Guide to Metal Fabrication: Types of Fabrication Process and Material Selection | CNCLATHING

2020.5.22

What should you know about metal fabrication and the techniques involved? Start with the types of fabrication processes and material selection, and choose the right technology and metal to get your desired parts. 

What is Fabrication/Metal Fabrication?

Fabrication is the act of producing a product, the fabrication process typically gives the metal material its desired shape or structure through some essential steps.


Metal fabrication is the creation of metal parts or structures from a variety of metal materials through different processes. The metal materials come in sheet, bar, plate, or other forms and can be made into specific shapes and dimensions. Metal fabrication needs a thorough plan and strategy to ensure the success of actual work. Technique and material selection is important before the process. 

Fabrication vs Manufacturing, What Are the Differences Between Them?

Fabrication and manufacturing sometimes overlap in usage, especially in complex production processes that involve both manufacturing and fabrication stages. To understand these two terms clearly, what are the differences between them?

1. Definition

– Manufacturing: The process of converting raw materials into finished products.

– Fabrication: The process of assembling standard parts to design or create a product.

2. Starting point

– Manufacturing: Begins with raw materials.

– Fabrication: Begins with pre-made, standardized parts or components.

3. Scope

– Manufacturing: Generally covers the complete production process from raw materials to finished goods.

– Fabrication: Often focuses on a specific stage of production, typically assembly or construction.

4. Industry usage

– Manufacturing: Commonly used in contexts involving mass production or large-scale industrial processes, applied in a much broader scope and includes industries like automotive, electronics, chemicals, textiles, etc.

– Fabrication: Often used in custom or specialized production, construction, and assembly work, commonly used in industries like steel and metal works. 

5. Automation

– Fabrication processes like cutting and welding can be automated using CNC machinery. 

– Manufacturing processes often rely more heavily on automation from raw material processing to finished product assembly.

Types of Fabrication Process

There are various types of fabrication processes or techniques applied in modern production, choose the right metal fabrication method based on the material, tolerances, strength requirements, quantity, surface finish, and other factors. 

– Cutting: a basic fabrication process where the material is cut into smaller sections or parts. It can make the sheet metal into pieces of the required size and shape. The cutting process involves the use of different tools.

– Forming: a metal fabrication process that involves bending, distorting, or shaping metal to produce parts and components without losing its mass, and can be applied to various material forms, including sheets, plates, and others, to produce simple components to complex assemblies. 

– Forging: using the pressure from a hammer or die when it striking to the metal to shape it. Cold forging, warm forging, or hot forging are determined by the temperature. 

– Casting: pouring the molten metal into a mold or die and allowing it to cool and harden into the desired shape. It is suitable for mass production. There are die casting, vacuum casting, sand casting, and more types.

– Extrusion: the process of creating objects of a fixed cross-sectional profile, the metal is pushed through a die of the desired cross-section. It can create very complex cross-sections and excellent surface finish. 

– Punching: employs specialized equipment and tooling to create holes, profiles, and forms in sheet metal or other flat materials. This process involves a punch press that drives a punch tool through the workpiece at high speed, forcing it against a die to cut out sections or create customized patterns. 

– Drawing: using the tensile force to pull metal into and through a die, a thinner shape is generally formed after the stretching. When the depth of the structure is equal to or greater than its radius, the process is considered a deep drawing. Drawing is a common way to produce wires.

– Welding: fuses materials, primarily metals, through the application of intense heat and pressure. Welding can be performed manually or with robotic assistance, depending on the project’s scale and intricacy. It serves as a fundamental step in metal fabrication, often employed as the final stage to unite components such as sheets, panels, bars, and custom shapes. 

– Shearing: also known as die cutting, is a method that cuts stock while not forming chips and does not involve burning and melting, it produces less waste and heat compared to cutting, but lacks precision. 

– Stamping: transforms flat metal sheets or coils into desired shapes using a stamping press equipped with specialized tools and dies. Stamping can be executed as a single-stage operation, where one press stroke produces the finished part, or through a series of stages for more complex shapes.

Metal Fabrication Materials Selection

To metal fabrication manufacturers, the understanding of metal types, looks, characteristics, machinability and properties are essential. Let’s define the metal material into different categories and explore the characteristics and usages of different materials, to know what process is required for the certain material or what material you should choose for your project. CNClathing.com works with a wide range of metal grades for our CNC machining services

 

1. Hardness

Soft Metals: Aluminum, Magnesium, Brass, and Copper

Hard Metals: Steel, Stainless Steel, Chrome, and Titanium

 

2. Machinability 

Easy to machine: carbon steel (1212, 1213, 12L14), aluminum (cold drawn, cast), magnesium (cold drawn, cast)

Difficult to machine: tool steel, gray cast iron, stainless steel (except 416), alloy steel

Common materials in metal fabrication

Aluminum

Pure aluminum is a soft metal that is highly malleable, not suitable for mechanical applications. Add other elements can make aluminum stronger, aluminum alloy products can be used for aerospace, automotive, and more industries. Commonly used aluminum alloys for CNC machining are including 6061, 6063, 7075, 2024, etc. Check out the properties and more information about aluminum at CNClathing.com.

Magnesium

Magnesium is the lightest of all structural metals, with strength close to aluminum, often used for production of camera and cell phone bodies, power tool frames, laptop computer chassis, transmission cases, seat frames, and intake manifolds and more. Magnesium is easy to machine, readily molded and die-cast, but it’s not resistant to corrosion. 

 

Brass

Brass is an alloy composed of copper and zinc, it has strong wear resistance, low melting point, good malleability, and high corrosion resistance, weather resistance. CNCLATHING provide custom CNC machining brass parts like knobs, bearings, gears, valves, sleeves, bushings, lock parts, nuts, etc. 

 

Carbon steel

Carbon steel is a combination of iron and carbon, also known as mild steel, frequently used structurally in buildings and bridges, axles, gears, shafts, rails, pipelines and couplings, cars, and fridges. High carbon steel gets a higher tensile strength, which makes it a preferred material in fabrication of cutting tools, blades, springs, dies, punches, and more. 

 

Stainless steel

Stainless steel is an alloy of iron with a minimum of 10.5% chromium, remarkable as its high corrosion resistance and rust-proof. The ease of cleaning makes stainless the first choice for strict hygiene conditions, such as hospitals, kitchens, abattoirs and other food processing plants. Common stainless steel grades are 304 and 316. 300-series stainless steel is very tough and can’t be hardened. Stainless steel 300-series are not easy to machine, but they are often used for medical instruments, vacuum and pressure vessels. 

 

Titanium

Titanium a transition metal, which is lightweight, strong, and corrosion-resistant,with tensile strength almost twice that of any mild steel but weighs just half as much, an ideal choice for aerospace industry, its biocompatibility make titanium a reliable material for bone screws, pins and plates

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