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Flame straightening is used to correct deformations from welding. When welding, shrinkage in the weld and surrounding material causes deformation. Flame straightening works by rapidly heating localized areas of plate with an oxy-acetylene flame to around 1000°C, increasing the plasticity of the steel. As the heated parts are constrained by the cooler surrounding material, excessively long parts will shorten during cooling. Multi-flame blowpipes are suitable for large areas while single-flame blowpipes can be used for thinner sheets. Straightening requires studying the deformations and applying intermittent heating bands above stiffeners to correct bending in small sections at a time.
Flame straightening is used to correct deformations from welding. When welding, shrinkage in the weld and surrounding material causes deformation. Flame straightening works by rapidly heating localized areas of plate with an oxy-acetylene flame to around 1000°C, increasing the plasticity of the steel. As the heated parts are constrained by the cooler surrounding material, excessively long parts will shorten during cooling. Multi-flame blowpipes are suitable for large areas while single-flame blowpipes can be used for thinner sheets. Straightening requires studying the deformations and applying intermittent heating bands above stiffeners to correct bending in small sections at a time.
Flame straightening is used to correct deformations from welding. When welding, shrinkage in the weld and surrounding material causes deformation. Flame straightening works by rapidly heating localized areas of plate with an oxy-acetylene flame to around 1000°C, increasing the plasticity of the steel. As the heated parts are constrained by the cooler surrounding material, excessively long parts will shorten during cooling. Multi-flame blowpipes are suitable for large areas while single-flame blowpipes can be used for thinner sheets. Straightening requires studying the deformations and applying intermittent heating bands above stiffeners to correct bending in small sections at a time.
MARKET BRIEF Flame straightening Technical information Flame straightening is used for correcting deformations which occur in welded constructions. Shrinage in the weld itself and the surrounding material due to cooling occurs in all welding. Shrinage causes deformation and !ucling in the surrounding "late# even at some distance from the welds. Deformation can also stem from thermal stresses created !$ rolling or thermal cutting. %he e&tent of the deformation is largel$ de"endent on how welding is e&ecuted. Distortions are es"eciall$ visi!le on "ainted or lac'uered surfaces. (t is usuall$ im"ossi!le to stretch areas that have shrun due to welding. )ne solution is to attem"t to shrin the over*e&tended areas# a +o! for which flame straightening has "roved to !e suita!le. Flame straightening is "articularl$ convenient since no e'ui"ment other than a !low"i"e is normall$ re'uired. %he o"erator however# must !e well aware of how the wor"iece will react to heating and how shrinage forces can !est !e utilised for straightening. (n contrast to mechanical straightening# the results of flame straightening are not evident until the structure has cooled. Principle %he "rinci"le of flame straightening is !ased on using the hottest flame "ossi!le (,refera!l$ )&$-.cet$lene) for ra"id heating of a limited "ortion of "late to a tem"erature of a""ro&. /00 degrees Centigrade# at which "oint the "lasticit$ of the steel has !een su!stantiall$ increased. Since the surrounding material remains cold# the heated "arts will !e restrained during the heating and u"set so that the e&cessivel$ long "arts will shorten during cooling. %he "late ma$ also !e restrained !$ e&ternal means such as clam"s or loads. %his e&am"le illustrates the "rinci"le of flame straightening. (f we first e&amine an unrestricted steel !ar which is uniforml$ heated (Fig.1)# we find that it will e&"and in all directions. 2hen the flame is removed the wor"iece will cool and contract to its original dimensions. (f the !ar is restrained during heating (Fig.3)# longitudinal e&"ansion is "revented. %his will lead to a !uild*u" of com"ression stresses which increase as the tem"erature increases. Finall$ the com"ressive $ield strength limit is reached and the material is "lasticall$ u"set. %his u"*set is e&"edited !$ the fact that the u"set limit decreases as the tem"erature increases. During the cooling the wor"iece will !e shortened due to the u"setting. ,age 1 of 10 4% 5une 3000 Unrestrained Fig.1 4estrained Fig.2 Heat Source Heat Source Equipment %he !est straightening effect is o!tained !$ a num!er of local heatings. %his has led to the use of multi* flame "late straightening !low"i"es with three flames. %his t$"e of !low"i"e greatl$ facilitates flame straightening# "ermits the !est "ossi!le control of the straightening "rocess# is the most economical and "roduces the smoothest surface. 6ulti*flame !low"i"es are es"eciall$ suita!le for straightening large areas of "late such as decs and dec structures on shi"s. For straightening !eams and sheet metal less than 7 mm thic# a single*flame !low"i"e is most suita!le. Single*flame !low"i"es of var$ing si8es can !e connected to the same t$"e of shan as the multi*flame !low"i"e. %he three*flame !low"i"e is suita!le for straightening "lates from 7 9 13 mm. %he o"erator should also have a straight edge of a""ro&imatel$ 1.: meters to determine the a""earance and si8e of deformations. Execution Different constructions with different t$"es of deformation demand different straightening methods. (t is therefore im"ossi!le to "rovide a general descri"tion of the flame straightening "rocess. Such factors as residual stresses due to rolling# thermal cutting and welding greatl$ affect the results of straightening. %olerance re'uirements can also var$ from case to case. . few e&am"les of how flame straightening can !e e&ecuted will !e given here. %he straightening involves a dec section and the wall of a dechouse# !oth with a "late thicness of a""ro&. ; mm. <oth of these constructions are flame straightened in the same manner e&ce"t that the dec can usuall$ onl$ !e reached from one side. <egin !$ straightening the "late directl$ a!ove the stiffeners. Straighten the side of the "late which is too long# i.e. the conve& side. ,age 3 of 10 4% 5une 3000 =o88le 7 mm ,late %he !low"i"e should !e held so that the ti" of the inner cone of the flame is a""ro&. 7 mm from the "late surface. Fig.3 6ove the !low"i"e directl$ over the stiffeners (Fig.3) so that the intermittent heat !ands !ecome dar red in colour (tem"erature a""ro&. /00 deg Centigrade). .lwa$s locate one of the flames directl$ a!ove the stiffener while the remaining flames are dis"laced according to t$"e of deformations in the surrounding "late. %he following e&am"les illustrate the location of the !low"i"es. 2here the "late has !een s$mmetricall$ deformed on !oth sides of the stiffener (Fig.4) either u"wards (>) or downwards (*). %he <low"i"e is then located s$mmetricall$ with one flame on either side of the stiffener# des"ite the fact that this is the concave side of the stiffener. %his "late is as$mmetricall$ deformed (Fig.5) it is deformed u"wards on one side of the stiffener and downwards on the other. %he !low"i"e should !e a""lied eccentricall$. )ne of the outer flames is located directl$ a!ove the stiffener while the remaining flames are over the side of the stiffener where the "late is deformed u"wards.
,age ? of 10 4% 5une 3000 Fig.4 Blopipes * * ! ! Fig.5 > * Fig." %he heat !ands should !e a""ro&. 100 mm long on a 7 * / mm thic "late and a""ro&. 3:0 9 ?:0 mm long on an ; 9 13 mm thic "late. %he distance !etween heat !ands should !e a""ro&. 100 mm. Deformations which are as distinct as those shown in the two e&am"les (Fig@s. 7 A :) are rare. (t is therefore essential that the deformations in the vicinit$ of the stiffener# i.e. the area directl$ affected !$ the flames# !e carefull$ studied. (n this case (Fig.#) the !low"i"e is located ecentricall$# since the "late is flat in the middle# the "late there will rise and then revert !ac to its original sha"e. .s in the "revious case# the flames are "ositioned over the high sections. %he stiffeners are distinctl$ visa!le in this case (Fig.$) since the "late has !een deformed downwards on !oth sides of the stiffeners. )nl$ one flame located directl$ over the stiffeners should !e used in this case. (n this case the "late in the middle is not deformed. (n an$ case# the o"erator should a""l$ the !low"i"e eccentricall$ while carefull$ o!serving how the "late reacts to the heating. (f the "late droo"s down# the !low"i"e must !e returned to the normal "osition with the centre flame directl$ over the stiffener. ,age 7 of 10 4% 5une 3000 Fig.# ! !% & !% Fig.$ Fig.' * > * >0 * > * 2hen flame straightening near the stiffeners the o"erator should tae care to ensure that as large an area as "ossi!le is treated in order to "revent the individual heating "asses from adversel$ affecting each other. %he following illustration (Fig.1%) "resents an e&am"le of a correct heating se'uence.
First the "late a!ove ever$ other stiffener is straightened (1#3 A ?). %hen the "late a!ove stiffeners 7# : A / are straightened# !ut with the heat !ands somewhat dis"laced. (f e&treme deformation still remains after the first straightening "ass (1 9 3)# further straightening ma$ !e necessar$. %hese "asses are mared with the num!ers ? 9 / (Fig.11). ,age : of 10 4% 5une 3000 & !0 ! & & ! ! 1 7 3 : ? / * >0 > * * > > Fig.1% (n cram"ed areas# the !low"i"e can !e dis"laced !$ half the distance !etween flames (see "ass ? A 7 fig.12) as heating the same area twice is not recomended. During the second straightening ensure that there is s"ace !etween the heat !ands otherwise the stiffener ma$ !end. %he a""earance of the "late after the initial straightening with the !low"i"e eccentricall$ located must !e studied carefull$. ,age / of 10 4% 5une 3000 Fig.11 1 ? : / 7 3 Fig.12 ? 7 1 3
1 A 3 ? A 7 4e"eated heating is not alwa$s advisa!le in ever$ case. <ucles with large !um"s# for e&am"le# are difficult to straighten. Fig.13 shows a !ucle which is suita!le for renewed heating. %his !ucle has the smooth contour which is necessar$ for a second straightening "ass to !e "ossi!le. (traightening )uc*les .fter the area around the !eams is straightened# the remaining !ucles in the intermediate "late surfaces must !e heated. Conve& !ucles on the dec must !e straightened first. %o o!tain the smoothest "ossi!le finish on the com"leted wor# the small !ucles must !e treated !efore the larger ones. ,age B of 10 4% 5une 3000 .fter the 1 st straightening "ass 3nd 1st .fter the 3 nd straightening "ass Fig.13 Fig.14 %he e&am"le in Fig.14 illustrates this method. Firstl$ 3 or ? s"ots are heated (=o.1 in fig.17). .fter these have cooled their e&tended areas are then heated (=o.3 in fig.17). (t is im"ortant that heating is not resumed until the first s"ots have com"letel$ cooled down. 1 3 Fig.15 ? ? (f the deformation is not corrected !$ heating the middle of the "late# new heating !ands (=o.? Fig.1:) must !e a""lied to the sides. Continued heating is now carried out de"ending on the t$"e of !ucle "resent in the "late# according to either Fig.1/ or Fig.1B !elow. ,age ; of 10 4% 5une 3000 Fig.1" ! 7 7 (f the !ucles are uniforml$ distri!uted over the entire "late# heat !ands are a""lied in accordance with Fig.1". (f the !ucles occur mostl$ in the middle# the new heat !ands shall !e a""lied within the "revious heat !ands as in Fig.1#. 6an$ of the "reviousl$ concave !ucles will disa""ear as the conve& !ucles are straightened. %hose !ucles still remaining on the wall are now straightened from the inside in the same manner as descri!ed a!ove. Fig.1# !0 ! 0 7 ? ? 7 1
3 3
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1 Fig.1$ (f there are an$ sections where the u""er "art is conve&l$ distorted and the lower "art is concavel$ distorted# straighten in the following se'uence. Firstl$ the conve&l$ distorted section is straightened from the outside (=o@s. 1 A 3 Fig.1$). %he lower "art is then heated from the inside (=o@s. ? A 7 Fig.1'). )!serve that the heating !ands on !oth the outside and the inside form a common "attern and that heating is e&ecuted from the conve& side of the "late. 2hether the final heating (=o.: Fig.2%) in the transitional area !etween the (>) to (*) is to !e done from the outside or the inside must !e determined in each individual case. Heating shall !e carried out from the conve& side of the "late# which in this case means from the outside. (n this case the !low"i"e should !e moved u"wards. (f heat has to !e a""lied from the inside the !low"i"e is moved in the other direction (alwa$s towards the conve&l$ distorted section). (n most cases the flame*straightened section will now !e within tolerance and straightening is concluded. However there ma$ !e some s"ecial cases such as short !ucles which re'uire further treatment as !elow. (hort )uc*les Short "rominent !ucles can "rove difficult to straighten !ut if treated in the following manner the !ucles can !e e&tended# there!$ lowering their rigidit$. %he flame is a""lied in the middle of the !ucles and directed forward. %his "reheats the material over a large area and the "late will then rise toward the flame (Fig.31). .fter the !ucle has !een e&tended in one direction# the !low"i"e is directed at the middle and the !ucle is e&tended in the other direction. %he !ucle then loses its rigidit$ and !ecomes easier to straighten. ,age C of 10 4% 5une 3000 7 7
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Fig.1' : : Fig.2% Direction of travel Starting "oint
Fig.21 Starting "oint Direction of travel Fig.22 Flame straightening of pre&fa)ricate+ parts ,re*fa!ricated "arts to !e flame straightened must !e firml$ fi&ed to "revent movement. (t is therefore im"ossi!le to straighten o"en "late surfaces efectivel$. (t is 'uite common for shi"$ards to construct dechouses as se"arate units from the shi" and then "lace them on the dec with all straightening com"leted. %his construction method is onl$ "ossi!le if the !ottom "lates that are to !e welded to the dec are sufficientl$ stiffened during straightening. Flame straightening cannot !egin until all welding is com"leted. %he dec "lates in the dechouse should !e straightened first and then the underl$ing walls (Fig.23). ,age 10 of 10 4% 5une 3000