CORRECTION OF DISTORTION USING

THE OXY-ACETYLENE FLAME PROCESS

The Process
Flame straightening is used for correcting deformations which occur in welded constructions.
Shrinkage in the weld it self and the surrounding material due to cooling occurs in all
welding. Shrinkage causes deformation and buckling in the surrounding plate, even at some
distance from the welds. Deformation can also stem from thermal stresses created by rolling
or thermal cutting, but the extent of deformation is largely dependent on how welding is
executed. Distortions are especially visible on painted or lacquered surfaces.
It is usually impossible to stretch areas that have shrunk due to welding. ne solution is to
attempt to shrink the over extended areas, a !ob for which flame straightening has proved to
be perfectly suitable.
Flame straightening is particularly convenient since no equipment other than a blowpipe is
normally required. "ut the operator must be well aware of how the work piece will react to
heating and how shrinkage forces straightening can best be utili#ed for straightening. In
contrast to mechanical straightening the results of flame straightening are not evident until
the structure has cooled.
Principle
$he %rinciple of flame straightening is based on using the hottest flame possible & acetylene
& oxygen & for rapid heating of a limited portion of plate to a temperature of approx '((
(
), at
which the plasticity of the steel has been substantially increased. Since the surrounding
material remains cold, the heated parts will be restrained during heating and upset so that the
excessively long parts will shorten during cooling. $he plate may also be restrained by
external means such as clamps or loads.
Fig.* illustrates the principle of flame straightening.
If a bar is restrained during heating longitudinal
expansion is prevented. $his leads to a build up of
compression stresses. Finally the compressive yield
strength limit is reached and the material is plastically
upset. +ssisting in the upset is the fact that as the
temperature increases the upset limit decreases. During
cooling the steel bar will be shortened due to the
upsetting or plastic deformation which has been made
to occur.
* of *'
Fig.*
E!ip"en#
$he most effective straightening result is obtained by using the high heat penetration
characteristic of the oxy,acetylene flame applied in a number of locali#ed heat patterns over
the surfaces to be rectified.
"lowpipes with multi,flame heat configurations -. no##le and / no##le0 have been developed
to achieve to such desired patterns, thus giving greater control of the straightening process in
the most economical manner.
$hese multi,headed blowpipes are especially suited for the straightening of large areas of
plate such as decks and deck superstructures on ships.
$he . no##le blowpipe of used for plate thickness between 1mm and *2mm, and the / no##le
head assemblies.
n plate thickness of 1mm to approx 3mm it may be necessary to limit the heat input. In
such cases series *.4( no##le si#e ' are recommended. "oth si#es of no##le are supplied with
each blowpipe.
For the treatment of beams, angles of deformation existing prior to the corrective treatment
commencing, the operator should have available a straight edge bar of length approx *./m.
In certain cases it may be necessary to supplement the flame process by the use of props or
!acks.
Fig.2
Fig..
Illustrates that . no##les blowpipe version comprising sharks, mixer, straight and
bent neck extensions, and adaptors and head assembly. $his blowpipe version id
used for most hori#ontal applications -decks0 with plate thickness up to *2mm.
+lso illustrated alongside is he alternative / no##le head assembly for use on
plate above *2mm thickness.
Illustrates the shorter blowpipe version using the bent extension only, and more
suited for use in vertical applications -deck superstructures0 and5or use in
confined areas.

2 of *'
I don6t know which one of these explanations
illustrates this bellow fairing line -Fig2 or
Fig . 70, and how the picture of the other.
Fig.2
. of *'
Fig..
1 of *'
S$%e#&
") equipment is manufactured to highest standard of quality and safety and will give first
class service for many years if operated correctly.
Safety precautions to be observed when using compressed gases with welding and cutting
equipment are described in the ") handbook 8S+F9 :;D9< %<9SS:<96 available free
of charge from your nearest ") Sales ffice.
+ny user requiring more derailed information on safety precautions should refer to =ome
ffice >emorandum 8Safety >easures for the use of xy,acetylene 9quipment in Factories6.
-Form *?(10.
$he following notes may, however, prove useful to ensure your equipment is efficient and
safe.
G$s C&lin'ers
@eakage round a valve spindle will be revealed by hissing or in some cases by a smell of gas.
$ighten the gland nut on the cylinder valve with a spanner and test with soapy water.
;9A9< :S9 + F@+B9.
Press!re Re(!l$#ors
+lways treat a regulator as a precision instrument, do not expose it to knocks, and !ar sudden
pressure surges caused by the rapid opening of the cylinder valve.
;ever use a regulator with other than the gas for which it was designed. <elease pressure on
the control spring when shutting down, after pressure in the hoses has been released.
If gauge pointers do not return to #ero when pressure is released, the mechanism is faulty and
the gauge should be replaced.
If the regulator 8creeps6 -passes gas when the pressure regulating screw is released0, or
builds,up pressure on the low pressure side when the blowpipe valve is shut, it should be
replaced -see details of ") Service 9xchange Scheme for safety and economy0.
Hoses
:se only hose which is in good condition and fitted with hose connections attached by
permanent ferrules.
Do not expose hoses to heat, tragic, slag, sparks, oil or grease. $est for leakage at working
pressure by immersing in waterC leak may be repaired by cutting out a faulty suction of hose
and inserting an approval coupling which ends should be cut back and re,fitted with hose
connectors and clips.
/ of *'
Saffire =ose )heck Aalves are recommended for fitting to all hoses. $he valve is an
automatic safeguard incorporating a spring loaded non,return valve, its purpose being to
prevent oxygen and fuel gases mixing in the hoses. $he saffire =ose )heck Aalve has
eliminated the conditions of flashback which are present when oxygen contaminates a fuel
gas hose or vice versa and it is well worth ensuring that your welding and cutting equipment
is protected as far as possible against flashback which as often serious and may cause
extensive damage to hoses is particularly severe.
Flashback can be avoided by adherence to recommended operating procedure, and the use of
hose check valves does not enable the operator to ignore good operating practices.
)lo*pipes
@eakage can be detected by soapy water bubbles or hissing and in the case of fuel gases also
by smell or ignition. @eakage at valves should be cured by tightening gland nutsC leakage at
the head nut or welding no##le by cleaning with a soft cloth. If leakage continues the
blowpipe shield be Service 9xchanged. In the case of a backfire, with gas burning inside the
blowpipe, first close the oxygen then the fuel gas valveC check delivery pressure, purge the
hoses and if these are correct after a pause relight the blowpipe, if backfiring persists it
indicates that the blowpipe is in need of replacement.
Pro#ec#i+e Clo#hin(
Doggles should be worn at all times whilst welding and cutting. @eather or asbestos
protective clothing should be worn for heavy cutting or welding. $he feet should be protected
from sparks, slag or falling off,cuts.
,en#il$#ion
In a confined space ensure that there is a suction fan to give adequate ventilation -a fume
hood at the source of fumes is the best method0C D ; :S9 < +; +I< "@E9< and
always post a helper outside for emergencies. $est all equipment for leaks before entering
and move it outside during interruptions and on completion of daily work.
Oper$#ion
perating data for all versions of the blowpipe are as follows F
"lowpipe
;o##le
$ype
xy. %ressure
bar -lbf5in20
+cet.
%ressure bar
-lbf5in20
xy. Flow
l5h -ft.5h0
+cet. Flow
l5h -ft.5h0
FS.
FS.
FS/
FS/
;o.'
;o.?
;o.'
;o.?
2.1-./0
2.1-./0
2.1-./0
2.1-./0
(..1-/0
(..1-/0
(.13-?0
(.13-?0
*..(-1?0
2('?-?.0
21./-3'0
2333-*(20
*2*3-1.0
*3?(-''0
22(3-?30
2'..-4.0
' of *'
)lo*pipe Posi#ion
$he blowpipe should be ad!usted by means of the wheel
bracket fixings so that the tip of the inner flame cone is
approx 1mm from the plate surface. -Fig.10
-Fig.** illustrated the alternative fixing positions for
no##le si#es ' and ? 0
=eating commences above the stiffener, -Fig./0 with one
of the multi,flames always positioned directly above the
stiffener. $he remaining flames are displaced according on
the plate ad!acent to the stiffener. -see >ethod of
+pplications0.
+llow sufficient time at the beginning of the cycle for the
plate to become dull red in color -temperature approx
'((
(
)5?((
(
)0.
=eat penetration for maximum effect should be *5. or
plate thickness as indicated in Fg.'
)onstant progress of the blowpipe at the correct speed for
the si#e of no##le selected can be maintained by
observation of the heat #ones formed by the individual
no##les.
Fig.? indicated the desired heat pattern, the gap between
the heat #ones being approx *5. width of the heat #one
itself.
? of *'
No--le
,
Fig./
Fig.1
Fig.'
Fig.?
Pl$#e
Appro.
/0
o
1""
2 T 234 T
Ehere the gap is as wide as or wider than the heat #one
-Fig.30 heat input is the insufficient indicating the speed is
too fast.
Ehere the gap is non existent with heat #ones overlapping
the heat is excessive indicating the speed is too slow.
-Fig.40
=eat bands should be approximately *((mm long on a 1,
'mm thick plate and approximately 2/(mm long on a 3,
*2mm thick plate. $he distance between the heat bands
should be approx *((mm to 2/(mm dependent upon the
plate thickness. -Fig.*(0
Me#ho' o% Applic$#ion
Different constructions with varying deformations require differing straightening methods. It
is not possible therefore to be specific of the method of application in all cases. 9xternal
factors such as residual stress due to rolling, thermal cutting and welding greatly affect the
results straightening. $olerance requirements can also vary from case to case.
+ few examples of how flame straightening can be executed will be given here. $he
straightening involves a deck section and the wall of a deckhouse, both with a plate thickness
of approx 3mm.
"oth these constructions are flame straightened in the same manner except that the deck can
usually only be reached from one side.
3 of *'
Fig.3
Fig.4
Fig.*(
"egin by straightening the plate directly above the stiffeners straightened the side of the plate
which is too long, i.e. the convex.
+lways locate one of the flames directly above the stiffener while we remaining flames are
displaced according to the type of deformations in the surrounding plate. $he following
examples illustrate the location of the blowpipes.
In this case the plate has been symmetrically
deformed on both sides of the stiffener either
upwards -G0 or downwards -,0. $he
blowpipe is then located symmetrically with
one frame on either side of the stiffener,
despite the fact that this is the concave side
of the stiffener.
$his plate is asymmetrically deformed it is
deformed upwards in one side of the
stiffener and downwards on the plate. $he
blowpipe should be applied eccentrically.
ne of the outer flames is located directly
above the stiffener while the remaining
flames are over the side of the stiffener
where the plate is deformed upwards.
=owever deformations as distinct as those shown in the two examples in Fig.*2
+bove are rare. It is therefore essential that the deformations in the vicinity of the stiffener,
i.e. the area directly affected by the flames, be studied carefully.
In the case of Fig.*1 the blowpipe is located
eccentrically, since the plate is flat in the
middle. $he plate there will rise and then
revert back to the original shape. In this case
as well the flames are placed over the high
parts.
$he stiffeners are distinctly visible in Fig.*/
since the plate has been deformed
downwards in both of the stiffeners. nly
one flame located directly over the stiffeners
should be used in this case.
4 of *'
Fig.*2
Fig.*.
Fig.*1
Fig.*/
, ,
Fig./
5 5
5
,
5 5
,
( 5 (
, ,
"lowpipes
In Fig.*' the plate I the middle is not
deformed. In any case, the operator should
apply the blowpipe eccentrically while
carefully observing how the plate reacts to
the heating. If the plate drops down, the
blowpipe must be returned to the normal
position with the center flame directly over
the stiffener.
If extreme deformation still remains after the
first straightening pass -*,20, further
straightening may be necessary. $hese
passes are marked with the numbers .,' in
Fig.*?
In cramped areas, Fig.*3 the blowpipe can
be displaced by half the distance between
the flames line . and 1 & since heating the
same area twice is not recommended.
+lso ensure that there is space between the
heat bands during the second straightening.
therwise the stiffener may bend out.
*( of *'
5 (
,
4 6 1
4
2
1
7
' 1 2
* . /
Fig.*'
Fig.*3
Fig.*?
26 7
G
,
G
, , ,
$he appearance of the plate after the initial
straightening with the blowpipe eccentrically
located must be studied carefully. Indicated
heating is not always advisable in every
case. "uckles with large bumps, for
example, are difficult to straighten.
+ buckle suitable for renewed heating
appears in Fig.*4 this buckle has the smooth
contours which are necessary for a second
straightening pass to be possible.
S#r$i(h#enin( )!c8les
+fter the area around the beams is
straightening, the remaining buckles in the
intermediate plate surfaces may be treated.
)onvex buckles on the deck must be
straightened first.
$he rule Hthe big ones follow the small
onesI, which means that the small buckles
are treated before the larger ones, applies
here. $his is illustrated in this example.
First 2 or . spots are heated -* in Fig.2(a0.
+fter they have cooled, their extended areas
are then heated -20. =owever, it is important
that heating not be resumed until the first
spots have completely cooled down.
If the deformation is not corrected by heating
the middle of the plate new heating bands -.0
must be applies to the sides. Fig 2(b

** of *'
Fig.*4
+fter the *
st
straightening pass
+fter the 2nd straightening pass
Fig.2(a
Fig.2(b
Fig.2(c Fig.2(d
2
7
4 4
7
2
)ontinued heating is carried out according to
either a or b.
If the buckles are uniformly distributed over
the entire plate, head bands shall be applied
in accordance with Fig.2(c
If the buckles occur mostly in the middle, the
new heat bands shall be applies within the
previous heat bands in accordance with
Fig.2(d.
If there are any sections where the upper part
in convexly distorted and the lower part is
concavely distorted, straighten in accordance
with Fig.2*a, b, c, d.
First, the part which is convexly distorted is
straightened from the outside -* and 20.
$he lower part is then heated from the inside
-. and 10. bserve that the heating bands on
both the outside and the inside form a
common pattern and that heating is executed
from the convex side of the plate.
Ehether the final heating -/0 in the
transitional area between -G0 to -,0 is to be
done from the outside or the inside must be
determined in each individual case. =eating
shall be carried out from the convex side
which means from outside in the above
figure. In this case, the blowpipe shall be
moved upwards. If head is applied from the
outside the blowpipe is moved in the
opposite direction.
In most cases the flame straightened section
will new be within the tolerance limits and
straightening is concluded.
$here may, however, be some special cases
such as short buckles, which require further
treatment.
*2 of *'
Fig.2*a
Fig.2*b
Fig.2*c
Fig.2*d
1 1
4 4
1 1
2
7
2
7
4 4
1 1
9 9
5
,
5(
,
5(
,
G
$
:
,
Shor# )!c8les
9xperience has shown that short, prominent buckles are difficult to straighten. If the
blowpipe is applies in the manner described in Fig.22a J 22b the buckles will be extended,
thereby lowering their rigidity.
$he flame is applied in the middle of
the buckles and directed forward. $hos
preheats the material aver a large area
and the plate will then rise towed the
flame.
+fter the buckle has been extended in
one direction, the blowpipe is directed
at the middle and the buckle is
extended in the other direction. $he
buckle then loses its rigidity and
becomes easier to straighten.
Thic8er Pl$#e
For plates approx, *2mm thick or more, it is usually sufficient to treat only the angular
deformation. If the stiffeners are thick and the angular deformation is not too great a five
flame torch is used. In this case as well, the length of the heat bands shall be approx. 2/( &
./(mm. If the initial heating pass is not sufficient to straighten the deformation, further
heating may be requited between first heat bands.
Fig.2. Shows how a ship hull with a
plate thickness of *2mm is
straightened. ;ote how the plate around
the butt weld has sunk down.
First the plate surrounding stiffeners *,
2, ., 1 and ' is straightened using a five
flame blowpipe. Due to the extreme
deformation at stiffener /, only a three
flame blowpipe was used there, since a
five flame blowpipe could make the
deformation worse. +fter the first
heating pass, it was apparent that
insufficient straightening had been
obtained around the butt weld.
$herefore, continuous heat bands were
applied over stiffeners * and 2.
Straightening was further increased by
using hacks to lift the butt weld form
the inside and using wedges on the
outside.
*. of *'
Starting point
Starting point
Forward
direction
Forward
direction
Fig.22a
Fig.22b
700
1 2 3 4 5 6
12
5 1 - ; 5 4 - < - 4
2000
=5 2> =- 2> =- 2> =? 0> =- 7>
V
Pl$#e S#r$i(h#enin( O% Pre-F$:ric$#e' P$r#s
%re,fabricate parts to be flame straightened must be firmly fixed to prevent movement. It is
therefore impossible to straighten open plate surfaces effectively.
It is quite common for shipyards to construct deckhouses as separate units from the ship and
then place them on the deck with all straightening completed.
$his construction method is only possible if the bottom plates that are to be welded to the
ship deck are sufficiently stiffened daring straightening.
Flame straightening cannot begin until all welding is completed. $he deck plates in the
deckhouse should be straightened first and then the underlying walls. +s indicated in fig.21
*1 of *'
Fig.21
9
< <
4
1 1
2
7 7
FLAME STRAIGHTENING OF )EAMS
@ & "9+>S
"egin by heating the hori#ontal flange
at the point indicated by the arrow
=eat both flanges. "egin at * and
continue with the other at 2.
I , "9+>S
=eat both flanges simultaneously,
starting at the points indicated by *.
"egin by heating the web at * and
continue with the flange at 2.
*/ of *'
7
2
7
2
7
2
FLAME STRAIGHTENING OF )EAMS
$ & "9+>S
"egin by heating the hori#ontal flange
at the point indicated by the arrow
.
.
=eat both flanges.
"egin with the hori#ontal flange at *
and continue at 2
=eat both flanges.
"egin with vertical flange at * and
continue with the other at 2.
*' of *'
2
2
7
7