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Lappeenrannan Teknilinen Yliopisto LUT UNIVERSITY LUT School of Energy Systems LUT Mechanical Engineering Joel Autio SAFETY REVIEW OF ALUMINIUM LASER WELDING AND INSTRUCTIONS FOR DESIGNING A SAFE WORKSTATION IN VALMET AUTOMOTIVE Examiners: Professor Heidi Piili, D. Sc. (Tech.) Post-doctoral researcher Anna Unt, D. Sc. (Tech.) TIIVISTELMÄ LUT-Yliopisto LUT School of Energy Systems LUT Kone Joel Autio Alumiinin laserhitsauksen turvallisuuskatsaus ja ohjeet turvallisen työaseman suunnittelemiseksi Valmet Automotivella Diplomityö 2020 135 sivua, 23 kuvaa, 6 taulukkoa ja 9 liitettä Tarkastajat: Professori Heidi Piili, TkT Tutkijatohtori Anna Unt, TkT Ohjaajat: Laboratorioinsinööri Ilkka Poutiainen, TkT Projekti insinööri Pekka Laihonen Hakusanat: alumiini, Al, alumiinin laserhitsaus, laserturvallisuus, alumiinin terveysriski, alumiinin pölyräjähdysriski, työaseman suunnittelu, työturvallisuusvaatimukset Tämän diplomityön tavoitteena oli selvittää, millaisia työturvallisuusriskejä liittyy alumiinin laserhitsaukseen ja kuinka näitä riskejä voidaan hallita. Työn toimeksiantaja Valmet Automotive harkitsee tulevaisuudessa ottavansa käyttöön alumiinin laserhitsausprosessin. Työturvallisuuden huomiointi ja työntekijöiden turvallisuus on työnantajan vastuulla. Alumiinin laserhitsauksen turvallisuuteen vaikuttavista seikoista on hyvä saada kattavaa tietoa jo suunnittelun alkuvaiheessa, jotta varmistetaan turvallinen työasema ja työprosessi. Alumiinin laserhitsauksen työturvallisuushaasteisiin perehdyttiin laajan kirjallisuuskatsauksen menetelmien avulla. Käytettävänä kirjallisuusmateriaalina käytettiin pääosin erilaisia vertaisarvioituja aiheeseen liittyviä tieteellisiä artikkeleita ja tutkimusraportteja, käsikirjoja ja oppaita. Tutkimus kokoaa yhteen pakettiin lukuisten tutkimusten sisältämän erillään olleen tiedon. Alumiinin laserhitsaukseen liittyy kaikki laserlaitteiston ja lasersäteen aiheuttamat turvallisuusriskit, ja lisäksi alumiini materiaalina aiheuttaa lukuisia terveyshaasteita ja turvallisuusriskejä. Alumiinin aiheuttamat terveyshaasteet ja turvallisuusriksit johtuvat pääosin hitsauksen aikana ilmaan vapautuvasta hienojakoisesta alumiinipölystä. Terveyshaasteiden ja turvallisuusriskien hallitsemiseksi on esitelty teknisiä ratkaisuja ja työn organisointiin liittyviä ohjeistuksia. Tämä tutkimus on tarkoitettu soveltuvaksi oppaaksi tuleville työasemien suunnittelijoille. Tämän avulla he osaavat ottaa riittävällä laajuudella ja vakavuudella alumiinin laserhitsauksen turvallisuuden huomioon, ja tietävät keinot ja ratkaisut, joilla turvallinen työ varmistetaan. Vaikka alumiinin laserhitsaukseen liittyy useita vakavia turvallisuusriskejä, sitä voidaan suorittaa täysin turvallisesti, kun työasema ja työprosessi on suunniteltu ja toteutettu oikealla tavalla. ABSTRACT LUT University LUT School of Energy Systems LUT Mechanical Engineering Joel Autio Safety review of aluminium laser welding and instructions for designing a safe workstation in Valmet Automotive Master’s thesis 2020 135 pages, 23 Figures, 6 Tables and 9 Appendices Examiners: Professor Heidi Piili, D. Sc. (Tech.) Post-doctoral researcher Anna Unt, D. Sc. (Tech.) Supervisor: Laboratory Engineer Ilkka Poutiainen, D. Sc. (Tech.) Project engineer Pekka Laihonen Keywords: aluminium, Al, aluminium laser welding, laser safety, health risk of aluminium, aluminium dust explosion, workstation design, occupational safety requirements The aim of this master’s thesis was to detect what occupational safety risks are associated with laser welding of aluminium and how these risks can be managed. Valmet Automotive as client, is considering implementing laser welding process for aluminium in the future. Consideration of occupational safety and safety of employees is responsibility of the employer. It is appropriate to offer comprehensive information on the factors that affect the safety of laser welding of aluminium at an early stage of design to ensure safe workstation and work process. The occupational safety challenges of laser welding of aluminium were studied using the methods of an extensive literature review. The literature used was mainly various peer- reviewed scientific articles and research reports, manuals and guides. This research brings together in a single package of relevant information contained in numerous studies. Laser welding of aluminium involves all the safety risks posed by laser equipment and the laser beam, and in addition, aluminium as a material poses numerous health challenges and safety risks. The health challenges and safety risks caused by aluminium are mainly due to the fine aluminium dust released into the air during welding. To manage health challenges and safety risks, technical solutions and guidelines related to work organization have been presented. This research is intended as appropriate guide for future workstation designers. This allows company to evaluate the safety of aluminium laser welding with sufficient scope and severity and to know the means and solutions to ensure work safety. Although there are several serious safety risks associated with laser welding of aluminium, it can be performed completely safely when the workstation and work process are designed and implemented correctly. ACKNOWLEDGEMENTS This thesis has been done at the request of Valmet Automotive in an employment relationship. I would like to thank my employer, Valmet Automotive, for the opportunity to do an interesting and educational research project, the result of which is this thesis. Especially, I would like to thank my manager Mr. Timo Karhu for his support and trust, and my supervisor Mr. Pekka Laihonen for his support, advice, and encouragement. I would like to thank the examiners of my thesis, Professor Heidi Piili and laboratory engineer Ilkka Poutiainen for giving valuable suggestions, ideas, and guidance for this thesis. I want to express my gratefulness to the supervisor post-doctoral researcher Anna Unt for guidance and help during writing the thesis. I would also like to thank Lappeenranta University of Technology for the opportunity to complete master's studies flexibly alongside the work with the special MEC study module. Huge thanks go to my family and friends who have supported me during my studies. Finally, I want to thank Paulina for all the support and love. Joel Autio Uusikaupunki 15.12.2020 5 TABLE OF CONTENTS TIIVISTELMÄ .................................................................................................................... 1 ABSTRACT .......................................................................................................................... 2 ACKNOWLEDGEMENTS ................................................................................................ 3 TABLE OF CONTENTS .................................................................................................... 5 LIST OF SYMBOLS AND ABBREVIATIONS ............................................................... 9 1 INTRODUCTION ..................................................................................................... 12 1.1 Background information and motivation ............................................................. 12 1.2 Research questions, framework and scope .......................................................... 12 1.3 Research methods ................................................................................................ 13 1.4 Valmet Automotive .............................................................................................. 14 2 LASER WELDING ................................................................................................... 15 2.1 General information on laser ............................................................................... 15 2.2 General information on laser welding ................................................................. 16 2.2.1 Different systems for laser welding ......................................................... 19 2.3 Advantages and opportunities of laser welding ................................................... 21 2.4 Disadvantages and limitations of laser welding .................................................. 21 2.5 Laser welding in automotive industry ................................................................. 21 2.6 Laser welding in Valmet Automotive .................................................................. 23 2.6.1 Laser equipment in Valmet Automotive .................................................. 24 3 ALUMINIUM............................................................................................................. 26 3.1 General information on aluminium ...................................................................... 26 3.2 Properties of aluminium ....................................................................................... 27 3.3 Aluminium alloys ................................................................................................ 28 3.3.1 Categorization of aluminium alloys ......................................................... 28 3.3.2 Properties and using of alloys .................................................................. 29 3.4 Aluminium in automotive industry ...................................................................... 30 3.4.1 Structure of car body ................................................................................ 30 4 ALUMINIUM LASER WELDING ......................................................................... 34 4.1 General information of aluminium laser welding ...............................................
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