Metal Fabrication Processes: Understanding the Different ...

Metal Fabrication Processes: Understanding the Different Types

In what can be called the Modern Industrial Age, there's metal all around us.  To list the litany of ways in which metal impacts our lives would take a lifetime.  With that being said, have you ever stopped to ponder how metal is shaped, formed, and treated for the desired outcome?  That broad definition can be summed in three words: metal fabrication processes.

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Indeed, metal fabrication is an umbrella term that most people can't wrap their heads around entirely.  Luckily, the experts at Meta Fab are here to help you develop a basic understanding of what this process involves in a little more depth.

Let's take a closer look.

Forging

Forging is a common practice for intricate metalwork.  The process involves using forced compression to achieve the desired shape.

Done by hand, forging involves heating metal to the point that it can be bent, shaped, and formed with the use of a hammer or die strikes.

One of the oldest forms of metal fabrication processes in existence, forging is still widely used by blacksmiths and fabricators for detailed and artistic work to this day.

Casting

Whereas forging metal is something that's done by hand, casting is the process of pouring molten metal into a mold.  From there, it's cooled to the point that it becomes hard.

Casting is widely accepted as the go-to process for mass-produced products where the same mold can be used over and over again with minimal variance in the final outcome.

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Drawing

This fabrication process utilizes tensile force to pull metal into a tapered die.  This stretches the metal into a thinner shape.

Drawing is most commonly used in sheet metal fabrication processes where the final product is a box-like or cylindrical vessel.

Forming

Just as the name would suggest, forming is the process of bending metal to the desired angle.  This is most often accomplished with a brake press that applies pressure to metal so that a crease is formed.

Other forms of folding can be done with the use of a hammer with clamp bars that hold the metal in place.

Machining

Machining is a subtractive shaping process that removes unwanted material to create a form.

Within this substrate, there are several different forms including drilling, turning, and milling.

Turning uses a lathe to rotate metal at a speed that allows cutting tools to remove the metal in a circular fashion.  A CNC machine is the most common tool used for turning and often involves precise measurements.

Just like it sounds, drilling uses a bit to protrude a hole in the metal.  Simple enough.

Lastly, milling is very common among the metal fabrication processes by which multi-point cutting tools remove metal from the workpiece.  CNC machines are also used for this process which normally functions as a final finish process to create a desired texture or appearance.

Extrusion

During extrusion, metal is forced between an opened or closed die.  Here, the piece of metal is reduced to the cross-section of the die.  As a result, a cavity is formed.

The end result is usually a cylindrical shape that's common in piping or wiring.

Cutting

One of the most versatile metal fabrication processes is cutting.  On the surface, the process is nothing more than cutting large pieces of metal into smaller ones.

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Cutting is quite intricate and involved, however.  Technology like lasers, waterjets, power scissors, and plasma are all utilized to create exacting cuts.

Depending on the project, cutting is often the first, if not only, process used in fabrication.

Punching

This process creates holes in a workpiece.  Punch presses have specially designed turrets that hit the metal through a die to produce holes in specific locations.

Punching is used in both light and heavy metalwork.

Stamping

Akin to punching, stamping involves creating indentations in metal, instead of holes with the use of a press or handheld hammer.

The most common applications for stamping are creating letters, shapes, and images.

Welding

Welding is the art of adjoining two or more pieces of metal through a mixture of heat and pressure.  This process is most common in large scale or industrial fabrication projects.

It's popular because various pieces of metal can be conjoined no matter their shape or size.

Depending on the project, the most common types of welding include MIG, stick and arc, TIG, and flux-cored arc.

Final Thoughts on Metal Fabrication Processes

Metal fabrication is easy to understand at an elementary level.  With that being said, the numerous metal fabrication processes involved are each unique and highly detailed.  Knowing the basic tenets of each is key to undertaking any metal fabrication project.

At MetaFab, we pride ourselves on being experts in many of the metal fabrication processes named above.  Furthermore, it's our goal to help you understand how each process is carried out from start to finish.

If you have questions about a particular metal fabrication processes, or which one is best for your project, give us a call today.

Metal fabrication plays a crucial role in various industries, from manufacturing to construction. Understanding the different methods of metal fabrication can help businesses optimize their production processes and create high-quality products. In this article, we will explore the three main types of metal fabrication techniques and their applications in different industries.

Introduction Metal fabrication is the process of shaping raw metal materials into finished products through a series of techniques such as cutting, bending, welding, and machining. This process is essential in various industries like automotive, aerospace, and construction, where customized metal parts are required for different applications.

Traditional Metal Fabrication Methods

Welding

Welding is a common metal fabrication technique that involves joining two or more metal pieces together using heat and pressure. There are several types of welding techniques, including MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), and stick welding. These techniques are used in industries like automotive, construction, and shipbuilding to create strong and durable metal structures.

Machining

Machining is another traditional metal fabrication method that involves removing material from a workpiece to create a desired shape or size. Operations like milling, turning, and drilling are used to cut, drill, and shape metal components for various applications. Machining is widely used in industries like aerospace, medical, and electronics for producing precision parts with tight tolerances.

Sheet Metal Fabrication Techniques

Laser Cutting

Laser cutting is a modern metal fabrication technique that uses a high-powered laser beam to cut through sheet metal with high precision. This method offers advantages over traditional cutting methods, such as faster cutting speeds, cleaner cuts, and minimal material waste. Industries like automotive, signage, and electronics commonly use laser cutting for producing intricate metal parts.

Bending and Forming

Bending and forming are essential processes in sheet metal fabrication that involve shaping metal sheets into desired forms. Tools like press brakes, rollers, and dies are used to bend, fold, and stretch metal sheets to create complex shapes. Bending and forming techniques are widely used in manufacturing industries for producing sheet metal components like enclosures, panels, and brackets.

Additive Manufacturing

3D Printing

3D printing, also known as additive manufacturing, is a revolutionary technology that creates three-dimensional objects by layering materials like plastic, metal, or composites. In metal fabrication, 3D printing enables complex geometries, rapid prototyping, and customization of parts. Materials like stainless steel, titanium, and aluminum are commonly used in metal 3D printing for various applications in aerospace, medical, and automotive industries.

Sintering

Sintering is a process of compacting and forming powdered metal materials into solid objects by heating them below their melting point. This method is used in additive manufacturing for creating metal parts with high density, strength, and dimensional accuracy. Sintering has applications in metal fabrication for producing complex components like gears, filters, and medical implants.

Conclusion

In conclusion, metal fabrication encompasses a wide range of techniques and processes that are essential for producing metal components used in various industries.By grasping the three primary metal fabrication methodologies ' traditional techniques, sheet metal fabrication methods, and additive manufacturing ' enterprises can retain their competitive edge and remain responsive to evolving industry dynamics. With technological progress propelling innovation in metal fabrication, there's a wealth of career prospects for individuals proficient in metalworking, welding, machining, and additive manufacturing. Keeping abreast of the latest advancements in metal fabrication is essential for staying at the forefront of the sector and capitalizing on the increasing need for bespoke metal goods.

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