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Thermal Upsetting

Thermal Upsetting. By Dennis Hanson Welding Student Lake Washington Institute of Technology. Introduction. Thermal Upsetting is the official term to cover: Flame/heat bending Flame/heat straightening. History. First documented by Joseph Holt, Seattle blacksmith

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Thermal Upsetting

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  1. Thermal Upsetting By Dennis Hanson Welding Student Lake Washington Institute of Technology

  2. Introduction Thermal Upsetting is the official term to cover: • Flame/heat bending • Flame/heat straightening

  3. History • First documented by Joseph Holt, Seattle blacksmith • Was more of an art than a science until recently • Is still very much an art

  4. Why its important Save time and money (and time IS money…) • Accomplish jobs that are not possible in any other way • Salvage projects that would otherwise be scrapped • Keep jobs on track by using equipment on hand

  5. Uses • For… • Straightening • Damaged structures • Damaged equipment • Out of spec parts/weldments • Bending • Ship building • Bridge Building • Truck trailers and railroad cars • Whatever! • On… • steel • nickel • copper • brass • aluminum • titanium Crane straightened by Casper, Phillips & Assoc. in Panama

  6. Heat Sources • Flame • OF welding torch • OF cutting torch • OF Rosebud • Other gas torch • Welding • Induction heater • Laser • Friction (shrinking disk)

  7. How it works - Intro • There is a lot of bad information about thermal upsetting on the internet. • Thermal upsetting depends on the heated metal being restrained in some way. • It’s all about thickening or lengthening the metal in one direction and shortening it in another direction.

  8. How it works – Bar experiment

  9. How it works – Bar experiment

  10. How it works – Bar experiment 101 mm - No Change 101 mm - No Change 100.78 mm – Shrank a little bit in length and increased 0.12 mm in width 99.94 mm – Shrank 1.06 mm and increased 0.7 mm in width

  11. Heating patterns • Heating patterns are critical to getting the results you want • Developed by Holt and still in use today • There are heating patterns already developed for standard stock like angle iron, I-beams, channel, etc. • The key to heating patterns is that they use the weldment itself to restrain the heated metal so that it thickens and then contracts in the direction you need. • We will look at angle iron as an example

  12. Heating patterns – Angle Iron • “Easy Way” vs. “Hard Way • What has to give when you bend angle iron? • So what heating pattern do you use? • Let’s use a piece of cardboard to think about this…

  13. Heating patterns – Angle Iron Bend after heat treating Angle iron is straight Mark a triangle

  14. Resources and References Used • Find this slide deck at http://www.firedupwelding.com/Blog.html • Induction Heating: http://www.efd-induction.com/en/Applications/Straightening.aspx • Holt Steel: http://www.holtsteel.com/about_us • U.S. Coast Guard whitepaper: www.dtic.mil/cgi-bin/GetTRDoc?AD=AD0710521 • Dan R. Dalton, Inc.: http://danrdaltoninc.com/?page_id=6 • Casper Phillips: http://www.casperphillips.com/flame_bending_and_straightening.htm • Flame On Inc.: http://www.flameoninc.com/process.html • ISI International Straightening: http://steelstraightening.com/about/ • Ohio DOT: http://www.dot.state.oh.us/engineering/OTEC/2010%20Presentations/51B-Mesler.pdf • Federal Highway Administration: http://www.fhwa.dot.gov/bridge/steel/01.cfm • Flame Straightening Technology For Welders, by John P. Stewart (in the LWIT library) • The Linde Group: http://www.holox.com/international/web/lg/us/likelgus30.nsf/docbyalias/ind_mv_auto5

  15. Conclusion What’s in your toolbox?

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