This article will take an in-depth look at metal fabrication.
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Metal fabrication involves transforming sheet metal and other flat metals into predefined shapes. The process starts with metal sheets no thicker than a quarter inch, which are malleable enough to be shaped into various forms. Fabricators then modify these sheets using techniques such as cutting, stamping, shaping, folding, and welding. Custom fabrication, a related practice, involves creating unique parts through innovative combinations of these processes.
During the design stage, an item's design is reviewed and adjusted as needed for manufacturing. This may involve either a general design or a custom design created by a metal fabricator. For custom designs, this stage often involves working closely with the customer to meet specific requirements, with the fabrication service provider contributing their expertise to unique projects. The manufacturer's design team uses CAD (computer-aided design) software to develop designs, collaborating with the customer to define project needs, manufacturing strategies, and areas for improvement. The designer and fabricator must work together to resolve any discrepancies between the original design and the fabrication methods, a process known as steel detailing.
The next stage in the process is typically prototyping, though it is not required for all projects. Prototyping is particularly important for custom fabrications, providing the client with a preview of the finished product. During this stage, a quick prototype or sample is created using methods such as rapid sheet metal prototyping or 3D printing, which builds the item by applying layers of various materials, including metals. The prototype is then evaluated to assess its viability in relation to the final design. Based on this evaluation, the customer and design team can decide whether any adjustments are needed before proceeding to the next manufacturing stage.
Sheet metal prototyping is crucial for the successful development of many metal products. Skipping this important step during a large production run can lead to significant adjustments, material losses, and time delays, potentially costing tens of thousands of dollars even on smaller projects. To prevent substantial expenses later, high-quality steel fabrication depends on thorough testing and adjustments from the design stage through manufacturing. Additionally, sheet metal prototyping allows businesses to visualize and better understand the product they are creating.
Rapid prototyping, facilitated by 3D computer-aided design (CAD), involves the quick production of a physical part, model, or assembly. Typically, this is achieved through additive manufacturing, also known as 3D printing. The advantages of rapid prototyping include accelerated new product development by allowing early confirmation of an item’s fit, form, and function. This early validation helps ensure that the final product meets both technical requirements and business objectives.
Once the product’s CAD design is finalized, it is converted into programming for use with computer-controlled production devices. This programming is essential for operating automated equipment such as cutting, punching, and turning machines. This step is specifically relevant for metal fabricators that utilize automated metal fabrication equipment.
Once programming is complete, fabrication can commence. The time required to produce a part depends on its complexity, the procedures involved, and the workload of the machine shop. The fabrication process may include several steps, such as cutting, punching, folding, machining, welding, and more, depending on the specific item being created.
After the object is created, the fabrication company may perform finishing operations. This often involves smoothing surfaces and edges, as well as applying various coatings, such as powder coating.
Some fabrication companies also offer assembly services, including electrical connections and welding.
Shearing is a distinct type of cutting due to its unique process. It involves using two tools—one positioned above and one below the metal piece—to create a continuous, straight cut. The process starts with the upper tool pressing down on the metal to create a fracture. Once the fracture is initiated, pressure is maintained to complete the cut. After shearing, the edges can be refined and cleaned up to ensure a smooth finish.
Cutting is a common method used in metal production to divide workpieces into smaller sections. While sawing remains the most traditional method, modern techniques have expanded to include laser cutting, waterjet cutting, power scissors, and plasma arc cutting, the latter of which uses hot plasma to cut through electrically conductive materials. Cutting can be performed with various tools, from hand and power tools to computer numerical control (CNC) cutters. It may serve as the initial step in a more complex fabrication process or be the only step required.
Die cutting is another metal cutting method that involves the use of a die. Traditional die cutting methods include rotary die cutting and flatbed die cutting. In rotary die cutting, a cylindrical die rotates and cuts material fed through a press. Flatbed die cutting, on the other hand, uses a stationary die that is pressed down onto the metal to cut out shapes. This method applies more force and is used for cutting thicker and stronger materials.
Drawing is a process used to elongate materials into narrower shapes by pushing metal through a tapered die. While drawing can often be performed at room temperature, heating the material beforehand can reduce the force needed to complete the process.
Deep drawing is a specialized form of drawing used to shape sheet metal into cylindrical or box-like vessels, particularly when the depth of the finished product is equal to or exceeds its radius.
Welding is a method used to join multiple pieces of metal into a single unit by applying heat and pressure. Its versatility makes it suitable for joining nearly any metal component. Common types of welding include FCAW, MIG/GMAW, SMAW, and TIG.
Flux-Cored Arc Welding (FCAW) eliminates the need for an external gas source by using a wire electrode with a core that produces its own shielding gas. Although similar to MIG welding (Metal Inert Gas), FCAW provides enhanced protection from environmental conditions by generating its own shielding gas, which speeds up the process and improves consistency.
Shielded Metal Arc Welding (SMAW), also known as stick welding, uses an electrode stick that creates an electric arc upon contact with the metal. The intense heat of the arc melts the metal, allowing the pieces to fuse together.
Metal Inert Gas (MIG) welding involves a solid wire electrode that forms an arc between the electrode and the metal being welded. This process fuses the metal pieces together with the help of an inert gas shield.
Tungsten Inert Gas (TIG) welding is suited for heavier metals, such as carbon steels. It employs a tungsten electrode to create precise arcs. While TIG welding is more complex and requires a high level of skill, it is effective for many metal-based applications.
Folding is another metal fabrication process used to shape raw metal material by directing it into a die. There are three main folding techniques, with the most common involving a brake press (or press brake).
In a brake press, the raw metal is positioned between a punch and a die. Pressure is applied to the metal, forcing it into the die to achieve the desired shape. This method is widely used for shaping sheet metal.
Manual folding can also be performed using a machine known as a folder. This simple machine features a flat surface with a clamping bar that holds the sheet metal in place, and a front panel that raises to bend the extended portion of the metal.
Forging is a well-known metal fabrication method that involves applying compressive force to raw metal by striking it with a hammer or a die. This process shapes the metal into the desired form.
Just like other metal fabrication procedures, the forging process has some variants.
Casting involves pouring molten metal into a die or mold and allowing it to cool to form an item. This method is ideal for producing identical parts, making it particularly useful for mass production. There are various casting techniques, such as die casting, where a die is used to hold the molten metal rather than a traditional mold. The die shapes the finished product in this process.
Permanent mold casting is another technique, where molten metal is poured into a permanent mold. This method produces stronger products compared to other casting techniques. However, removing the mold after cooling can be challenging and time-consuming, especially if the mold needs to be reused.
To address the difficulties of mold removal, semi-permanent molds can be used. These molds incorporate a disposable core, which simplifies the removal process compared to permanent molds.
Sand casting will be the final metal fabrication technique discussed. In this process, sand serves as the mould material with the desired form created within it. When complex designs are required, this particular procedure takes longer than the others but is also a little more cost-effective since the mould material is so plentiful.
Extrusion is a more complex metal fabrication process used to create cylindrical components, commonly employed in wiring or plumbing. This method involves forcing material through a die to shape it. Typically, the raw material is a metal slug or cylinder. The material's diameter is reduced to match the cross-sectional size of the die, creating the desired shape inside the material as it is pressed through the die.
There are two main variants of extrusion: hot extrusion and cold extrusion.
Hot extrusion is frequently employed when working with materials like copper or aluminum since it raises the temperature of the material, increasing its likelihood of being moulded into a certain shape. In contrast, room-temperature cold extrusion is used to fabricate steel metal to increase product durability.
Machining is a process that involves removing excess material from raw metal to achieve the desired shape. While the basic concept of machining is straightforward, there are several techniques, including turning, milling, and drilling.
Milling involves removing material from a metal component using specialized multi-point cutting tools. This process can be performed manually or with a CNC milling machine. Milling is generally used as a secondary fabrication step to refine or finish parts.
Turning uses a lathe to create cylindrical shapes by removing material from a rotating metal piece with a cutting tool. This process can also be done manually or with a CNC turning machine, which provides higher precision for complex or critical components.
Drilling is the simplest of the three machining processes. It involves using a drill with a rotary cutting tool to create holes in the metal.
Stamping is a process that creates indentations or impressions on the surface of raw material, rather than drilling holes. It is commonly used to imprint symbols, such as letters, numbers, or images, onto metal objects.
There are two main types of stamping presses: mechanical stamping presses, which use electrical power, and hydraulic stamping presses, which use pressurized liquids. Stamping is typically performed on metal sheets up to 14 inches thick and is used to produce a wide range of products, including coins (through coining) and smaller metal parts for electronics (via four-slide shaping).
Automation has revolutionized the fabrication process by integrating programming capabilities into fabrication equipment. This advancement allows machines to perform tasks automatically according to predefined specifications, with minimal human intervention. Automation reduces operational costs and enhances both precision and consistency. Today, automated tools are available for various processes, including cutting, welding, folding, and numerous machining operations.
Automated machinery offers several advantages in manufacturing and fabrication. Automated systems typically provide higher speed and accuracy compared to manual operations, which is particularly important in industries such as aerospace and defense, where precision and timely delivery are critical. Additionally, using machines for dangerous tasks reduces the risk of workplace accidents and minimizes employee exposure to hazardous conditions.
Computer-Aided Design (CAD) software has become indispensable in metal manufacturing projects. Engineers use CAD to create detailed designs that guide fabrication processes. This software facilitates the development of 3D models and allows for quick updates and modifications. Additionally, CAD software simplifies the translation of designs into programming languages for fabrication machinery. With CAD, engineers can easily fine-tune parts and quickly identify critical data, such as potential structural weaknesses.
CAD also enables the evaluation of tool paths required for production before cutting begins, which helps prevent costly errors with expensive metals. Moreover, CAD simulations allow users to estimate supply and delivery timelines, providing insights into production durations and helping to optimize scheduling.
Laser cutting is the industry standard for precise, quick manufacturing. A strong laser may create precise incisions in sheet metal by actually melting the metal. Under this process, a laser beam is combined with high-pressure gasses- usually nitrogen or oxygen. A cutting head moves over the metal plate to produce an exothermic reaction that results in precise cut details. When performed by experienced users, laser equipment can also be used to etch material, however a laser engraver made expressly to etch and mark materials can perform the task more effectively. On the other hand, laser engraving equipment isn't specifically designed to cut through materials. Although both devices are designed to perform specific tasks better, they are often used interchangeably.
Plasma cutting uses a focused stream of ionized, highly heated plasma to cut through metal. As a thermal cutting method, plasma cutting relies on intense heat to achieve its results. While the three traditional states of matter are solid, liquid, and gas, plasma is the fourth state, characterized by its high concentration of charged ions and electrons. Despite often being overlooked, plasma is highly effective in metal cutting.
Plasma arc cutters are popular in metal fabrication due to their fast cutting speed and precision. These advantages make plasma cutting a cost-effective choice that maintains high cut quality. As a result, plasma cutting is rapidly becoming a preferred method in the metal fabrication industry.
One of the most rapidly expanding machining techniques today is using a water jet cutter, a piece of manufacturing equipment that has actually been around for decades. Water jet cutters use a water jet with high pressure and velocity to cut through metal or, virtually any, other material. The material is sliced through by a jet of fast-moving water discharged from the cutter's nozzle after it is coupled to a high-pressure water pump. They can also mix water and abrasive material to boost cutting power. This is a concentrated and accelerated version of natural water erosion.
Power scissors can operate using either batteries or an electric source. Typically resembling a knife with dual blades at one end, these scissors are designed to cut through a range of materials including fabrics, paper, and other softer substances. In some cases, they may also be used to cut very thin layers of metal.
Carbon steels are the most common metals for industrial use and the ones that metal fabricators utilize the most since they can be used for anything from the construction of buildings to the assembly of various machines. Carbon steels are also referred to as low-carbon steels or plain-carbon steels. Despite being very cheap and with low tensile strength, they are appropriate for many uses. In addition, they are malleable and pliable. These materials are simple to work with and popular among fabricators because there are many different methods to finish them. The strength and durability of carbon steels are well known. They can endure extreme conditions in industrial locations and are easily accessible in various thicknesses and stock sizes.
Stainless steel is well-known for its silver mirror finish and is favored by fabricators for its ease of use. Its composition includes chromium, which provides excellent corrosion resistance and prevents rusting. Additionally, stainless steel is highly suitable for welding and bending, making it a popular choice for applications that require durability and resistance to corrosion.
Aluminum is a popular choice in manufacturing for applications where a lightweight metal is needed. Its low density makes it ideal for projects in industries such as automotive and aerospace, where reducing weight is crucial. Despite its lightness, aluminum is also strong and possesses excellent thermal properties. Its versatility further enhances its suitability for a wide range of uses.
Brass alloys, primarily composed of copper and zinc, are known for their high malleability and low melting point, making them easy to cast. Their attractive reddish-yellow color often makes them a choice for decorative applications. Additionally, brass is used in various medical devices for its antibacterial properties that help combat diseases and microbes. Brass can also be customized by adjusting its composition to enhance specific properties such as strength, machinability, and corrosion resistance.
Bronze is a copper alloy with tin as its main component. It is resistant to corrosion and metal fatigue, especially corrosion brought on by seawater. Additionally, it is a good heat and electrical conductor. Bronze is also strong and malleable.
Copper is a naturally occurring metal that can be used directly without additional processing. It is valued for its excellent electrical and thermal conductivity, as well as its ductility, malleability, and softness. These properties make copper an ideal material for wiring and various industrial machinery components. Additionally, copper is a key ingredient in alloys such as bronze and brass.
Titanium is a lightweight yet exceptionally strong transition metal. It is highly resistant to corrosion from seawater and chlorine, making it a common choice for desalination plants. Titanium also bonds effectively with bone, which makes it valuable for medical applications such as joint replacements. Additionally, it offers good electrical and thermal conductivity.
Structural steel is a specialized form of carbon steel used in the construction of bridges, buildings, and other structures. It contains up to 2.1% carbon by weight, making carbon the second most important element in steel after iron. Increasing the carbon content enhances the steel's strength but reduces its ductility. The specific carbon content required depends on the intended use of the steel. Because safety and quality standards for structural steel vary by region and country, it is often produced to order to meet these specific requirements.
Type of Material: Steel comes in many varieties, and slight adjustments in the metallurgical composition of an iron and carbon alloy can significantly alter its tensile strength, flexibility, and hardness. Purchasing steel from a reputable supplier ensures that these key properties meet high standards. Reliable suppliers provide steel made to precise specifications tailored for its intended use. For instance, carbon steel, valued for its hardness, is often used for barriers, whereas welding applications require steel with lower elasticity. Working with an established supplier helps ensure that the steel's properties align with the specific requirements of your project.
Finishing: Despite the binding of carbon atoms to iron in a steel alloy, the risk of oxidation remains, necessitating protective measures. Steel barriers, for example, can be coated in various ways. Powder coating not only enhances appearance but also offers protection, while hot zinc spray treatments provide a cost-effective solution for improving corrosion resistance. Galvanizing steel through a hot zinc dip, though more time-consuming and expensive, offers superior protection and has traditionally been preferred for many fabricated metal applications.
Design: Effective design is crucial for any steel application, impacting the feasibility, structural integrity, and efficient use of resources. The design phase involves creating detailed 3D CAD blueprints, a computer modeling technique that allows for thorough evaluation, adjustment, and finalization before the manufacturing process begins.
Fabrication: Each fabrication job is unique, requiring a tailored approach. As previously discussed, various metals and fabrication processes are better suited to different projects. Fabrication is a collaborative process involving the expertise of multiple specialists to achieve the best results.
Contract manufacturing is a business model in which a company hires a contract manufacturer to produce its products or components of its products. It is a strategic action widely adopted by companies to save extensive resources and...
Sheet metal fabrication is metal that has been formed into thin and flat sheets which is then cut and bent into various shapes. Different metals, brass, steel, copper, tin, titanium, aluminium, etc., can be made into sheet metal...
Stainless steel can be fabricated using any of the traditional forming and shaping methods. Austenitic stainless steel can be rolled, spun, deep drawn, cold forged, hot forged, or stippled using force and stress...
Secondary manufacturing processes, or fabrication, work on products from primary processes to create a metal part or structure that is suitable for end-use. In these processes, semi-finished metal products are reshaped and joined...
Laser cutting is a non-traditional machining method that uses an intensely focused, coherent stream of light called lasers to cut through the material. This is a type of subtractive machining process where the material is continuously removed during the cutting process...
Plastic fabrication is the process of designing, manufacturing, and assembling a product made out of plastic material or composites that contain plastic. There are numerous plastic fabrication methods known today, considering...
Water jet cutting is a manufacturing process that uses high pressure jets of water provided by pressurizing pumps that deliver a supersonic stream of water to cut and shape various types of materials. The water in water jet cutting is...