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Choosing the Right Sheet Metal Materials

Author Archives: Elizabeth Hall

  1. Choosing the Right Sheet Metal Materials

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    Sheet metal is a thin, flat sheet formed through an industrial process. It is versatile as it can be cut or bent into various shapes to make everyday objects. When fabricating sheet metal, there are a lot of different metals to choose from. And while they may all look like thin sheets of metal, the materials are what makes each sheet of metal unique.

    Different Sheet Metal Materials

    Each type of metal has specific properties that set it apart and give it an advantage over other metals for specific projects. There are seven common types of sheet metal materials for sheet metal fabrication:

    Aluminum

    Aluminum is an excellent option for applications that require a lightweight material. This sheet metal material offers reliable corrosion resistance even without a finish. It is also widely used for fabrication because it is strong and can undergo laser cutting, welding, and machining. Overall, aluminum is a moderately-priced material with various characteristics across several grades to meet different application requirements.

    Carbon Steel

    This sheet metal material is a product of iron alloyed with carbon. It features high amounts of strength with options of low, medium, or high carbon contents, depending on the desired application. Higher levels of carbon usually result in a more fragile product, and carbon steel with lower amounts of carbon is more sturdy, making it a preferred choice for creating fences or gates. Meanwhile, carbon steel with mid-level carbon is favored for automotive vehicles and appliances.

    Alloy Steel

    Alloy steel combines different elements, with carbon steel as the main component. The common metals added to form alloy steel are tungsten, chromium, and manganese if a sheet metal fabricator aims to achieve rigidity. But if the goal is strength, vanadium or nickel is added. Overall, this sheet metal material is highly versatile and affordable.

    Tool Steel

    Tool steel is also a very versatile sheet metal material and is rigid as it only contains 1% carbon. Like alloy steel, tool steel combines different mixed and matched metals to exploit a particular characteristic. Aside from rigidity, the other advantages of tool steel are its resistance to abrasion and outstanding performance under extreme temperatures. Because of its properties, this sheet metal material is famously used for construction tools like blades, hammers, dies, and punches.

    Galvanized Steel

    Galvanized steel can be classified into electro-galvanized sheets or hot-dipped metallic-coated sheets. Electro-galvanized sheets are made from cold-rolled annealed steel with a pure zinc coating with no zinc spangle. Meanwhile, a hot-dipped metallic-coated sheet is made from cold-rolled rigid steel plates and coated with pure zinc and an iron-zinc alloy. Hot-dipped metallic coated sheets have more corrosion resistance and are more affordable than electro-galvanized metal sheets.

    Stainless Steel

    This sheet metal material works great for products constantly exposed to moisture. It contains chromium, which gives it excellent corrosion resistance against harsh or damp environments. Because of this characteristic, kitchen and office products made from stainless steel sheet metal usually have a longer lifespan.

    Cold-Rolled Steel

    Cold-rolled steel is made in cold-reduction mills. This material is cooled near room temperature, followed by annealing or rolling tempers. It also has a wide range of surface finishes and possesses excellent tolerance, concentricity, and straightness.

    Key Factors To Consider When Selecting a Sheet Metal Material

    Selecting a suitable sheet metal for your project is crucial as it determines whether the fabricated component or parts will perform faultlessly. Here are some key factors to consider:

    Size and Application of the Component

    Knowing the component’s size and intended use is essential when selecting a sheet metal material. Keeping these factors in mind will help you determine how strong the piece needs to be and which sheet metal material is the most applicable in its use-case scenario. For example, aerospace industry components require a sheet metal material with an excellent strength-to-weight ratio.

    Design and Tolerance Requirements

    When choosing a sheet metal material, the design and tolerance requirements of the component you manufacture are essential to keep in mind. Wall thickness, bend allowance, K-factor, and the orientation of holes and slots are some elements that will influence your choice.

    Compatibility With Manufacturing Processes

    The manufacturing process also dictates which sheet metal material is suitable for the job. The sheet metal material must withstand the manufacturing process, including laser cutting,

    Compatibility With Common Fabrication Methods

    As with manufacturing processes, the chosen sheet metal material must also be compatible with standard fabrication methods used to finish corners, close gaps, and enhance or maintain the shape and integrity of a component. TIG welding, MIG welding, riveting, and brazing are typical fabrication methods.

    Learn More About Sheet Metal Materials From Metal Works

    We at Metal Works of High Point have a team of experts with a hundred years of combined experience to provide you with a responsive and personalized service! We also offer state-of-the-art equipment and software that deliver precise and high-quality products.

    Metal Works’ ISO 9001: 2015 Certified facility features bar-coded scheduling software and ERP technology, enabling us to get a real-time view of your product while it is manufacturing. Moreover, our capabilities grant us the knowledge and expertise to guide you through any questions or concerns that you may have about sheet metal materials.

    Contact us today for your next metalworking project!

  2. Which Type of Sheet Metal Fabrication Is Right for Your Project?

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    Sheet metal fabrication entails forming metal sheets into the desired shape using various manufacturing techniques. Typically, numerous processes are required to complete a product, including cutting, bending, welding, and assembly.

    There are various dependable techniques for fabricating sheet metal, although some may be more suitable for specific purposes than others. Therefore, it is crucial to understand the different types of sheet metal fabrication to choose the most appropriate approach for your applications.

    This article will list and discuss the types of sheet metal fabrication forming, cutting, and joining offered by Metal Works of High Point..

    What Is Sheet Metal Fabrication?

    Sheet metal fabrication uses different methods to create metal structures. Steel or other metal sheets are typically fabricated or assembled to produce a bigger finished product. In addition, it encompasses a variety of techniques, such as welding, to offer a high-quality finish on a diverse range of products of varying sizes and shapes.

    Types of Sheet Metal Fabrication

    Generally, various fabrication techniques can achieve similar results. However, choosing a method that fits your budget and specific requirements is crucial. Here is an overview of different sheet metal fabrication techniques:

    Metal Cutting

    Metal Works of High Point is equipped with 3-axis laser cutting equipment, sheet loading and unloading automation, and a system that enables 24-hour metal-cutting operations.

    Laser Cutting

    Laser cutting is a sheet metal fabrication technique performed by CNC laser cutters. The laser beam strikes the material’s surface and heats it to the point where it melts or evaporates.

    The main advantage of this method is its ability to precisely cut through the thickest metals and most intricate designs.

    Metal Forming

    Metal Works of High Point is an experienced and reliable manufacturer of custom metal components and stampings that provides CNC forming and bending services.

    Bending

    The method of bending sheet metal involves applying force to the material, which forces the metal to bend at an angle and achieve the desired shape. Press brakes are utilized to bend sheet metal components. However, due to the complexity of certain bends, this procedure is the most challenging stage in metal fabrication, requiring extensive knowledge and experience.

    Metal Joining

    At Metal Works of High Point, our expert welders employ cutting-edge technologies and 3D software to develop and build solutions that meet or exceed your requirements.

    MIG and TIG Welding

    MIG (metal inert gas) welding uses a feed wire that runs continuously through the gun to generate the spark and then melts to make the weld. On the other hand, TIG (tungsten inert gas) welding utilizes rods to precisely join two metals.

    MIG and TIG welding may be used on a wide variety of metals, with MIG being better suited for thicker materials and TIG being suitable for thinner ones.

    Spot Welding

    Spot welding is resistance welding that joins two or more metal sheets by applying pressure and heat from an electric current to the weld area. It is commonly used when welding specific types of sheet metal, welded wire, or wire mesh.

    Robotic Welding

    Robotic welding uses mechanized, programmable instruments that fully automate the welding process by conducting the weld and manipulating the workpiece. As a result, it removes the welder from an uncomfortable and potentially hazardous environment while reducing costs and improving quality. You can also automate short runs, but the economic impact is inevitably greater for larger quantities.

    Partner With Metal Works of High Point for Your Sheet Metal Fabrication Needs!

    Metal Works of High Point has a team of experts with a combined century of experience to provide prompt and individualized service! Our team is proud of our D 1.3-certified welders, and we adhere to the most stringent industry requirements. Moreover, we are an ISO 9001:2015-certified establishment.

    We also have cutting-edge equipment that yields precise and high-quality products! Contact us for additional information on the different types of sheet metal fabrication, or obtain a quote immediately.

  3. Laser Cutting vs. Plasma Cutting

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    Modern cutting methods allow manufacturers to improve the accuracy of their metal and plastic products. As a result, better, more precise quality parts are produced without compromising productivity. Increased efficiency and reduced production costs are also achieved through precise cutting methods.

    Laser and plasma cutting are two of today’s most popular cutting methods. Both offer distinct advantages and disadvantages for different industries. This article provides a detailed comparison of plasma cutting vs. laser cutting and their value in today’s manufacturing industries.

    Plasma Cutting vs. Laser Cutting

    Both plasma and laser cutting are advantageous and feature unique applications for various manufacturing needs. Let’s look into their differences in a few aspects:

    Cutting Thickness

    Thickness is a common factor that may determine how efficient a cutting process is compared to other methods. For example, the maximum metal sheet thickness in laser-cutting metals ranges from 20-25 mm for mild steel. To cut efficiently beyond this thickness, high-powered CO2 lasers are required.

    Plasma cutting is ideal when dealing with thicker cutting requirements. Handheld plasma cutters can easily cut into steep plates of up to 38 mm, and stronger automated machines can cut even as much as 150 mm.

    Speed

    Laser cutting is accurate, dependable, and significantly faster than other techniques, especially when making intricate cuts. Different cutting techniques, such as plasma or flame cutting, can be time-consuming for complicated or big metal components.

    On the other hand, plasma cutters can easily reach high temperatures, cutting through materials faster than many methods, such as oxy or waterjet cutting.

    Accuracy

    Plasma cutters can produce clean cuts in various steel sheets (+/- . 01″ – . 030″ relative to the setup). The cut will become less precise as material thickness increases because the plasma attempts to melt through more material without creating unneeded slag.

    Laser cutting is incredibly precise. It allows for extremely fine dimensional precision (less than 0.0005 inches) and narrow cut widths (less than 0.0001 inches).

    Plasma Cutting Advantages

    The plasma cutter is one of the most specialized, widely used, effective, and adaptable pieces of equipment for quick and easy cutting. It is a versatile device that offers the following advantages:

    Versatility

    Different kinds of metal can be cut with plasma. Likewise, any conductive metal — including steel, iron, copper, brass, aluminum, stainless steel, and other hard materials — can be cut using an electric arc. Plasma may also cut objects stacked on top of one another.

    Ease of Use

    Plasma cutters are portable and can be moved where the job requires it or operated by an individual.

    Cost-Effectiveness

    Plasma can cut materials faster, with less waste, and more safely. This results in lower costs for the consumer, making it a more economical process than other cutting techniques.

    Precision Cuts

    One of the key benefits of a plasma cutter is precision or exact cutting, particularly when cutting sheet metal into various shapes or angles. However, the operator must have a steady hand to execute the cut effectively.

    Laser Cutting Advantages

    Laser cutting is one of the go-to manufacturing technologies of today. Among its advantages over other cutting methods are as follows:

    Flexibility

    When using a laser cutter, there is no need to switch out equipment between cuts. With the same configuration, several different forms can be cut out of the same material thickness, including intricate cuts.

    Tight Tolerances

    One of the main benefits of laser cutting over other thermal cutting techniques is accuracy. With a +/-0.1 mm accuracy, great precision can be attained without post-treatment. Such a high quality typically negates the need for further tolerances.

    Automation

    Laser cutting automation requires little manual labor. While an expert machine operator still contributes significantly to the end product’s quality, the cutting speed and minimal manual labor requirement lead to cheaper costs than other cutting techniques.

    Exceptional Laser Cutting Solutions From Metal Works of High Point

    Metal Works of High Point is committed to helping clients reduce manufacturing costs without compromising quality! We use our metal laser cutting services to increase fabrication process efficiency and lower production costs.

    We specialize in laser cutting techniques such as fusion cutting, flame cutting, and sublimation cutting. With 3-axis laser cutting systems and experienced professionals on our team, Metal Works of High Point can handle all your custom laser cutting requirements! Additionally, our system is capable of 24-hour metal-cutting operations, for guaranteed efficiency.

    Contact us for more information on our metal laser cutting services.

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