analysis was used to determine the response of the supporting trusses to these pressure forces. The field observation portion consisted of short-term monitoring of several DMS Cabinet/Trusses and long-term monitoring of one DMS Cabinet/Truss. The short-term monitoring was a single (or two) day event in which several message sign panel/trusses were tested. The long-term monitoring field study extended over several months. Analysis of the data focused on trying to identify important behaviors under both ambient and truck induced winds and the effect of daily temperature changes. Results of the CFD investigation, field experiments and structural analysis of the wind induced forces on the DMS cabinets and their effect on the supporting trusses showed that the passage of trucks cannot be responsible for the problems observed to develop at trusses supporting DMS cabinets. Rather the data pointed toward the important effect of the thermal load induced by cyclic (diurnal) variations of the temperature. Thermal influence is not discussed in the specification, either in limit load or fatigue design. Although the frequency of the thermal load is low, results showed that when temperature range is large the restress range would be significant to the structure, especially near welding areas where stress concentrations may occur. Moreover stress amplitude and range are the primary parameters for brittle fracture and fatigue life estimation. Long-term field monitoring of one of the overhead truss structures in Iowa was used as the research baseline to estimate the effects of diurnal temperature changes to fatigue damage. The evaluation of the collected data is an important approach for understanding the structural behavior and for the advancement of future code provisions. Finite element modeling was developed to estimate the strain and stress magnitudes, which were compared with the field monitoring data. Fatigue life of the truss structures was also estimated based on AASHTO specifications and the numerical modeling. The main conclusion of the study is that thermal induced fatigue damage of the truss structures supporting DMS cabinets is likely a significant contributing cause for the cracks observed to develop at such structures. Other probable causes for fatigue damage not investigated in this study are the cyclic oscillations of the total wind load associated with the vortex shedding behind the DMS cabinet at high wind conditions and fabrication tolerances and induced stresses due to fitting of tube to tube connections.

Multiple processes regulate long-term population dynamics of sea urchins on Mediterranean rocky reefs

We annually monitored the abundance and size structure of herbivorous sea urchin populations (Paracentrotus lividus and Arbacia lixula) inside and outside a marine reserve in the Northwestern Mediterranean on two distinct habitats (boulders and vertical walls) over a period of 20 years, with the aim of analyzing changes at different temporal scales in relation to biotic and abiotic drivers. P. lividus exhibited significant variability in density over time on boulder bottoms but not on vertical walls, and temporal trends were not significantly different between the protection levels. Differences in densities were caused primarily by variance in recruitment, which was less pronounced inside the MPA and was correlated with adult density, indicating density-dependent recruitment under high predation pressure, as well as some positive feedback mechanisms that may facilitate higher urchin abundances despite higher predator abundance. Populations within the reserve were less variable in abundance and did not exhibit the hyper-abundances observed outside the reserve, suggesting that predation effects maybe more subtle than simply lowering the numbers of urchins in reserves. A. lixula densities were an order of magnitude lower than P. lividus densities and varied within sites and over time on boulder bottoms but did not differ between protection levels. In December 2008, an exceptionally violent storm reduced sea urchin densities drastically (by 50% to 80%) on boulder substrates, resulting in the lowest values observed over the entire study period, which remained at that level for at least two years (up to the present). Our results also showed great variability in the biological and physical processes acting at different temporal scales. This study highlights the need for appropriate temporal scales for studies to fully understand ecosystem functioning, the concepts of which are fundamental to successful conservation and management.

Electrical signature of modern and ancient tectonic processes in the crust of the Atlas mountains of Morocco.

The Atlas Mountains in Morocco are considered as type examples of intracontinental chains, with high topography that contrasts with moderate crustal shortening and thickening. Whereas recent geological studies and geodynamic modeling have suggested the existence of dynamic topography to explain this apparent contradiction, there is a lack of modern geophysical data at the crustal scale to corroborate this hypothesis. Newly-acquired magnetotelluric data image the electrical resistivity distribution of the crust from the Middle Atlas to the Anti-Atlas, crossing the tabular Moulouya Plain and the High Atlas. All the units show different and unique electrical signatures throughout the crust reflecting the tectonic history of development of each one. In the upper crust electrical resistivity values may be associated to sediment sequences in the Moulouya and Anti-Atlas and to crustal scale fault systems in the High Atlas developed during the Cenozoic times. In the lower crust the low resistivity anomaly found below the Mouluya plain, together with other geophysical (low velocity anomaly, lack of earthquakes and minimum Bouguer anomaly) and geochemical (Neogene-Quaternary intraplate alkaline volcanic fields) evidence, infer the existence of a small degree of partial melt at the base of the lower crust. The low resistivity anomaly found below the Anti-Atlas may be associated with a relict subduction of Precambrian oceanic sediments, or to precipitated minerals during the release of fluids from the mantle during the accretion of the Anti-Atlas to the West African Supercontinent during the Panafrican orogeny ca. 685 Ma).

Quantifying sediment storage in a high Alpine valley (Turtmanntal, Switzerland)

The determination of sediment storage is a critical parameter in sediment budget analyses. But, in many sediment budget studies the quantification of magnitude and time-scale of sediment storage is still the weakest part and often relies on crude estimations only, especially in large drainage basins (>100km2). We present a new approach to storage quantification in a meso-scale alpine catchment of the Swiss Alps (Turtmann Valley, 110km2). The quantification of depositional volumes was performed by combining geophysical surveys and geographic information system (GIS) modelling techniques. Mean thickness values of each landform type calculated from these data was used to estimate the sediment volume in the hanging valleys and the trough slopes. Sediment volume of the remaining subsystems was determined by modelling an assumed parabolic bedrock surface using digital elevation model (DEM) data. A total sediment volume of 781·3×106?1005·7×106m3 is deposited in the Turtmann Valley. Over 60% of this volume is stored in the 13 hanging valleys. Moraine landforms contain over 60% of the deposits in the hanging valleys followed by sediment stored on slopes (20%) and rock glaciers (15%). For the first time, a detailed quantification of different storage types was achieved in a catchment of this size. Sediment volumes have been used to calculate mean denudation rates for the different processes ranging from 0·1 to 2·6mm/a based on a time span of 10ka. As the quantification approach includes a number of assumptions and various sources of error the values given represent the order of magnitude of sediment storage that has to be expected in a catchment of this size.

Stable isotope (C, O, S) systematics of the mercury mineralization at Idrija, Slovenia: constraints on fluid source and alteration processes

The world-class Idrija mercury deposit (western Slovenia) is hosted by highly deformed Permocarboniferous to Middle Triassic sedimentary rocks within a complex tectonic structure at the transition between the External Dinarides and the Southern Alps. Concordant and discordant mineralization formed concomitant with Middle Triassic bimodal volcanism in an aborted rift. A multiple isotopic (C, O, S) investigation of host rocks and ore minerals was performed to put constraints on the source and composition of the fluid, and the hydrothermal alteration. The distributions of the delta(13)C and delta(18)O values of host and gangue carbonates are indicative of a fracture-controlled hydrothermal system, with locally high fluid-rock ratios. Quantitative modeling of the delta(13)C and delta(18)O covariation for host carbonates during temperature dependent fluid-rock interaction, and concomitant precipitation of void-filling dolomites points to a slightly acidic hydrothermal fluid (delta(13)Capproximate to-4parts per thousand and delta(18)Oapproximate to+10parts per thousand), which most likely evolved during isotopic exchange with carbonates under low fluid/rock ratios. The delta(34)S values of hydrothermal and sedimentary sulfur minerals were used to re-evaluate the previously proposed magmatic and evaporitic sulfur sources for the mineralization, and to assess the importance of other possible sulfur sources such as the contemporaneous seawater sulfate, sedimentary pyrite, and organic sulfur compounds. The delta(34)S values of the sulfides show a large variation at deposit down to hand-specimen scale. They range for cinnabar and pyrite from -19.1 to +22.8parts per thousand, and from -22.4 to +59.6parts per thousand, respectively, suggesting mixing of sulfur from different sources. The peak of delta(34)S values of cinnabar and pyrite close to 0parts per thousand is compatible with ore sulfur derived dominantly from a magmatic fluid and/or from hydrothermal leaching of basement rocks. The similar stratigraphic trends of the delta(34)S values of both cinnabar and pyrite suggest a minor contribution of sedimentary sulfur (pyrite and organic sulfur) to the ore formation. Some of the positive delta(34)S values are probably derived from thermochemical reduction of evaporitic and contemporaneous seawater sulfates.

Towards Machine Consciousness: Grounding Abstract Models as pi-Processes

We present a two-level model of concurrent communicating systems (CCS) to serve as a basis formachine consciousness. A language implementing threads within logic programming is ¯rstintroduced. This high-level framework allows for the de¯nition of abstract processes that can beexecuted on a virtual machine. We then look for a possible grounding of these processes into thebrain. Towards this end, we map abstract de¯nitions (including logical expressions representingcompiled knowledge) into a variant of the pi-calculus. We illustrate this approach through aseries of examples extending from a purely reactive behavior to patterns of consciousness.

Combining Internet Monitoring Processes, Packaging and Isotopic Analyses to Determine The Market Structure: Example of Gamma Butyrolactone

The Internet is becoming more and more popular among drug users. The use of websites and forums to obtain illicit drugs and relevant information about the means of consumption is a growing phenomenon mainly for new synthetic drugs. Gamma Butyrolactone (GBL), a chemical precursor of Gamma Hydroxy Butyric acid (GHB), is used as a "club drug" and also in drug facilitated sexual assaults. Its market takes place mainly on the Internet through online websites but the structure of the market remains unknown. This research aims to combine digital, physical and chemical information to help understand the distribution routes and the structure of the GBL market. Based on an Internet monitoring process, thirty-nine websites selling GBL, mainly in the Netherlands, were detected between January 2010 and December 2011. Seventeen websites were categorized into six groups based on digital traces (e.g. IP addresses and contact information). In parallel, twenty-five bulk GBL specimens were purchased from sixteen websites for packaging comparisons and carbon isotopic measurements. Packaging information showed a high correlation with digital data confirming the links previously established whereas chemical information revealed undetected links and provided complementary information. Indeed, while digital and packaging data give relevant information about the retailers, the supply routes and the distribution close to the consumer, the carbon isotopic data provides upstream information about the production level and in particular the synthesis pathways and the chemical precursors. A three-level structured market has been thereby identified with a production level mainly located in China and in Germany, an online distribution level mainly hosted in the Netherlands and the customers who order on the Internet.

Effect of spatial processes on the evolution of ecological niches and dispersal in metacommunity systems

RésuméLa coexistence de nombreuses espèces différentes a de tout temps intrigué les biologistes. La diversité et la composition des communautés sont influencées par les perturbations et l'hétérogénéité des conditions environnementales. Bien que dans la nature la distribution spatiale des conditions environnementales soit généralement autocorrélée, cet aspect est rarement pris en compte dans les modèles étudiant la coexistence des espèces. Dans ce travail, nous avons donc abordé, à l'aide de simulations numériques, la coexistence des espèces ainsi que leurs caractéristiques au sein d'un environnement autocorrélé.Afin de prendre en compte cet élément spatial, nous avons développé un modèle de métacommunauté (un ensemble de communautés reliées par la dispersion des espèces) spatialement explicite. Dans ce modèle, les espèces sont en compétition les unes avec les autres pour s'établir dans un nombre de places limité, dans un environnement hétérogène. Les espèces sont caractérisées par six traits: optimum de niche, largeur de niche, capacité de dispersion, compétitivité, investissement dans la reproduction et taux de survie. Nous nous sommes particulièrement intéressés à l'influence de l'autocorrélation spatiale et des perturbations sur la diversité des espèces et sur les traits favorisés dans la métacommunauté. Nous avons montré que l'autocorrélation spatiale peut avoir des effets antagonistes sur la diversité, en fonction du taux de perturbations considéré. L'influence de l'autocorrélation spatiale sur la capacité de dispersion moyenne dans la métacommunauté dépend également des taux de perturbations et survie. Nos résultats ont aussi révélé que de nombreuses espèces avec différents degrés de spécialisation (i.e. différentes largeurs de niche) peuvent coexister. Toutefois, les espèces spécialistes sont favorisées en absence de perturbations et quand la dispersion est illimitée. A l'opposé, un taux élevé de perturbations sélectionne des espèces plus généralistes, associées avec une faible compétitivité.L'autocorrélation spatiale de l'environnement, en interaction avec l'intensité des perturbations, influence donc de manière considérable la coexistence ainsi que les caractéristiques des espèces. Ces caractéristiques sont à leur tour souvent impliquées dans d'importants processus, comme le fonctionnement des écosystèmes, la capacité des espèces à réagir aux invasions, à la fragmentation de l'habitat ou aux changements climatiques. Ce travail a permis une meilleure compréhension des mécanismes responsables de la coexistence et des caractéristiques des espèces, ce qui est crucial afin de prédire le devenir des communautés naturelles dans un environnement changeant.AbstractUnderstanding how so many different species can coexist in nature is a fundamental and long-standing question in ecology. Community diversity and composition are known to be influenced by heterogeneity in environmental conditions and disturbance. Though in nature the spatial distribution of environmental conditions is frequently autocorrelated, this aspect is seldom considered in models investigating species coexistence. In this work, we thus addressed several questions pertaining to species coexistence and composition in spatially autocorrelated environments, with a numerical simulations approach.To take into account this spatial aspect, we developed a spatially explicit model of metacommunity (a set of communities linked by dispersal of species). In this model, species are trophically equivalent, and compete for space in a heterogeneous environment. Species are characterized by six life-history traits: niche optimum, niche breadth, dispersal, competitiveness, reproductive investment and survival rate. We were particularly interested in the influence of environmental spatial autocorrelation and disturbance on species diversity and on the traits of the species favoured in the metacommunity. We showed that spatial autocorrelation can have antagonistic effects on diversity depending on disturbance rate. Similarly, spatial autocorrelation interacted with disturbance rate and survival rate to shape the mean dispersal ability observed in the metacommunity. Our results also revealed that many species with various degrees of specialization (i.e. different niche breadths) can coexist together. However specialist species were favoured in the absence of disturbance, and when dispersal was unlimited. In contrast, high disturbance rate selected for more generalist species, associated with low competitive ability.The spatial structure of the environment, together with disturbance and species traits, thus strongly impacts species diversity and, more importantly, species composition. Species composition is known to affect several important metacommunity properties such as ecosystem functioning, resistance and reaction to invasion, to habitat fragmentation and to climate changes. This work allowed a better understanding of the mechanisms responsible for species composition, which is of crucial importance to predict the fate of natural metacommunities in changing environments

Hiiliteräspalkin kuitulaserhitsaus

Hitsaavassa teollisuudessa kilpailukyvyn säilyttäminen ja mahdollinen parantaminen edellyttää hitsauksen tehokkuuden nostoa. Laserhitsauksen nopeus, tarkkuus, tasainen laatu ja aikaansaatava syvä tunkeuma ovatkin vakiinnuttaneet menetelmän vankan aseman tehokkaana valmistusmenetelmänä. Sähkön ja heliumin hinnan nousu ovat pakottaneet teollisuuden miettimään entistä tehokkaampien ja ympäristöystävällisempien laserlähteiden hankkimista. Kuitulaserin korkea hyötysuhde, hyvä säteenlaatu, suuri teho ja matalat käyttökustannukset ovat herättäneet kiinnostusta laserhitsaavassa teollisuudessa. Diplomityössä keskityttiin kuitulaserhitsauksen soveltamiseen. Työn tavoitteena oli parantaa kuitulaserhitsausmenetelmän ymmärrystä ja saada käsitys siitä, miten valitaan hitsausparametrien arvot, ja soveltuuko kuitulaser teolliseen tuotantoon. Tutkimuksessa pyrittiin löytämään peruskokeilla optimaaliset hitsausparametrit, joilla syntyy hyvin tunkeutunut, vähän huokosia sisältävä, ja ulkoisesti laadukas hitsi, sekä optimaalinen hitsin tunkeumaprofiili. Lopuksi hitsausparametreja testattiin tuotteen hitsauksessa. Kuitulaser soveltuu erinomaisesti hiiliteräksen hitsaukseen ja hyvin erikoislujien terästen hitsaukseen, kun teräksen hiili- ja rikkipitoisuudet ovat matalia. Sillä on laaja parametrialue. Yleisimmät hitsausvirheet ovat vajaa hitsautumissyvyys ja huokoset. Tässä diplomityössä keskityttiin etsimään yhdelle valmistettavalle tuotteelle optimaaliset kuitulaserhitsausparametrit. Kuitulaserin laser- ja prosessiparametrien vaikutusta hitsiin ei ole juurikaan tutkittu. Diplomityön kokeiden perusteella olisi hyvä tehdä eri materiaalien jatkotutkimusta railonvalmistuksen, kuten liitoksen oksidikerroksen ja ilmaraon sekä suojakaasun, vaikutuksesta hitsiin. Kuitulaserin hyvä säteenlaatu ja muut laser-parametrit ovat tuoneet mukanaan prosessiin uusia ilmiöitä, joita on syytä tutkia lisää.

Metsäkonetuotannon hitsauksen robotisointi

Diplomityön tavoitteena oli selvittää robottihitsauksen antamat mahdollisuudet metsäkoneen runkorakenteiden hitsauksessa. Työn teoriaosassa selvitettiin kaarihitsauksen automatisointia ja sen tuomia etuja manuaaliseen hitsaukseen verrattuna. Työssä käytiin läpi kaarihitsauksen automatisointiinsoveltuvat robottivaihtoehdot, nykyaikaisen robotin hitsausvarustus, sekä kappaleenkäsittelylaitteet ja robotisoidun käytön turvallisuus. Hitsauksen robotisointiin soveltuvat eri hitsausmenetelmät ja perinteisten menetelmien tehostamiskeinot käytiin lävitse teoriaosuudessa. Hitsaustuotannon laatuun vaikuttavia asioitaja robottihitsattavan kappaleen suunnittelun huomioonottamista tuotesuunnittelussa tarkasteltiin myös työn teoriaosuudessa. Käytännön osiossa tarkasteltiin robotilla hitsattavat tuotteet ja tehtiin niille luoksepäästävyystarkasteluja. Laadittiin vaatimusluettelo tarvittavalle hitsausrobottilaitteistolle ja mallinnettiin erilaisia vaihtoehtoisia ratkaisuja hitsausrobottiympäristöstä kaarihitsauksen graafista simulointiohjelmaa käyttäen. Vertailtiin eri laitetoimittajilta saatuja 'avaimet käteen'- periaatteella tarjottuja ratkaisuja janiiden vastaavuutta laadittuun vaatimusluetteloon sekä eri laiteratkaisujen keskinäistä paremmuutta kyseiseen tapaukseen. Päätuotteille määritettiin hitsausajat ja selvitettiin laitteiston hitsauskapasiteettia. Investoinnin taloudellista kannattavuutta tarkasteltiin eri laskentamenetelmien avulla. Lopuksi arvioitiin hitsaustuotannon jatkokehitystarpeita tulevaisuutta ajatellen.

Hitsauksen joustava laadunhallinta tilauskonepajassa

Diplomityön tavoitteena oli hitsauksen laadunhallinnan kuvaaminen ja kehittäminen ISO 9001 laadunhallintajärjestelmän ja uudistetun hitsauksen laatuvaatimusstandardin SFS-EN ISO3834-2:n mukaisesti tilauskonepajaan. Diplomityö koostuu teoriaosasta ja käytännön osasta. Teoriaosassa on käsitelty yleisiä laadunhallintaan liittyviä asioitasekä hitsauksen laadunhallintaan liittyviä asioita. Tarkastelun kohteina ovat olleet laadunhallinnan vaikutukset kilpailukykyyn sekä laadunhallinnan työkalut. Hitsauksen laadunhallintaa on käsitelty hitsatun rakenteen ja hitsausliitoksen laatuvaatimuksien, hitsaukseen vaikuttavien viranomaismääräysten sekä työturvallisuuden näkökulmista. Käytännön osassa kerrotaan hitsauksen laatujärjestelmän rakentamisesta Lievestuoreella sijaitsevaan TTP-Yhtiöt Oy:n tilauskonepajaan. Yrityksen hitsaustoiminnan nykytilanne arvioitiin ja sen pohjaltalaadittiin hitsauksen laatukäsikirja. Hitsauksen laatukäsikirja rakennettiin noudattaen hitsauksen laatuvaatimusstandardia SFS-EN ISO 3834-2 ja käyttäen apuna yrityksen ISO 9001:2000 laatukäsikirjaa. Tilauskonepajassa hitsauksen toimintajärjestelmältä vaaditaan joustavuutta, koska asiakkaiden hitsaustyölle asettamat vaatimukset vaihtelevat suuresti. Diplomityössä kuvataan esimerkin avulla hitsausohjeiden laatiminen, joka muodostaa yhden keskeisen osa-alueen hitsauksen laadunhallintajärjestelmästä. Hitsauksen laatujärjestelmän rakentamisen aikana hitsaushenkilöstöä informoitiin laatujärjestelmän edellyttämistä toimenpiteistä ja muutoksista luentojen avulla. Työn tuloksena saatiin myös yrityksen hitsaustoimintojen kehittämiseen, tehostamiseen sekä henkilökunnan koulutukseen liittyviä jatkotoimenpiteitä esille.

Levyrakenteistentuotteiden hitsauksen automatisointi

Työn teoriaosassa esitellään automatisodun hitsauksen etuja ja vaatimuksia. Teoriaosuuden edetessä keskitytään erityisesti robotisoituun MIG/MAG -hitsaukseen sekä teknisestä että taloudellisesta näkökulmasta katsottuna. Työn kokeelliseen osaan osallistui kaksi metallialan yritystä Pohjois-Karjalan alueelta. Ensimmäisessä yrityksessä kartoitettiin nykyisestä tuotannosta robottihitsattavia tuotteita. Tarkasteluun valituille tuotteille määriteltiin sopiva hitsausrobottijärjestelmä. Yrityksen tuotannolle oli ominaista asiakasohjautuva tuotanto, suhteellisen pienet sarjat ja tuotteet, joissa oli vähän hitsattavaa. Toisessa yrityksessä eräästä tuoteperheestä otettiin yksi tuote. Tuotteen avulla tutkittiin tuoteperheen hitsauksen automatisoinnin mahdollisuuksia ja sen aiheuttamia ongelmia. Suurimmat ongelmat tuotteen hitsauksen automatisoituessa ovat liitosten luoksepäästävyys, muodonmuutokset hitsauksen aikana ja erilaisten käytettävien materiaalien runsaus. Ensimmäisessä yrityksessä hitsattavien materiaalien paksuudet ovat pääosin kolme millimetriä tai sen alle. Toisessa yrityksessä hitsattavien materiaalin paksuudet ovat pääsääntöisesti yli kolme millimetriä. Työn kokeellisessa osassa vertaillaan ohuiden ja paksujen levyrakenteisten tuotteidenhitsauksen automatisoinnin yhteneväisyyksiä ja eroja teorian- ja käytännön osuuksien valossa.

Hitsauksen mekanisointi laivan runkorakenteiden valmistuksessa

Hitsauksen mekanisoinnilla ja erityisesti kevytmekanisoinnilla saavutetaan melko pienin kustannuksin suuria etuja tuottavuudessa, laadussa ja työergonomiassa. Mekanisoinnin avulla voidaan saavuttaa soveltuvissa kohteissa hitsauksen kaariaikasuhteen kaksinkertaistuminen esim. 10 %:sta 20 %:iin. Tämä voi tarkoittaa kohteen kokonaishitsaustyöajan puolittumista. Mekanisoinnin tehokas hyödyntäminen edellyttää kuitenkin, että laitteet ovat helppokäyttöisiä ja haluttuja hitsauksen apuvälineitä. Genesis-projekti, jonka on määrä valmistua syksyllä 2009, tuo uuden haasteen Aker Yardsin Turun telakalle. Aluksen aikaisempia laivoja suurempi koko aiheuttaa haasteita tilankäytölle ja kapasiteetin riittävyydelle. Lisäksi käytettävät rakenteet aiheuttavat tuotantoon erityisiä ongelmia, joihin tämän diplomityön puitteissa on etsitty soveltuvia mekanisointiratkaisuja. Diplomityössä mekanisointilaitehankinnoilla lisättiin telakan laitekantaa ja korvattiin vanhentuneita laitteita. Laitteiden käyttöönotossa tarkasteltiin laitteiden puutteita ja pyrittiin löytämään käytettävyyttä parantavia ratkaisuja. Tässä työssä esitellyillä parannuksilla käytössä oleviin laitteisiin ja työmenetelmiin hitsauksen mekanisoinnin käyttöä voitaisiin lisätä vielä merkittävästi.