Flanging signifies the turning or bending over of the edges of a
plate to afford a means of union to other plates. Examples occur in
the back end-plates of Lancashire and Cornish boilers, the front and
back plates of marine boilers, the fire-boxes of locomotive boilers,
the crowns of vertical boilers, the ends of conical cross-tubes, and
the Adamson seams of furnace flues. This practice has superseded the
older system of effecting union by means of rings forming two sides of
a rectangular section (angle iron rings). These were a fruitful source
of grooving and explosions in steam boilers, because their sharp
angular form lacked elasticity; hence the reason for the substitution
of a flange turned with a large radius, which afforded the elasticity
necessary to counteract the effects of changes in temperature. In
girder work where such conditions do not exist, the method of union
with angles is of course retained. In the early days of flanging the
process was performed in detail by a skilled workman (the angle
ironsmith), and it is still so done in small establishments. A length
of edge of about 10 in. or a foot is heated, and bent by hammering
around the edge of a block of iron of suitable shape. Then another
"heat" is taken and flanged, and another, until the work is complete.
But in modern boiler shops little hand work is ever done; instead,
plates 4 ft., 6 ft., or 8 ft. in diameter, and fire-box plates for
locomotive boilers, have their entire flanges bent at a single squeeze
between massive dies in a hydraulic press. In the case of the ends of
marine boilers which are too large for such treatment, a special form
of press bends the edges over in successive heats. The flanges of
Adamson seams are rolled over in a special machine. A length of flue
is rotated on a table, while the flange is turned over within a minute
between revolving rollers. There is another advantage in the adoption
of machine-flanging, besides the enormous saving of time, namely, that
the material suffers far less injury than it does in hand-flanging.
These differences in practice would not have assumed such magnitude
but for the introduction of mild steel in place of malleable iron.
Iron suffers less from overheating and irregular heating than does
steel. Steel possesses higher ductility, but it is also more liable to
develop cracks if subjected to improper treatment. All this and much
more is writ large in the early testing of steel, and is reflected in
present-day practice.
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