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Metal fabrication

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For other uses, see Fabricator (disambiguation).
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A set of six-axis welding robots

Metal fabrication is the building of metal structures by cutting, bending, and assembling processes.
It is a value added process that involves the construction of machines and structures from various
raw materials. A fab shop will bid on a job, usually based on theengineering drawings, and if
awarded the contract will build the product. Large fab shops will employ a multitude of value added
processes in one plant or facility including welding, cutting, forming and machining. These large fab
shops offer additional value to their customers by limiting the need for purchasing personnel to
locate multiple vendors for different services. Metal fabrication jobs usually start with shop drawings
including precise measurements then move to the fabrication stage and finally to the installation of
the final project. Fabrication shops are employed by contractors, OEMs and VARs. Typical projects
include loose parts, structural frames for buildings and heavy equipment, and stairs and hand
railings for buildings.
Contents
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1Processes

2Overlap

3Raw materials

4Cutting and burning

5Forming

6Machining

7Welding

8Final assembly

but fabrication shops generally concentrate on metal preparation and assembly as described above.  Boilermakers originally specialized in boilers. Structural steel and sheet metal are the usual starting materials for fabrication. which are often referred to as weldments. or even yet more bending in the form of a crimped seam. but they are more concerned with the machining of parts on machine tools. torch.  The products produced by welders. metal stamping. 9Specialities  10See also  11References Processes[edit]  Cutting is done by sawing. threaded fasteners. Off-line programing software now makes programing the CNC-controlled press brakes seamless and very efficient. Modern metal fabricators use press brakes to either coin or air-bend metal sheet into form.  Blacksmithing has always involved fabrication. riveting. The end products of other common types of metalworking. or water jet). and fasteners that will join the cut pieces. leading to their trade's name. flux. although it was not always called by that name. The product resulting from fabrication may be called a fabrication. but those processes are not classified as fabrication. but today they may be called upon for a broad range of fabrication work. Overlap[edit] Fabrication comprises or overlaps with various metalworking specialties:  Fabrication shops and machine shops have overlapping capabilities. are an example of fabrication. CNC-controlled backgauges use hard stops to position cut parts in order to place bend lines in the correct position. mill bits. torching with hand-held torches (such as oxy-fuel torches or plasma torches). but the term as used today has a broader meaning. or chiseling (all with manual and powered variants). along with the welding wire. . By comparison. Shops that specialize in this type of metal work are called fab shops. shearing. and casting.  Similarly. forging. As with other manufacturing processes.  Assembling (joining of the pieces) is done by welding. such as machining. and vianumerical control (CNC) cutters (using a laser. may be similar in shape and function. machine shops also cut metal. both human labor and automation are commonly used. Firms that encompass both fab work and machining are also common. millwrights originally specialized in setting up grain mills and saw mills. binding with adhesives.  Bending is done by hammering (manual or powered) or via press brakes and similar tools.

To define the process. civil and architectural. Plate steel is loaded on a table and the parts are cut out as programmed. Some very expensive burn tables also include CNC punch capability. a raw material piece is formed by applying force to an object. The support table is made of a grid of bars that can be replaced. Ironworkers. Special band saws designed for cutting metal have hardened blades and a feed mechanism for even cutting. Forming[edit] Forming is a process of material deformation. automotive. then are moved to the site by truck. although Fab shops will generally entail a limited . Abrasive cut-off saws. Plasma and laser cutting tables. Fabrication of structural steel by plasma and laser cutting introduces robots to move the cutting head in three dimensions around the material to be cut. Machining[edit] Machining is the process of removing unwanted material from the block of metal to get the desire shape. including jewelry. and Water jet cutters. rail. Machinery can also be used to regulate force magnitude and direction. usually natural gas powered. construction. Machining is a trade.(see example). in and of itself. etc.  welding wire/welding rod  casting Cutting and burning[edit] The raw material has to be cut to size. are also common. are similar to miter saws but with a steel cutting abrasive disk.[1] Proper design and use of tools with machinery creates a repeatable form which can be used to create products for many industries. also engage in fabrication. The force must be great enough to change the shape of the object from its initial shape. or barge.  plate metal  formed and expanded metal  tube stock. aerospace. The process of forming can be controlled with the use of tools such as punches or dies. also known as chop saws. The most common way to cut material is by Shearing (metalworking). and finally are installed by erectors. Cutting torches can cut very large sections of steel with little effort. Burn tables are CNC cutting torches. with a carousel of different punches and taps. This is done with a variety of tools. also known as steel erectors. An example of machine based forming can also combine forming and welding to produce lengths of fabricated sheeting. Often the fabrications for structural work begin as prefabricated segments in a fab shop. most commonly seen in the form of linear grating (used principally for water drainage) . Raw materials[edit] Standard raw materials used by metal fabricators are. Forming is typically applied to metals.

magnetic based drills. The formed and machined parts will be assembled and tack welded into place then re-checked for accuracy. along with other portable metal working tools. primed and painted. and straightening operations after welding. based on their customers needs and their expertise:  casting  chipping  extrusion  forging  heat treatment  hydroforming  plastic welding  powder coating . The finished product is then inspected and shipped. upon cooling. The welder then completes welding as per the engineering drawings if welding is detailed. linear sweep. Such weldments. These may include re-designing the weldment to use less weld. may be line-bored after heat treatment. metal lathes. particularly those employed for engine blocks. welding in a staggered fashion. Any additional manufacturing specified by the customer is then completed. covering the weldment in sand during cooling. Welding[edit] Main article: welding Welding is the main focus of steel fabrication. Steel weldments are occasionally annealed in a low temperature oven to relieve residual stresses.machining capability including. in the direction of the sweep. The steel will have a net contraction. Special precautions may be needed to prevent warping of the weldment due to heat. Straightening of warped steel weldments is done with an Oxy-acetylene torch and is somewhat of an art. using a stout fixture. or as per his/her own judgement if no welding details are provided. Heat is selectively applied to the steel in a slow. Specialities[edit] Many fabrication shops have speciality processes which they develop or invest in. A highly skilled welder can remove significant warpage using this technique. A fixture may be used to locate parts for welding if multiple weldments have been ordered. mills. Final assembly[edit] After the weldment has cooled it is generally sand blasted.

 powder metallurgy  welding .