The Need and Significance of Metal Fabrication Welding

The Need and Significance of Metal Fabrication Welding

The process of metal fabrication welding is as much an art as it is a science. This process entails joining two metal pieces into a single piece with the use of heat. In most cases, the two pieces of metal to be joined together are molten at the targeted joint and they are further bonded by using a filler material that securely holds these two materials together. While the use of heat (usually in the form of a flame) has been the conventional welding method, today you shall find lasers, electric arcs and even ultrasound to carry out this process.

This method is also used for prototype machining, in which an archetype of a machine is made and tested for feasibility before the final product can be made. Since both these techniques require a considerable amount of skill, one needs to partner with a reputable firm for such services.

A firm that boasts of metal fabrication welding as their core competency is more likely to offer you a better service. Since these services are used for the high end manufacturing of large and small industrial machinery or components, one cannot take a chance with quality. So whether you need a unique product or a batch of components, you can outsource these requirements to a machining firm. This process begins with a design-so a lot depends on the accuracy of the design that is being created for you.

These services are required by several industries including but not limited to aerospace, tooling and fixtures, assemblies, composites, energy sector, wind, hydro power, nuclear power, pipelines, marine industry, infrastructure construction and many others.

Now let’s discuss some of the salient features of Metal Fabrication Welding:

  • This technique of joining two metals endows the final part with strength and stability.
  • Parts or components such as valves can be made according to tight tolerances and in adherence to industry codes.
  • It is possible to create machines and components that can offer you different work patterns and outputs.
  • Welding can be performed on different shapes and sizes of welds. It can help join metal pieces at different angles.
  • Once the welding process is executed, its strength can be ascertained with the help of several tests. This helps to check defects such as cracks, incomplete fusion, distortion, undercutting etc at an early stage. The errors can then be rectified suitably. Testing errors is an important aspect of Prototype machining.

When the process of welding is carried out, the risk of distortion exists. Only an expert machinist can help control such risks. In addition, if you need to procure highly complex or intricate parts with difficult metals and geometrical shapes, it is advisable to enlist the services of a reputable metal fabrication welding firm.

I am a registered Professional Engineer & Certified Metal Fabrication Welding Inspector who has worked the last ten years. My interest is the training aspect on Prototype machining, metal fabrication welding processes, machine tools, conducts through seminars.

Article Source: http://EzineArticles.com/7167087

Sheet Metal Fabricators – Hot Tips For Welding Flat Rolled Steel

Sheet Metal Fabricators – Hot Tips For Welding Flat Rolled Steel

As fabricators acquire experience welding SCS strip steel we discover great news with regards to better weld quality, cost savings on filler wire and, of course, decreases in toxic welding fumes as opposed to welding P&O steel. Still, we sometimes learn of a new user having problems with too much weld spatter while welding the SCS steel. Research show that modest alterations in shielding gas and filler wire feed eradicate excessive spatter and produce larger cost savings on consumables. This write-up offers the foundation of theSCS sheet steel strengths and describes welding practices that permit sheet metal fabricators to enjoy those rewards while steering clear of the excessive spatter.

Consistently Stronger Welds.
Six years ago comparable samples of welded SCS treated steel and Hot rolled pickled and oiled sheets were tested metals testing laboratory. It required an average 580 pounds greater shear load to induce failure in welded SCS treated steel samples than the P&O samples.

SCS treated steel benefit comes from greater weld integrity. A certain amount of weld arc’s energy would go to burning up the oil on Hot band oiled sheets. This brings out even even more contaminants to a Pickled and oiled surface that is already fairly dirty when compared to SCS sheet steel. The net outcome is to lower the integrity of HRPO welds compared to SCS treated steel welds.

That Issue of Excess Spatter.
Most sheet metal fabricators who switched to SCS treated steel reported cleaner, stronger welds with really no spatter. However, a handful noted unacceptable amounts of spatter.

To discover the underlying cause, The Material Works, Ltd. recruited the support of the Illinois Manufacturing Extension Center (IMEC) which provides technical services to companies. IMEC’s project manager partnered with Optimum Engineering Solutions, Inc. to perform controlled welding tests of SCS sheet steel. They duplicated the welding procedures of fabricators who reported excessive spatter and observed similarly undesirable results.

Then they, evaluated adjustments in shielding gas make up and filler wire feed rate. Changing from 90%Argon-10%CO2 to 95%Argon-5%Oxygen enhanced arc stability and greatly decreased spatter. Decreasing wire feed speed worked well with the new gas recipe. Using ER70S-6 filler wire at a slower feed rate with the Argon-Oxygen selection delivered notably better penetration and improved bead appearance when welding at the same speed.

The study discovered that the best parameters for welding SCS sheet steel (or Oiled strip steel for that matter) were different from what these fabricators had been using. A change to the optimized shielding gas and filler wire combination not simply assures exceptional SCS treated steel welding performance, it also provides savings on consumables!

The gas supplier for the analysis sells the Argon-Oxygen mix at five percent under the Argon-CO2 mix. But even bigger savings are realized on filler wire. The more even weld bead you receive with optimized SCS sheet steel parameters translates to less filler material for a given weld joint. Couple that with a lower wire feed rate for the identical welding rate, and the savings in welding wire can reach 30%.

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Different Types of Stainless Steel Has Different Welding Properties

Different Types of Stainless Steel Has Different Welding Properties

If you are thinking about the steel fabrications, it is wise to perhaps think about the welding requirements later. After all, the steel fabrications are done by using different types of steel alloys. Now, they have different properties, and features. Therefore, it is important that you choose the right alloy for the purpose. Remember, some of the alloys provide high corrosive resistance. But, they may not be high in terms of the machinability. So, it is really essential that you choose the right material that will complement the purpose and the environment of the fabrication. Another very important factor to consider is of course the welding properties. Actually, there are some steel alloys that can’t be used for welding.

A great exception to this is of course the austenitic stainless steel. This is the type is readily welded. The great thing with this type is that every type of electric welding methods can be utilized for this purpose. The standard equipments are useful for the welding process. However, you must note that these facilities are not applicable to the free machine grade versions of this type of stainless steel. If you are thinking about heavy sections that need welding, you should be going for the stabilized grades or grades that contain low carbon. However, you can also use the improved machinability grades for this purpose.

Another type of steel that you can use for welding is the duplex steel. Though they are not as good as the austenitic types, still you can use all the standard methods and consumables though the 2209 is the most used. However, the good thing with this type of steel is that it is less coefficient in thermal expansion than the austenitic steel and in fact, matches the carbon steels in this regard.

The next type is the martensitic stainless steel. This steel too, can be welded. However, one must take some precautions to make it effective. For, it generally produces extremely hard and brittle zone attached to the place of welding. So, one must take a lot of care in the pre heating to make sure that there is no crack occurring there. Sometimes, people weld this steel with the austenitic steel filler rods to improve the ductility of the deposits.

Finally, there is the Ferritic stainless steel which is the worst choice in case of welding. They have excessive grain growth, they lack ductility and they have sensitization – all three hampering the welding properties of the type.

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Welding Techniques for Fabrication

Welding Techniques for Fabrication

In industry most of the materials are fabricated into the desired shapes mainly by one of the four methods, casting, forming, machining and welding. The selection of a particular technique depends upon different factors which may include shape and the size of the component, precision required, cost, material and its availability. Sometimes it is possible to use only one specific process to achieve the desired object. However, more often it is possible to have a choice between the processes available for making the end product. In the latter case economy plays the decisive role in making the final choice.

CASTING

Casting is perhaps the oldest known method of giving shapes to metals and alloys. When found suitable, it is the shortest route from the ore to the end product and usually the most economical. Through these days techniques have been developed to cast almost all metals and their alloys but still there are certain specific materials which have very superior casting properties, for example grey cast iron.

FORMING

After casting followed the forming process in which the metals and their alloys are given desired shapes by the application of pressure, either by sudden impact as in the case of hammer blows or by slow kneading action as in hydraulic presses. Mechanical working of a metal below its recrystallisation temperature is called ‘Cold Working’ and that accomplished above this temperature is known as ‘Hot Working’. Both hot and cold working (and forming) is practised extensively in the industry.

MACHINING

It is the process of giving the desired shape to a given material by removing the extra or unwanted material by cutting in the form of chips. The cutting tool material is by necessity harder and stronger than the material to be cut. The machining processes commonly employed are turning, milling, drilling, shaping, planning, reaming, boring etc. Through lathes and milling machines were used in connection with watch making even in the fifteenth and sixteenth centuries but most of theses processes were introduced into the high volume industries in their present forms for making stream engine parts in the late nineteenth century but have come of age in the present century.

WELDING

Welding as it is normally understood today is comparatively a new corner amongst the fabrication process through smith forging to join metal pieces was practised even before Christ. Through there are a number of well established welding process but arc welding with coated electrodes is still most popular welding process the world over.

These days different welding machine developed for different welding process like arc welding machine, MIG welding machine, TIG welding machine, welding rectifier, spot welding machine, plasma cutting machine and also portable welding machine like inverter welding machine (IGBT welding).

Arc welding in its present form appeared on industrial scene in 1880’s. Through there are conflicting claims about the inventor of this process but very often it is attributed to a Russian named Slavianoff who is claimed to have patented it in 1881. Arc welding machine, however, was not accepted for fabrication of critical components till about 1920 by which time coating for electrodes had been well developed. However, the demand for large scale production of heavy items like ships, pressure vessels, construction of bridges and the like provided the necessary impetus for welding to come of age and the Second World War firmly established it as the major fabrication process.

Welding which is a process of joining two or more parts of material (s) through provides a permanent join but does normally affect the metallurgy of the components. It is therefore usually accompanied by post weld heat treatment (PWHT) for most of the critical components.

Most materials can be welded by one process or the other. However, some are easier to weld than others. To compare this ease in Welding a term “Weldability” is often used. Weldability of a material depends upon various factors like the metallurgical changes that occur due to welding, changes in hardness in and around the weld, gas evolution and absorption, extent of oxidation, and the effect on cracking tendency of the joint. Depending upon these factors plain low carbon steels have the best weldability amongst metals. Quite often materials with high castability usually have low weldability.

Welding process widely used in the industry include oxy-acetylene, manual metal arc or shield metal arc (SMAW), submerged arc welding (SAW), metal inert gas (MIG), tungsten inert gas (TIG), thermit welding and cold pressure welding. Most of these processes have special fields of influence like resistance welding is popular with the automobile industry, thermit welding for joining rails in situ, MIG welding is particularly suited for welding of low carbon steel structures as also welding of stainless steels and aluminium, TIG welding is more popular with aeronautical and nuclear industries, SAW welding for ship building, cold pressure welding by food processing industry, and the like. However, SMAW or stick electrode welding and oxy-acetylene welding processes are the general purpose processes with a wide range of applications.

Some of the typical applications of welding include the fabrication of ships, pressure vessels, automobile bodies, off-shore platforms, bridges, welded pipes, sealing of nuclear fuel and explosives etc.

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A Closer Look at Metal Fabrication Welding Process

A Closer Look at Metal Fabrication Welding Process

Metal fabrication welding has become an industry in itself with many fabrication shops operating all across the world to provide products that are required in various important industrial sectors. Among the various projects that an efficient service provider dealing with metal fabrication provides are making loose parts, structural frames for buildings and heavy equipment, and hand railings and stairs for buildings.

The entire process of welding begins with preparing shop drawings, which is sometimes provided by the customer needing metal fabricated parts. Or sometimes the job is also entrusted on steel detailers. This is used as a reference point in the final manufacturing process. The CNC machines are programmed accordingly by the manufacturing engineer expert in the process of welding.

A fabrication provider may use many raw materials for manufacturing their products and this may range from plate metal, welding wire, castings, and various other types of fittings. The total fabrication involves many different steps like cutting and burning, forming, machining, welding, and then the final assembly.

Different fabrication shops use different methods for cutting metals to the required size, and they use a variety of tools for the purpose. Shearing is the most common method used in cutting any material as it is very effective and can get the work done in no time for all types of metal fabrication welding. The tools used in this method may range from special band saws equipped with blades, waterjet cutters, plasma and laser cutting tables etc. and many more.

Of all the steps in metal fabrication, welding is the most important especially if the metal used is steel. As soon as all the parts required for the project are machined, they are assembled and then welded properly for the final product. Proper care should be taken during welding so that no loose parts are left behind or there should be no welding of two wrong parts. Proper temperature should be maintained so that there are no unwanted errors in the final product.

Use custom fabricated metal only from experienced and certified user and ensure greater productivity whatever your area of operation!

I am a registered professional engineer & certified metal fabrication welding service inspector working from the past ten years. I am passionate about writing on prototype machining service industry and wish to share what I has learned from my experience.

Article Source: http://EzineArticles.com/5308482

Metal Fabrication Welding – How to Get Unsurpassed Quality Products

Metal Fabrication Welding – How to Get Unsurpassed Quality Products

Metal fabrication welding is an integral part of the entire fabrication of metal process. It helps in providing services to an impressive array of processing technologies. Apart from welding, some of the other services the metal fabrication industry can offer are CNC punching, laser, CNC forming, rolling and hardware additions. Apart from these, for offering the best final additions, a Metal Fabrication Welding firm should also manage other facilities like painting, plating and so on.

Among the different metals and metal alloys that require fabrication welding firm for various welding forms are stainless steels, carbon steels and aluminum. The various technologies, which any quality firm brings to the table, include MIG, TIG, MMA and Brazing. Some of the metal fabrication welding projects include stands and tables for TVs/LCD TVs, stands for tabletop machinery, food packaging machine etc. The various fabrications need in hotel equipment category includes trolleys, working cabinets and shelving and various high-precision metal components etc.

Drive production efficiencies with advanced technologies is the basis of welding in fabrication process today. One of the most used techniques in this process is the arc welding method. It is nothing but the use of an electric arc created between an electrode and the base material used to melt the metals at the welding point. The current can be either direct (DC) or alternating (AC) current, and the electrodes can be consumable or non-consumable. A quality team can offer both conventional and hybrid arc systems, and is highly skilled in the entire arc welding, surfacing and cutting technologies.

Among the various industries that use fabrication welding processes are construction, consumer goods, defense, energy and transportation industries. In the construction segment, this is used to in heavy construction and repair equipment, mining and off-highway vehicles etc. In the consumer goods, you would find this used among medical manufacturers for developing smaller, lighter, safer medical devices that meet industry demand for higher product quality, reduced cost and greater production efficiencies. Again, in packaging manufacturing they are used to produce polymers, plastics, and adhesives.

Hence, metal fabrication welding is important in all manufacturing and service industry sectors.

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Metal Fabrication Welding for High End Industrial Equipment

Metal Fabrication Welding for High End Industrial Equipment

Choosing a metal fabrication welding provider that can deliver tight-tolerance machining requirements needs some amount of discretion. High-end creation of industrial equipment calls for the right resources, capabilities and experience. A firm that demonstrates all of these characteristics is definitely in a better position to meet your machining requirements.

Fabrication and welding processes are indispensable in prototype machining as well as the final products. In both these cases, it becomes imperative to get the best services at competitive market rates. Whether it is ongoing or repetitive production, getting the same quality and consistency time after time is of supreme importance. Besides, a fabrication or welding job should be good enough to last you for years at a stretch without any maintenance or performance issues. Luckily, a number of companies offering metal fabrication welding have made their presence felt on the internet. You could simply browse through their websites to learn about their capabilities and resources.

In addition, following are a few tips that will help you make an informed choice in choosing the right fabrication and welding service provider:

  • Choose a manufacturer that has a proven track record in manufacturing heavy industrial equipment by using latest and the most advanced fabrication welding techniques. The chosen company should ideally be the masters in fabrication and welding.
  • The next most important thing to check is whether your chosen firm comprises a team of skilled and experienced technicians.An experienced team will help create the most accurate designs and outputs,which in turn will help you achieve the best products.
  • Whether you are an OEM or a contract manufacturer, getting a competitive price for welding and fabrication services is important. Choose a firm that can offer you top notch services at reasonable prices. Besides, the company should respect your deadlines and deliver on-time.

There are several industries that heavily rely on metal fabrication welding and prototype machining at different stages in the product design and development process. Industries such as aerospace, tooling and fixtures, assemblies, composites, energy sector, wind, hydro, nuclear, pipelines, marine segment, repairs, fittings, research labs, laser, transportation and automobiles etc stand to benefit from welding and fabrication.

  • Why is fabrication and welding required?

Metal fabrication and welding is necessary as it lends strength, stability and durability to the working of an equipment or device. The most intricate machine designs can be achieved with these two processes. Thus, it ensures different work patterns and outputs. This process is one of the oldest techniques of creating heavy machinery and equipment and it continues to evolve with the passage of time. It plays an integral role in the design and manufacture of industrial as well as commercial products. If prototype machining and metal fabrication welding isn’t carried out professionally, the chances of a product passing quality tests are low.

I am a registered Professional Engineer & Certified Metal Fabrication Welding Inspector who has worked the last ten years. My interest is the training aspect on Prototype machining service, machine tools, conducts through seminars.

Article Source: http://EzineArticles.com/6943890

How to Fabricate a Metal by Welding Process

How to Fabricate a Metal by Welding Process

Metal Fabrication is one of the traditional ways of creating heavy equipment and today many welding companies are providing a modern touch to this technique. Metal fabrication may be described as a value addition process that entails the construction of machines and structures from various raw materials.

There can be no doubt that metal fabrication welding imparts strength and stability for a working equipment or device. Metal Fabrication and welding for heavy industrial devices lends itself to different work patterns and outputs.

Fabrication is rather a wide term to denote building metal structures through the three different steps -cutting, bending, and assembling. The cutting part of fabrication is done by sawing/shearing/chiseling (either manual or powered); cutting is done via CNC cutters using laser, torch, or water jet). The bending is by means of hammering (manual or powered) or press brakes. The assembling is achieved mostly by welding – if not, through adhesives, riveting, threaded fasteners etc.

Structural steel and sheet metal are the standard materials for fabrication – not to speak of the welding wire, flux, and fasteners that will join the cut pieces. There are fabrication shops that undertake these jobs. The products produced by welders, which are often referred to as weldments are classic examples of fabrication. The field of welding continues to evolve with significant advancements in technology. There are highly skilled infrastructure fabrication welding operators who are adepts in basic welding and fabrication methods, blueprint reading etc.

Several welding processes are used in metal fabrication. The two most common welding processes we know for fabricating metals are TIG (Tungsten Inert Gas) welding and MIG (Metal Inert Gas) welding. The other name for TIG is GTAW (Gas Tungsten Arc Welding) and MIG also is oftentimes referred to as GMAW (Gas Metal Arc Welding).

The third is Arc Welding that is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. You can use either direct (DC) or alternating (AC) current and consumable or non-consumable electrodes.

The term ‘Metal’ in Gas Metal Arc Welding denotes the wire that is used to create the arc. It is shielded by inert gas and the feeding wire also acts as the filler rod. MIG is a semi-automatic welding process and it is quite straightforward. Versatility is the key advantage of MIG welding process. It is capable of joining several types of metals and it can be performed in different positions.

TIG welding starts with a tungsten electrode shielded by inert gas and filler rod is fed into the weld puddle separately. The gas shielding that is needed to protect the molten metal from contamination and amperage is supplied during the TIG welding operation. TIG welding, though slower than MIG process, produces a more precise weld and can be used at lower amperages for thinner metal and even exotic metals.

Even though TIG is a well known welding process, it has some limitations. It requires greater welder dexterity, it yields lower deposition rates and it is costlier for welding thick metal sections.

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The Importance of Welding in Industries

The Importance of Welding in Industries

Welding means the process of joining metals by causing coalescence due to heat. It happens by melting the workpiece with weld pool. The joint gets stronger when it cools down. It’s heats when the weld pool is used with the workpiece & produces weld in that time. In all fabrication companies welding is very essential. Since welding has been used in steel fabrication its uses has expanded in other industrial sectors like construction, mechanical and car manufacturing etc. If we look back in the past, we can see that welding had been used for many years. It has been passed through the Bronze age and the Iron age and it has branched around the world.

There are three kinds of welding, they are ARC, MIG and TIG welding. There have been many different kinds of welding which have branched as the years passed. Arc welding is done by consumable electrode by aiming to an electric arc. Parent metal & the addition of metal must be together when the electrode is stuck. Metal Inert Gas or MIG is the easiest way of welding. It is like wire but combined electrode and filler material. It is easy to use because the welding process has been made very easy. TIG welding uses a permanent non-melting electrode made of tungsten. This kind of welding process is very flexible because the metal added separately.

These three kinds of welding requires a power supplier for maintaining electric arc between electrode & base material to melt metals at the meeting point. DC or AC currents can be used for these kind of welding. In every type of welding some semi-inert gas is used o prevent combustion in the welding region.

A welder must be well trained for welding works. Sometimes many problems occur because of lack of safety precautions. Working unsafely i.e without welding glass and near combustible materials can be a dangerous. By taking preventive measures, the risks of death or health hazards can be reduced. For example, in the Arc Welding the worker must wear helmet, hand gloves & other protective things which helps the welder to work in safely the process is very essential and has been used in various industries.

Sarah Hanley is an expert in steel fabrication and works in a Steel Fabrication Dubai. He has consulted many clients on issues of construction, steel fabrication and mechanical engineering.

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Metal Fabrication Welding in the Energy Sector

Metal Fabrication Welding in the Energy Sector

Metal fabrication welding is an essential part of the entire metal fabrication process. It is of great significance in almost all the important industry sectors in today’s civilization. Among all the diverse industry sectors, the energy sector uses these services quite extensively. In fact, recently many innovative processes have been developed to get optimal results for companies involved in this sector that include oil and gas exploration, production and refinement and chemical processing.

Both traditional and advanced energy suppliers rely on fabrication welding expertise in materials joining and proven energy industry experience. This industry uses a variety of services to help them to design for manufacturability, improve reliability, and realize cost savings through product and process optimization. Yes, quality metal fabrication welding involves optimizing fabrication, operation, maintenance and repair of complex refinery equipment as well.

Apart from the refining industry, other energy sectors that use the fabrication welding services are battery and fuel cell manufacturers, as well as other advanced energy providers. This helps in proper designing for manufacturability, transitioning to high-volume manufacturing and getting products to market at a faster rate. Talking of energy, let us look at its usefulness in the assembling of lithium-ion batteries, which is finding increasing application due to their high voltage, high power density, and low weight compared to other battery varieties.

Fabrication and welding can be used increasingly in accomplishing a very hard task namely tabbing dissimilar materials in assembling Lithium-ion cell. Well in this method, ultrasonic welding method is used to join thin aluminum, copper or nickel tabs, often in multiple-layers and to thicker (and often dissimilar) interconnects. This indeed bears great results. Moreover, this is economical as it requires no flux, can also be used with coated materials, produces low-resistance joints and produces the minimal amount of heat.

Well, so where can you avail the services of the best metal fabrication welding expert. The answer is simple the internet. Indeed the online source offers you many options for all your fabrication needs. This is one platform where you can get access to many different firms that suit your specific fabrication needs. So, just log online and fulfill all your metal fabrication needs from just the comforts of your home and at the most cost effective prices.

I am a registered professional engineer & certified metal fabrication welding process inspector working from the past ten years. I am passionate about writing on industry and wish to share what I has learned from my experience.

Article Source: http://EzineArticles.com/5735620