Types of Metal Fabrication Processes and Their Applications

It is important that a material undergoes several metal fabrication processes before you use it for your assembly and manufacturing tasks. These metal manufacturing processes could vary, and this depends on what you intend to use the metal for. However, you can use them in several decorative, industrial, or structural applications. There are different types of metal fabrication projects.

In most cases, manufacturers combine one type with other types. These methods include any or some of stamping, casting, cutting, extrusion, etc. Also, these methods of metal part fabrication reveals a metal’s properties and how versatile it is in specific applications.

What is Metal Fabrication?

Metal fabrication is a process for cutting, shaping, and molding metal materials to create an end product. Rather than assembling the product from pre-prepared components, fabrication deals with the use of semi-completed or raw materials for producing the final product. Metal fabrication manufacturing is useful for both stock and custom products.

You can create most custom products from different commonly-used metals as well as their alloys. These metal fabricators usually begin with raw metal components like rods, bars, sheets, etc. for creating new products.

Equipment manufacturers, resellers, and contractors make use of metal fabricators when handling different projects. Fabricators usually submit their drawings to bid on different jobs and then start building the project once they get the contract. They start planning by getting the right materials. Next is to hire the professional services of an engineer to program the CNC machines.

Also, fabrication shops might utilize many processes for creating the end product. Furthermore, they offer finishing services like coating, polishing, painting, and deburring to the end product. Note that, finishing and fabrication differ.

Finishing is not a primary process, in contrast to metal fabrication, and it helps in treating a product’s exterior. On the other hand, fabrication techniques shape a product or create a new one.

Different Types of Metal Fabrication

Selecting a particular method for your metal fabrication that suits a specific product is dependent on some factors

• Geometry of the designed part
• The materials you use
• The intended purpose of the product

Below are the processes of metal fabrication:

Casting

Casting occurs when molten metal is transferred into a die or mold and left to cool down and harden, taking the desired shape. Also, this process is perfect during bulk manufacturing of parts, reusing the mold to produce similar products. Casting comes in different forms, including die casting, semi-permanent mold casting, permanent mold casting, etc.

Die casting is the process of forcing liquid metal into a steel mold. The mold is a die. During die casting, you place the metal you’re injecting under high pressure and kept in place to harden. This procedure is great for high-speed applications.

Semi-permanent mold casting features expandable cores, which makes them less expensive to remove and manageable. For permanent mold casting, metal components manufacturers can produce stronger castings compared to when using die casting. However, removing them from the end product could be difficult.

There’s sand casting as well. With this process, you can create casting by pressing a specific pattern into a sand mixture. This creates a mold, where you can pour in the molten metal. It is a slow process but is less expensive compared to other casting types. Also, it is useful when dealing with complex designs.

Cutting

This is one of the most common metal fabrication methods. It deals with splitting a metal workpiece into smaller bits. While the oldest cutting method is sawing, modern methods for cutting include power scissors, waterjet cutting, laser cutting, etc.

You can engage in cutting in different ways, these include the use of power tools, manual tools, and CNC cutters. At times, cutting could be the initial stage in fabrication or it may be the only process.

Another type of cutting is die cutting. This cutting process makes use of a die for slicing metal. Dies are specially designed tools that have sharp edges. Rotary die cutting makes use of a spinning die for cutting material, which you then feed through the press.

You can also use flatbed die cutting. This cutting method also serves thicker metal materials and for cutting out shapes.

Punching

Punch presses feature well-shaped turrets that aid in striking metals through dies, which creates holes. Whatever product results could be perforated metal pieces that help in fastening. You can achieve smaller punches manually, while the majority of punch presses are mechanical. Also, CNC punch presses have become common and are suitable for light and heavy Metalworking.

Drawing

Drawing makes use of tensile force in pulling metal through and inside tapered dies. This die transforms the metal to take a thinner shape by stretching it. You can draw at room temperature in a process called cold drawing.  However, you can heat the workpiece to help in reducing the necessary force.

The process is also deep drawing whenever the depth of the final product is higher than or equal to its radius. Most times, it uses a suitable die setup to transform blank sheets into vessels having a box or cylindrical shape.

Folding

Folding is a process of metal fabrication that allows you to manipulate metal to bend at a specific angle. Using a brake press is the most frequently used, as it pinches the metal to create creases in it. Also, you place the workpiece between the die and the punch, with the punch delivering pressure that forces it to crease.

The process helps in shaping the metal sheets. Also, you can achieve folding by hitting the workpiece till it bends. You may also make use of a folding machine. This machine features a front panel, which lifts upwards. This causes the extended metal to bend, a flat metal surface where you can place your flat sheet, and a clamp that ensures the workpiece stays in place.

Welding

Welding allows the joining together of at least two metal pieces by combining pressure and heat. This process is well-known because the individual pieces could take any size, form, or shape. Some well-known welding procedures include MIG welding, Arc or Stick welding, Flux Cored Arc welding, and Tungsten Inert Gas (TIG) welding.

Metal Inert Gas (MIG) Welding or Gas Metal Arc (GMA) Welding utilizes an external gas supply with a solid wire electrode for offering protection against environmental factors, ensuring that welding happens faster and is continuous. Also, this shielding gas helps to create less fumes during welding.

Arc or Stick Welding makes use of an electrode stick, which creates an electric current. This current creates an electric arc whenever it touches the metal. The arc’s high temperature welds the metal.

Flux Cored Arc Welding works with similar equipment and fabricating techniques as the metal inert gas welding. Here, a wire electrode which contains a core that manufactures shielding is used, so there’s no need for a secondary source of gas.  This welding technique is more portable compared to the stick or MIG welding types. However, you cannot use this welding method on thinner sheets.

Tungsten Inert Gas (TIG) Welding makes use of tungsten electrode rods for creating short arcs, which are useful in welding heavy metals during heavy fabrication. With TIG welding, you need a professional in the field, because it is a very difficult process. However, it is useful for complex tasks and the majority of finished metal products.

Forging

Just like cutting, forging is one of the oldest metal fabrication techniques. If you worked with this, you’ll surely have the idea of a blade hammering a solid anvil block.

Till date, forging is a reliable method, still used for shaping metals into different sizes. Also, forging comes in different types. These include open die forging, hot forging, and cold forging. While each method comes with its unique features. They are all similar in their utilization of the forces of compression in pressing, bending, or shaping a metal to take the chosen form.

Extrusion

The process of extrusion is non-specific to metals because you can also use it in manufacturing polymers and plastic products. Moreover, they are useful in profile making for sectional components or for aluminum or steel beams.

During extrusion, a solid billet made from metal or alloy passes through the tooling die, which contains a unique cross-section. You can achieve this using a high-pressure and high-powered hydraulic system, which allows the die to shape the billet. Immediately you eject the extruded product, then you may subject it to post-processing measures to get rid of defects, give it a better appearance, and make some adjustments.

An aluminum extruded profile is the most used application for extrusions. They are useful in making door and window frames, mullions, railings, etc. Though aluminum is non-corrosive, manufacturers usually add an additional powder coating layer to the material. This gives it a better aesthetic look and makes it long-lasting.

Machining

Machining is another method of metal fabrication that involves removing material from work to shape it. You can perform this process in different ways. Machining offers different processes. Let’s consider them.

Drilling:

This process creates holes in materials using drill bits. These drill bits usually press on the material and rotate quickly to create circular holes.

Turning:

Turning rotates the metal using a lathe, while the cutting tool moves linearly to get rid of metals along its diameter. Also, you can angle the cutting tool differently in order to create several shapes. You may achieve this using a CNC turning machine or do it manually. Generally, CNC machining is necessary when you must be very accurate with part measurements.

Milling:

This metal product manufacturing method makes use of rotating cutting tools to take out materials from your workpiece till you get the preferred shape. During milling, you pass the metal slowly into the cutting tool.  You can also perform this operation manually or by using a CNC milling machine.

Generally, milling is a finishing process. However, you can use it as the main technique for your metal fabrication. Milling also comes in different types including climb milling, angular milling, form milling, face milling, etc.

Metal Stamping

This process is specifically useful for sheet metals such as aluminum, brass/copper, stainless steel, etc. You may also use this procedure with other methods of fabrication to achieve the required result.

One important application of the stamping technique is seen in the assembly and manufacturing of automotive components. Also, this method helps in designing the components of vehicles including wheel hubcaps, firewalls, trunk lids, etc.

Another reason why l stamping is great for automotives is the ability to use it to create custom-built and unique designs. Car enthusiasts and manufacturers can capitalize on this method and create components for their vehicles.

Shearing

Shearing is a process whereby you can achieve a straight and long cut through the use of two tools, one tool is placed above the metal, while the other helps to apply pressure and is located beneath it l. The upper blade pushes down the metal to the stationary blade, fracturing it as a result. This fracture now spreads inwards to achieve full separation.

In addition, shearing is great when cutting materials with different shapes and for cutting small lengths. This is possible because you can mount the blades at angles to help in reducing the needed force.

Which Metals are Usually Fabricated?

Ductility (or formability) is the key material properties that define whether you can fabricate a metal or not. Highly ductile materials like aluminum alloys are easy to process with different types of metal fabrication processes, whereas it might be difficult for stainless steel.

Carbon steels

You can use carbon steels across different industries due to their properties. You can use these metals in construction, machine assemblies, and other high-end applications. They are versatile and can withstand various working conditions. Aside from these benefits, carbon steels are very durable and can resist wear.

Aluminum

This lightweight metal is suitable for use in manufacturing. Due to its low density, you can use aluminum in the aerospace and automotive industries. This is because it is important to maintain low weight in such applications. It has a high strength-to-weight ratio and good thermal properties, which makes it excel in almost all applications.

Bronze

Bronze is a less popular choice among metals. This material comprises a large percentage of tin. Also, bronze is wear resistant and corrosion resistant. As a good conductor of heat and electricity, this material is ideal for use in the manufacturing industry.

Brass Alloys

Brass alloys are a combination of zinc and copper. These metals are malleable and have low melting points. Their reddish color sets them apart from other metals.  Due to their attractive look, you can use them in applications where aesthetics is a major concern.

Also, brass alloy features antibacterial properties which makes them useful in the medical industry. You can use this material to fight diseases. Also, you can customize this metal to your desire based on its composition.

Stainless Steel

Stainless steel is known for its ability to resist corrosion and rust and durability. It has a fine, mirror-like finish, which enhances its appeal. Therefore, it is highly preferred among manufacturers. Also, you can bend and weld this metal according to your desire.

Copper

This metal doesn’t need to go through extra processing before you can use it. Copper has good properties like thermal and electrical conductivity, malleability, softness, tensile strength, and ductility. Due to these properties, you can use copper in many high-performance applications.

Structural Steel

This type of steel is commonly integrated into the construction industry. You can use it in the construction of buildings and other structures like bridges, tunnels, etc. Structural steel comprises about 2.1% carbon. To achieve great strength, you can increase the amount of carbon present in this steel. However, doing this will reduce the steel’s ductility.

In some applications, you need to consider the amount of carbon you need. You have to ensure the carbon content meets the requirements of your desired project and some specific standards.

Titanium

As a lightweight metal with high resistance to corrosion, titanium has become a preferable choice among fabricators. You can use this steel in medical projects that have to deal with joint replacements. Its capability to bond with bone makes it suitable for medical applications.

What Technologies Can You Use During Metal Fabrication?

You can integrate different types of metal fabrication technologies during the metal fabrication process. Here are some common technologies you can rely on;

Laser Technology

If you want to achieve precise and prompt manufacturing of metal, this method is the best you can integrate. This technology requires you to make accurate incursions on sheet metal with the help of a laser. This laser achieves this by melting, at a temperature over 1000 degrees. During this process, you will need to combine a laser beam with oxygen or nitrogen.

You can use laser equipment to etch material if properly carried out with expertise. To achieve a better outcome, you can use a laser engraver solely designed to etch materials.

CAD Software

CAD which stands for Computer Aided Design, is a popular software used in advanced applications like metal manufacturing. With this software, you can create designs that help you all through the fabrication techniques. CAD enables you to create 3D models which you can update anytime.

Also, CAD helps you to translate the designs you created into programming language. This software is highly reliable, making it a preferred choice amongst engineers. As an advanced software, CAD allows you to detect important data during the fabrication process.

Plasma Cutting

Plasma cutting is a common technology used in fabrication. In this process, you can cut through metals by using hot plasma. It is a thermal cutting process that uses intense heat. Plasma comprises charged electrons and ions, which are accelerated and collide before forming a concentrated plasma torch.

Automation

The automation process uses programming capabilities during fabrication. It is a sophisticated technology which allows you to use machines to carry out specific tasks based on some specifications or settings. This automation process doesn’t really require human intervention. The benefits of automation outweigh its weaknesses. This method improves consistency and accuracy while minimizing operational costs.

What are the Pros and Cons of Metal Fabrication?

Pros of Metal Fabrication

Metal is a strong, durable material that is resistant to damage. This material can stand the test of time despite its exposure to rigorous use. Therefore, metal fabrications can last a long time without the need to replace them. You can consider them as a great option in applications that require durability.

There are various applications where you can integrate specialized fabrication. These days, it is easy to tailor metal fabrications based on your preference. Therefore, you can get a suitable design and size for your intended project. Below are the key benefits;

Versatility

Metal is versatile in nature as it is widely used in many applications. From construction to manufacturing, custom metal fabrication processes play a crucial role in these applications.

Competitively priced

Metals are competitively priced products which are considered a perfect option for the production of a wide range of items. Also, they are considered a cost effective alternative since they are durable. Integrating this material into your project will help you save more money. Also, metals are more affordable which makes them a good option for use in applications where cost is a cause for concern.

Simple to maintain

Metals are a good material that requires low maintenance, all thanks to their corrosion -resistance property. Due to their ease of maintenance, you can use them in outdoor applications. As a fire and heat resistant material, you can use them in extreme temperatures. Due to their thermal properties, metal fabrications are great for both industrial and commercial use.

Cons of Metal Fabrication

Initial costs may be higher

Although it is cheaper in the long term to create items from a raw metal material based on durability, the initial cost may be more compared to other materials

Longer time

Using metal fabrication may take a longer period, especially when there is a need for customized tooling.

More finishing procedures

Once fabrication is completed, there’s a high chance that some metals will require more finishing procedures such as deburring and painting. This could delay production as well as increase the overall prices.

Design constraints

During the construction of complicated systems, metals may experience design constraints. This could lead to components having different sizes, small sizes, or unusual forms.

What are the Applications of Metal Fabrication?

Below are some of the areas where metal fabrication can be applied:

Aerospace

You can use metal fabrication in aircraft. These include commercial airplanes and military planes. This field cannot exist without the use of metal fabrication.

Construction

Most engineers and architects prefer using metal fabricated products/parts for their tasks. The important framework for warehouses, bridges, buildings, and many mega structures are manufactured from steel ladders, girders, beams, platforms, and handrails, which are manufactured by metal fabricators. You cannot talk about construction without discussing metal fabrication.

Shipbuilding

Items used for metal fabrication are important in different equipment used in shipbuilding. Some of the items are ladders, steel flooring, conveyance tubing, platforms, stairs, etc.

Hardware Manufacturing

Manufacturers deal with fabricating metals for use in different hardware components and this is why computers have been able to spread far and wide. Metal fabrication has ensured that computer systems stay strong for both office and home use for almost 40 years.

Mining

Steel is very important in the mining sector because a majority of tools used here i.e. pickaxes, shovels, bulldozers, etc. need steel while constructing them. Funny enough, steel can be viewed as a byproduct of mining because it cannot exist in the absence of the metals needed to manufacture it.

Military

The military industry works with metal fabrication for various items. These include body armor, aircraft, ammunition, subs, etc.

Energy

The energy sector also works with metal fabrication. These include businesses producing electricity from nuclear sources, sun, oil and gas, etc. Some goods used in the energy field that are manufactured through metal fabrication include electromagnetic shields, transmission towers, transformer cores, wind turbines, pipelines, electromagnets, etc.

Conclusion

Metal fabrication is important in many industries and that is why it is important to understand the types of metal fabrication as well as the needed accuracy to achieve high-quality components. Regarding metal fabrication, it is important to work with a professional service provider.

This is where RapidDirect comes in. They work with recent technology and are focused on providing great results. Whatever your needs are, be it custom metal parts fabrication, prototyping, or large-scale manufacturing, RapidDirects’ advanced metal fabricating facilities can deliver competitive pricing, efficiency, and accuracy.

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