PROCEDURE FOR FLAME CUTTING AND JOINT PREPERATION OF STEEL.

1. SCOPE
1.1. This document describes the procedure for flame cutting and joint preparation by flame.

2. REFERENCE DOCUMENTS
2.1. DIN EN ISO 9013
2.2. DIN EN ISO 1090-2
2.3. DIN EN 10160
3. GENERAL
3.1. The sheet metal blank is defined by the current drawing.
3.2. If the quality of the cut surface produced by thermal cutting is not defined on the drawing , the cut
surfaces must comply with the cutting quality 331 according to DIN EN ISO 9013.

4. CUTTING PROCEDURE SPECIFICATION (CPS), CUTTING PROCEDURE QUALIFICATION RECORD(CPQR).

4.1. Parameters for shall be followed as per Qualified CPS.
5. FLAME CUTTING ROCEDURE
5.5. The capability of thermal cutting process shall be checked on every 6 month as set out below
5.5.1.A straight cut form the thicket constituent product.
5.5.2.A straight cut from the thinnest constituent product.
5.5.3.A Sharp corner from a representative thickness,
5.5.4.A curved arc form a representative thickness.
Measurement shall be taken on the straight samples over at least a 200mm length on each and
checked against the appropriate quality class. The sharp corner and curved samples shall be
inspected to establish that they produce edges equivalent standard to the straight cuts
5.6. The quality of cut surfaces shall be accordance with below class and range EN ISO 9013.
5.6.1.Limit deviations for nominal dimensions tolerance class-1
5.6.2.Range 3 of table 4 of EN ISO 9013 for Perpendicularity or Angularity tolerance
5.6.3.Table 5 Range 3 of EN ISO 9013 for Mean height of the profile, Rz5.

Issue Date 13.11.2014

Prepared By: S.Kalimuthu, IWT Page 1 of 4
 PROCEDURE FOR FLAME CUTTING AND JOINT PREPERATION OF STEEL.

Table 4-Perendicularity or angularity tolerance, u

Range Table 4-Perendicularity or angularity tolerance, u in mm

3 0.4 + 0.01 a a= cut thickness

Table 5 –Mean hight of the profile, Rz5

Range Mean height of the profile, Rz5

3 70+(1.2 a mm) a= cut thickness

5.7. The maximum hardness of thermally cut surfaces is based on DIN EN ISO 1090-, Table 10.

Table 10-Permitted maximum hardness values (HV 10)

Product standards Steel grade Hardness value

EN 10025-2 to 5 S 235 to S 460 380

EN 10210-1, EN 10219-1

EN 10149-2 and EN 10149-3 S260 to S700 450

EN 10025-6 S460 to S690

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 PROCEDURE FOR FLAME CUTTING AND JOINT PREPERATION OF STEEL.

5.8. Four local hardness tests shall be done on each sample in locations likely to be affected. The test
shall be in accordance with EN ISO 6507.
5.9. In order to achieve the required hardness of free edge surfaces. the material shall be adequately
preheated minimum 100mm on both sides of the cut, preheating temperature for cutting shall as
follows.
5.10. For thermal cutting, the material shall be adequately preheated minimum 100mm on both sides of
the cut, preheating temperature for cutting shall as follows.

Base material Thickness Minimum Preheating Maximum Preheating

temperature (⁰C) temperature (⁰C)

S 355 <100 Room temperature 250

>100 120

<20 Room temperature 200

S 690 >20-80 100
>80 150

Hardox 400 <44.9 Room temperature 225

45-59.9 100
60-80 150
>80 175

Hardox 450 <39.9 Room temperature 225

40-49.9 100
50-69.9 150
≥70 175

Hardox 500 <25 Room temperature 225

25-49.9 100
50-59.9 150
60-80 175

Dillidur 500 <25 Room temperature

25-70 80
>70 125˚C

Note: If the temperature of the work piece is < 10⁰C preheating is required in any case.

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 PROCEDURE FOR FLAME CUTTING AND JOINT PREPERATION OF STEEL.
For Hardox reference document is SSAB, Technical support document no: #16
For Dillidur plates reference document is Dillidur 500 V data sheet.

5.11. Straightness and flatness of the cut plates shall be as per DIN EN 10029.

6. JOINT PREPERATION
6.1 Joint preparation shall be appropriate for the welding process and customer drawing.
6.2 Production engineer is responsible for Joint preparation. Production engineer shall verify the
customer drawing and approved WPS, and he will select the suitable Joint preparation profile
consulting with shift welding supervisor.
6.3 QC Engineer shall conduct random check of Joint preparation. That covers the following.
i) Joint preparation shall be free from visible cracks.
ii) Bevel angles (If applicable)
iii) Root face (If applicable)
iv) Root land (If applicable)
v) Orientation and location of bevelling.
vi) Following tables tolerance shall be followed if the joint preparation by flame.

Table 4 of EN ISO 9013, Perendicularity or angularity tolerance, u

Range Table 4-Perendicularity or angularity tolerance, u in mm

3 0.4 + 0.01 a a= cut thickness

Table 5 of EN ISO 9013, Mean hight of the profile, Rz5

Range Mean height of the profile, Rz5

3 700+(1.2 a mm) a= cut thickness

6.4 If large notches or other errors in joint geometry are corrected by welding a qualified procedure
shall be used. And the area shall be subsequently ground smooth and feathered into the adjacent
surface.
6.5 All surfaces to be welded shall be dry and free from material that would adversely affect the quality
of the welds (Rust, Organic material or Galvanizing).

Issue Date 13.11.2014

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