FE Simulation of the Flame Straightening Process on Shipbuilding Aluminum Structures Made of EN AW-5083

Abstract The use of aluminum alloys is becoming increasingly important, particularly in special shipbuilding, where the low density and high corrosion resistance of the materials offer decisive advantages. In practice, however, there are considerable technical challenges. Compared to steel, the use of aluminum alloys implies a significantly greater welding-related distortion of the structure. This distortion must then be reduced using costly and time-consuming processes. The most commonly used process for this is the acetylene-oxygen flame straightening process. However, the knowledge and skills of experienced flame straighteners are largely subjective, which limits the possibility of a general process characterization. In order to make the process accessible to inexperienced prospective flame straighteners, the idea was born to systematize the process and work out promising straightening strategies in advance. This simulation-based approach not only reduces the probability of wrong decisions during the process, but also creates a basis for making the process more efficient and easier to plan. It is shown how the FE method can be used to optimize a straightening strategy in order to reduce distortion on larger assemblies. A series of experimental investigations help to validate the virtual simulation model.