Four Metal Fabrication Processes 101

The use of metal to produce different materials for industry, office, and home use is a common practice that has existed for years. In the manufacturing industry, metal is fractured into various forms using suitable methods to shape them for further use. This article will provide basic information on metal fabrication and its processes. 

What is Metal Fabrication?

Metal fabrication is building structures by fusing pre-made metal of different materials to produce final products. Raw metal materials such as sheets, bars, and strips are coupled into various components, further joined into a final product. The fabrication process involves cutting, drilling, folding, and assembling methods. Here are the four most common processes used for metal fabrication.

4 Metal Fabrication Processes

Cutting

The cutting process is a popular and widely used method in a fabrication process; this method is used for splitting a single and substantial raw metal such as a sheet into smaller parts. Typically, the metal materials are newly produced and have not been formed; on the other hand, ready-made metals are provided for cutting in other processes.

Different tools are used in cutting, ranging from simple machines such as manually operated cutting torches to complex devices such as lasers.  

Folding

Although popular, this method is one of the most complicated methods in metal fabrication processes. The folding process involves bending a metal surface to form at a precise angle, usually 90 degrees but can be lesser or more. This process can only be carried out in factories with advanced tech machines due to complex processes. Coupling two metals at certain angles is an ideal option when a fold is required.

Casting

The casting process in a manufacturing industry involves melting metal and pouring the molten metal into a mold of the desired shape. The selected shapes are created using affordable and quick forming material; then, pour the molten metal into the mold with a hollow cavity of the desired shape and leave it to solidify. When the metal solidifies, it takes the form of a hollow cavity; the solidified metal part is removed to complete the fabrication process.

Welding

Welding is one of the most popular fabrication processes to fuse different metal parts. This method involves melting metal in the form of a rod into an already made joint to form a structure. The metal parts could be in the form of sheets or panels. Welding is achieved by introducing heat energy on the joining points of the metal parts. There are four different types of welding technologies which include:

1. MIG-Gas Metal Arc Welding (GMAW): Is used in the auto industry to repair car exhausts.
2. TIG-Gas Tungsten Arc Welding (GTAW): Aside from industrial fabrication, it is also used by aerospace and auto. It is one of the most rigid metal materials as it neither dissolves nor burns off.
3. STICK- Shielded Metal Arc Welding (SMAW): This portable stick welding is used to construct and maintain underwater pipelines and industrial fabrication.
4. FLUX-CORED-Flux- Cored Arc Welding (FCAW): This is often used for welding thicker metals; it requires steady wire and power supplies.

How do I choose the most Suitable Process for my Project?

There are no precise “best methods” to choose from if you are trying to work on a metal project because complex projects often require various fabrication processes. It can be tricky to go for a particular method, and once you choose the wrong one, it can complicate the whole process and increase final production costs.