Fab TimesIf you are interested in reading articles about the metal fabrication industry, including robotic welding, lean processes, e-coating, and powder coating, check out our blog, The Fab Times. Sign up to receive new posts as soon as they are published. No spam, guaranteed!https://www.schuettemetals.com/blogTroubled by an admittedly daunting metal fabrication world? Start Simplehttps://www.schuettemetals.com/blog/postid/16/types-of-custom-metal-fabrication-and-their-applicationsFabricationWed, 10 Jun 2020 16:18:00 GMT<p style="text-align: center;"><img alt="Troubled by an admittedly daunting metal fabrication world? Start Simple" src="/Portals/0/LiveBlog/blog/metal-fabrication-process.jpg?ver=-iNJygdxethQA8yaShzBTQ%3d%3d" style="margin-top: 10px; margin-bottom: 10px; width: 900px; height: 452px;" /></p> <p>One thing identifying us as sentient beings is how we can accomplish the same task using different methods. Simple things like adding air to a bike tire. You manually pump or use an air compressor.</p> <p>That same concept applies to metal fabrication.</p> <h2>Custom Metal Fabrication</h2> <p><img alt="Metal Fabrication by Waterjet cutting" src="/Portals/0/LiveBlog/blog/Waterjet-Cutting.jpg?ver=bCvW2yP1oN7CdYQT9CaAbg%3d%3d" style="border-width: 1px; border-style: solid; margin: 15px; float: right; width: 321px; height: 281px;" />Any changes made to metal, such as cutting, folding, welding, etc., are part of the metal fabrication process. Each type of fabrication process means meeting a specific purpose.</p> <p>For instance, cutting, one of the most common metal fabrication processes, divides large sections of metal sheets and plates. In most cases, the cut metal is fresh.</p> <p>Some of the most common metal fabrication processes are:</p> <ul style="margin-left: 40px;"> <li>Cutting</li> <li>Folding</li> <li>Machining</li> <li>Punching</li> <li>Welding</li> </ul> <p>Other methods include:</p> <ul style="margin-left: 40px;"> <li>Annealing</li> <li>Bending</li> <li>Cold Forming and Rolling</li> <li>Drawing</li> <li>Electro-Discharge</li> <li>Extrusion</li> <li>Forge Hammering</li> <li>Laser Cutting</li> <li>Rolling</li> <li>Spinning</li> <li>Water Jet Cutting</li> <li>Wire Cut EDM</li> </ul> <p>Here are some other custom metal fabrication techniques and their applications.</p> <h3><img alt="Different and widely used Metal Fabrication Methods." src="/Portals/0/LiveBlog/blog/metal-fabrication-methods.jpg?ver=ngozo5nEM2CysynfeKk_iQ%3d%3d" style="border-width: 1px; border-style: solid; margin: 15px; float: right; width: 250px; height: 350px;" />Sheet Metal Shearing</h3> <p>Shearing is a metal fabrication method used to cut long metal sheets horizontally. In some applications, the cutting tool vertically cuts against the length of the sheet. Another shearing method moves the metal towards an open cutting blade, like a guillotine paper cutter.</p> <p>The most common use of shearing is to trim the edges of the metal sheet. The resulting products from metal shearing are used in the manufacture of refrigerators, oven side panels, other household appliances, and the automotive industry. </p> <h3>Stamping—The Use of a Die</h3> <p>It is essential to clarify that stamping isn’t the only metal fabrication process to use a die. In some applications, the purpose is making a hole, while in others to raise a part of the sheet metal without punching through it.</p> <p>Stamping creates impressions for letters, images, logos, etc., on a metal panel or sheet. Coins provide an excellent example of the stamping process. </p> <p>The automotive industry stamps part and vehicle identification numbers of components. The electronic industry stamps patent and part numbers, as well.</p> <h3>Casting: Oldest Fabrication Form</h3> <p>Humans have been casting metal for hundreds of years. The process involves pouring molten metal into a mold, which then solidifies. Casting may be the oldest method, but it’s also the most flexible. When fabricating complex shapes, casting becomes the easiest option.</p> <p>Casting overcomes the issues associated with other methods of fabrication—making assembly parts needing folding, stamping, and shearing. </p> <p>Metals like copper, silver, iron, magnesium, and steel are often cast because they are used across various industries.</p> <h2>Common Fabrication Examples</h2> <p>The most typical items produced are metallic cabinets, enclosures, ventilation shafts, hoods, exhaust systems, tanks, and prototypes.</p> <h2>Fabricating Exotic Metals</h2> <p>We've only discussed <em>normal </em>metal, but what happens when you need to work with something <em>different</em>? As we explain in our article, <a href="https://www.schuettemetals.com/blog/fabricating-exotic-metals" target="_blank"><strong>Fabricating Exotic Metals</strong></a>, you need non-standard tooling:</p> <blockquote> <p>Most exotic metals have very different thermal properties than metals such as steels, titanium, or Inconel®, which impacts the type of tooling needed to machine these materials. For example, tools may need to be larger than standard materials.</p> <p>Exotic metals also have different thermal expansion properties than common steels. Therefore, a standard machine tool may not work well for these. Some metals can have thermal gradients 50-100 times greater than steel.</p> <p>Exotic metals generally need a higher spindle speed, higher horsepower, and more horsepower per tooth than steels, which is particularly true when machining hard materials.</p> </blockquote> <h2>Geometric Dimensions and Tolerances</h2> <p>Before turning on a brake press or lighting a welder, make sure you know what you're doing! Work off properly designed and marked drawing from an engineer following geometric dimensions and tolerances (GD&T) guidelines. We explain why this is important in our article, <a href="https://www.schuettemetals.com/blog/gdt-accepted-method" target="_blank"><strong>GD&T Part 1</strong></a>.</p> <blockquote> <p>When producing goods, the manufacturing industry must adhere to several regulatory standards, such as ISO quality management. To do so, manufacturers typically apply the principles of geometric dimensioning and tolerancing to their design and production processes.</p> <p>GD&T allows engineers to communicate the critical aspects of their designs while accommodating variability because of manufacturing processes. This means designers and engineers can effectively communicate with manufacturers uniformly.</p> <p>This standardization in communication is necessary because many manufacturers produce and ship goods globally. Differences in design requirements, engineering conventions, and regulatory standards can cause confusion and delays in the supply chain. GD&T eliminates these issues.</p> </blockquote> <h2>In Sum</h2> <p>When designing any product, it’s important to consider the fabrication process. For example, how it will be manufactured matters.</p> <p>The resulting product may be stronger and more durable depending on the process used. Other factors are also important, like using, cutting, and finishing the type of metal, which makes the choice of the manufacturing process for your next product important.</p> <p>Besides these considerations, each process has its strengths and weaknesses. Learning about each type of fabrication method is important so you can make the best possible decision when fabricating your product.</p> <p>For example, welding is very strong in a welded joint but can’t be bent. It’s strong, but not flexible. Punching, on the other hand, is strong but flexible.</p> <p>As you research the different fabrication options, keep in mind that the most effective one depends on the needs of your project. It’s also important to remember that each process has its upsides and downsides, and it’s up to you to choose the right method.</p> <p> </p> <hr /> <p> </p> 16The naturally destructive force of oxidation, or as most call it, rust!https://www.schuettemetals.com/blog/postid/17/the-transformative-and-destructive-nature-of-rustProtective FinishingWed, 03 Jun 2020 16:18:00 GMT<p style="text-align: center;"><img alt="The naturally destructive force of oxidation, or as most call it, rust!" src="/Portals/0/LiveBlog/blog/rust-naturally-destructive-force.jpg?ver=go913BwNYphOw8y4w5Y1fA%3d%3d" style="width: 900px; height: 436px;" /></p> <p>When growing up, I started collecting beer cans. It was fun discovering the unfamiliar beer cans found worldwide—their designs, what information brewers thought most important to share, and the shapes of the cans.</p> <p><img alt="A pile of cans, most of them quite rusty." longdesc="rusty pile of beer cans" src="/Portals/0/Images/rusty%20beer%20can%20pile.jpg?ver=2020-06-03-110802-297" style="border: 1px solid rgb(0, 0, 0); float: right; margin: 5px; width: 300px; height: 200px;" />It also provided my dad with amusement. Whenever my brother, dad, and I would go bird hunting, I’d invariably spend an impressive deal of time looking for junk piles people left in the woods. Dad, a big-time outdoorsman, spent time with me in the piles looking for cans. The prize finds were the old cone top cans. I’ll always remember him setting the shotgun along a tree, squatting down, and yelling, “<em>found one!</em>” All my brother Dean did was shake his head, roll his eyes, and keep walking.</p> <p>As great as it was finding cone tops, it was also frustrating. The biggest reason? Rust, finding a can that didn’t have at least a light surface covered was uncommon. I researched and tried all methods of removing it but never found a suitable way. Remember, personal computers at that time were found only in sci-fi movies.</p> <p>Seasons changed, and finding anything resembling an excellent catch became harder. Time doesn’t stand still, and neither does rust.</p> <h2>What Causes Rust?</h2> <p>Before solving a problem, you first need to understand it. </p> <p>Rust results from a chemical reaction between iron, oxygen, and water. Although commonly referred to as iron oxide, rust is iron oxide hydrate because pure iron oxide isn't rust. </p> <p style="text-align: center;"><strong>iron + water + oxygen = hydrated iron(III) oxide</strong></p> <p>Even though roughly <a href="https://www.thoughtco.com/chemical-composition-of-air-604288" target="_blank" title="Thoughco.com">21% of air</a> consists of oxygen, rust needs moist air and water. Oxidation doesn't occur in arid regions but <a href="https://www.thoughtco.com/how-rust-works-608461" target="_blank" title="Thoughtco.com">thrives in other areas</a>.</p> <div class="comp mntl-sc-block mntl-sc-block-html" id="mntl-sc-block_1-0-26" style="color: #282828;"> <blockquote>Because of the electrochemical nature of the reaction, dissolved electrolytes in water aid the reaction. Rust occurs more quickly in saltwater than in pure water, for example.</blockquote> <blockquote>Keep in mind oxygen gas (O<sub>2</sub>) is not the only source of oxygen in air or water. Carbon dioxide (CO<sub>2</sub>) also contains oxygen. Carbon dioxide and water react to form weak carbonic acid. Carbonic acid is a better electrolyte than pure water. As the acid attacks the iron, water breaks into hydrogen and oxygen. Free oxygen and dissolved iron form iron oxide, releasing electrons, which can flow to another part of the metal. Once rusting starts, it continues to corrode the metal.</blockquote> <p>Most metals are susceptible to rusting. The only exceptions are rare metals such as gold, diamond, copper, and bronze. Rust occurs whenever exposing metals to natural elements such as rain, sunshine, and air. These elements bring with them water, heat, and oxygen—paramount for rust to occur. In other words, the absence of oxygen prevents rust.</p> </div> <h2>Effects Of Rust On Metals</h2> <p><img alt="Rusty Excavator" src="/Portals/0/LiveBlog/blog/rust-excavator.jpg?ver=HNg8uF-y5fB0Yn1q0ej_Mw%3d%3d" style="border-width: 1px; border-style: solid; margin: 5px; float: right; width: 240px; height: 160px;" />Machinery is made from a combination of metallic substances with other materials such as plastic and wood. The metallic component of machines is most likely to rust in their everyday use if left unprotected. So then, what are the effects of rust on your equipment?</p> <p>When corrosion occurs on a metallic surface, the top layer of the surface reacts with the oxygen forming rust. Oxidation is referred to as ferric oxide. Ferrum is the chemical name of iron. Rust does not constitute a harmonious layer on the metal’s surface; therefore, it quickly falls off or is blown away in powder form. As a result, it exposes a fresh new surface of the metal to oxygen and the other elements, and the cycle of rusting continues.</p> <p>Ultimately, when corrosion occurs repetitively, it compromises the object's structural integrity. As a result, equipment becomes weaker and, therefore, cannot handle the same workloads as it used to. In cases where the rust is not uniform, fatigue stress occurs on the corroded parts on elements of your machinery. This means components may crack or fail at their weakest point caused by severe corrosion. Heavy machinery often undergoes total failure or sharp performance reduction because of this fatigue. Either way, it’s not pleasant news.</p> <h2>Weakest Link</h2> <p>When the metal reinforcing other structural material rusts, it compromises the machine’s structural integrity. In other words, the bond strength of the metal decreases because of the destruction or disruption of the bond. You can further visualize this destruction by imagining how the different metals expand and contract, thanks to their unique chemical properties.</p> <p><img alt="Row of Rusty Cars" src="/Portals/0/LiveBlog/blog/rust-cars.jpg?ver=HNg8uF-y5fB0Yn1q0ej_Mw%3d%3d" style="border-width: 1px; border-style: solid; margin: 5px; float: right; width: 240px; height: 160px;" />With agricultural machinery, Caterpillar and John Deere have, over the years, dominated the industry. A significant problem faced by agrarian machinery is rusting. Rusting occurs because of the constant exposure of equipment to the natural elements. Unfortunately, this exposure is unavoidable thanks to oxygen in the air, water, and soil.</p> <p>The presence of rust in these pieces of machinery has adverse effects, such as contamination of agricultural products. If undetected, the ferric oxide, especially when in powder form, easily mixes with food substances, causing potential harm to all consumers.</p> <p>Rusted machinery also puts workers and handlers at grave risk, as these machines could fail at any point during operation. Another prominent effect of oxidization in metals is the deterioration of the material’s appearance, making the equipment unsightly. Environmentally, there is no biodegradable way to dispose of unwanted iron oxide. This emphasizes the importance of avoiding rust at all costs.</p> <h2>Preventing Rust</h2> <p>Since it is impossible to isolate your agricultural machinery from the elements, the secret to preventing rust is by creating a shield between the metal and oxygen. A simple method of achieving this is by using metallic material resistant to rust. An excellent example is coating iron with chromium. Chromium is a non-corrosive alloy resistant to rust.</p> <p><img alt="The protective layer provided by the combination of an e-coat/topcoat." longdesc="e-coat topcoat" src="/Portals/0/Images/2-coat-topcoat.jpg?ver=2020-01-20-135448-900" style="float: right; margin: 12px; height: 197px; width: 250px;" />Another way to protect metal is by applying a protective barrier between the metal and elements using <a href="https://www.schuettemetals.com/blog/id/9" target="_blank" title="Two-Coat System">e-coating</a>. Electrophoretic deposition (e coating/electric coating) is like electroplating. The electroplating process uses electric current reducing dissolved metal cations, forming a thin, coherent metal coating.</p> <p>E coating occurs while dipping the parts in a bath of epoxy, water-based solutions, or paint while adding an electric current.</p> <p>The current causes a reaction within the bath, depositing floating particles on the component. The amount of time using the electric current determines the coating thickness. After coating the part, it's moved to a curing oven finishing the process.</p> <p>A common alternative is <strong><a href="https://www.schuettemetals.com/blog/one-of-the-most-reliable-ways-of-protecting-steel-galvanization" target="_blank">galvanization</a></strong>, which refers to zinc-plating your metal. Similar to chromium, zinc is also resistant to rust. Coating the metal with paint, lacquer, or even varnish is a more affordable option. However, this option requires frequent maintenance because of the “light” nature of the coating.</p> <p><img alt="Rusty Cone Top Beer Cans" longdesc="Rusty Cone Top Beer Cans" src="/Portals/0/Images/rusted-cone-top-cans.jpg?ver=2020-06-03-111526-663" style="float: right; margin: 12px; width: 187px; height: 250px;" />Other methods of rust prevention that may not be beneficial in the agricultural sector include minimizing exposure of your machines to the natural elements and sacrificial coating. The latter primarily refers to coating your machine with an additional metal type that’s more likely to oxidize than the primary metal, hence the name.</p> <h2>In Sum</h2> <p>Neat as they were on the wall alongside other cans, rust took away some of the glamors of those cone-top beer cans. It was as frustrating as it was seeing them, looking at history, and spending time with my dad, but it was still pretty cool.</p> <p>Rust is a natural process that occurs with or without our help. However, the only remaining option is finding smart ways to work around it. So if you have an old derelict piece of machinery that succumbed to corrosion, pick it up, scrape off the rust, identify the right preventive measure suitable for you, and get to work.</p> <p> </p> <hr /> <p> </p> 17How Much do you Know About the Process of Cutting Metal?https://www.schuettemetals.com/blog/postid/18/how-much-do-you-know-about-the-process-of-cutting-metalFabricationWed, 20 May 2020 16:19:00 GMT<p><img src="/Portals/0/Images/Iron%20Age%20Smitty.jpg?ver=2020-05-20-163514-633" alt="Smitty during iron age" longdesc="Smitty during iron age" style="border: 1px solid #000000; float: right; margin: 12px; width: 150px; height: 225px;" />Historians often discuss historical events while connecting them with industrial advancements taken place during that time. These advancements include the Stone Age, Bronze Age, and Iron Age, discovered around 9000 BC, 2000 BC, and 1500 BC, respectively, in the Middle East.</p> <p>Understanding the evolution of metal cutting includes learning about metal properties and their numerous historical applications.</p> <p>History states that the prehistoric man was familiar with six metals:</p> <ul style="margin-left: 40px;"> <li>Copper</li> <li>Tin</li> <li>Lead</li> <li>Gold</li> <li>Silver</li> <li>Iron</li> </ul> <p><img src="/Portals/0/Images/3%20common%20metals.jpg?ver=2020-05-20-163608-113" alt="3 common metals" longdesc="3 common metals" style="float: right; margin: 12px; width: 250px; height: 184px;" />He discovered that each metal had unique properties, therefore requiring different manipulation methods, and eventually, various end applications.</p> <p>For instance, he realized that gold and silver were softer than the other metals and used them for decoration purposes. He also realized that copper could be hardened by hammering and used to make tools.</p> <h2>Metal Cutting</h2> <p>A few factors come into play for metal cutting: </p> <ul style="margin-left: 40px;"> <li>Subject metal</li> <li>Cutting Tool</li> <li>Cutting Speed</li> <li>Chip Formation</li> <li>Force</li> <li>Energy Dissipated</li> <li>Desired Feeling of the Finished Surface</li> </ul> <p>Metal cutting generally falls under the following categories: </p> <ul style="margin-left: 40px;"> <li>Chip Forming Method - Drilling</li> <li>Shearing</li> <li>Abrasive Material Removal Method - Grinding</li> <li>Heat Method - Laser Cutting</li> <li>Electrochemically</li> </ul> <h3><img src="/Portals/0/Images/Drilling%20Metal.jpg?ver=2020-05-20-163921-570" alt="Drilling Metals" longdesc="Drilling Metals" style="border: 1px solid #000000; width: 202px; height: 275px; float: right; margin: 12px;" />Chip Forming Method - Drilling</h3> <p>Drilling is the process of cutting a circular hole into solid materials using a drill bit. The drilling bits come in different shapes and sizes, thus producing varying hollows on the metallic surfaces. The bits rotate and press against the workpiece at a high velocity. This drilling process results in chippings from the workpiece to eventually form the drill holes.</p> <p>They also incorporate lubricants and other cutting fluids, ensuring smooth cutting. Other chip forming metal cutting processes include sawing and milling.</p> <h3>Shearing</h3> <p>Shearing has existed since the Bronze Age in the form of scissors that operated manually. It entails cutting a metal without using heat (burning or melting) and without the formation of chips.</p> <p>Shearing involves using the cutting blades in a straight or curved manner. The process consists in having one moving part of the blade pushing the material onto the fixed counterpart. The two edges simultaneously apply pressure on the workpiece and eventually cut it.</p> <p>Other shearing methods include punching and stamping.</p> <h3>Abrasive Material Removal Method - Grinding</h3> <p>Grinding is an abrasive process that involves using a grinding wheel machine to cut metal. Grinding is diversely used in the manufacturing and tool-making industries as it produces very smooth finishes, and can also produce mass quantities of roughly cut metal pieces as desired. It is used to cut hard metals and generates very accurate dimensions, as little as 13 micrometers.</p> <p>Incorporate lapping, sanding, and polishing activities to smooth the materials further. It requires lubrication of the grinding wheel for cooling purposes and keeping the grinder working at peak performance. The chips produced should also be cleaned off before you resume working.</p> <h3>Heat Method - Laser Cutting</h3> <p>Laser cutting is a modern cutting technology that uses high-power laser beams to cut into materials. Commercial laser machines are programmed to cut into the metallic materials mechanically. When you direct the laser beam at the metal, it either melts, blows, or burns away to produce a desired high-quality end design.</p> <p>The laser cutting machine was first introduced to the diamond drilling industry in 1965. The technology was later introduced in metal cutting in 1967, and into aerospace applications in 1970. Today, however, it is common to find laser cutting machines used in various schools, small businesses such as metal fabrication, and individuals.</p> <p>The advantages of laser cutting over the typical mechanical cutting methods are many. One of the most apparent benefits is its versatility to be used on a variety of materials:</p> <ul style="margin-left: 40px;"> <li>Steel</li> <li>Aluminum</li> <li>Brass</li> <li>Gold</li> <li>Silver</li> <li>Rubber</li> <li>Plastics</li> </ul> <p>Other advantages include precision cutting, the ability to cut through very thick materials, increasing mass production, reduced contamination of work pieces, and smooth operations.</p> <h3>Electrochemical Method - Etching</h3> <p><img src="/Portals/0/Images/Metal%20Etching.jpg?ver=2020-05-20-164019-627" alt="Etching Metal" longdesc="Etching Metal" style="width: 300px; height: 200px; float: right; margin: 12px; border-width: 1px; border-style: solid;" />Etching dates back to the Middle Ages and refers to the process of using strong chemicals to cut into metals. Traditionally, goldsmiths and other metal-workers would decorate metallic items such as armors and guns.</p> <p>These men would cover a metallic plate (whether copper or steel) with an acid-resistant wax, scratch off the wax into the desired motif using an etching needle, then immerse the plate into an acid bath. The acid would then “bite” into the exposed metal to produce a carving of the drawn motif. The depth of the print depended on the duration of immersion.</p> <p>In modern times, however, electroetching has been introduced to avoid the side effects of traditional etching. Some of these side effects include the burning of the skin and damaging of the metallic plate. Electroetching involves using an electrolyte solution, an anode, and a cathode to etch onto the metal.</p> <p>Other metal cutting methods that use heat include flame cutting and plasma cutting that use oxygen-fueled flames and hot plasma, respectively.</p> <h2>In Sum</h2> <p>As time keeps changing, so does technology. Incorporating laser cutting machines into your business improves efficiency and ensures consistent, higher quality.</p>18