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 creation of metalstructures by cutting, bending and

assembling processes. It is a value-added[1] process involving the creation of
machines, parts, and structures from various raw materials.
Typically, a fabrication shop bids on a job, usually based on engineering drawings, and
if awarded the contract, builds the product. Large fab shops employ a multitude of
value-added processes, including welding, cutting, forming and machining.
As with other manufacturing processes, both human labor and automation are
commonly used. A fabricated product may be called a fabrication, and shops
specializing in this type of work are called fab shops. The end products of other
common types of metalworking, such as machining, metal stamping, forging,
and casting, may be similar in shape and function, but those processes are not
classified as fabrication.
ProcessesEdit
 Cutting is done by sawing[2], shearing, or chiseling (all with manual and poweredvariants);
torching with handheld torches (such as oxy-fuel torches or plasma torches); and
via numerical control (CNC) cutters (using a laser, mill bits, torch, or water jet).[3]
 Bending is done by hammering (manual or powered) or via press brakes, tube bendersand
similar tools. Modern metal fabricators use press brakes to coin or air-bend metal sheet into
form. CNC-controlled backgauges use hard stops to position cut parts to place bend lines in
specific positions.
 Assembling (joining of pieces) is done by welding, binding with adhesives, riveting, threaded
fasteners, or further bending in the form of crimped seams. Structural steeland sheet metal are
the usual materials for fabrication; welding wire, flux and/or fasteners are used to join the cut
pieces.
 Fabrication comprises or overlaps with various metalworking specialties:

 Fabrication shops and machine shops have overlapping capabilities, but fabrication shops
generally concentrate on metal preparation and assembly (as described above). Machine
shops cut metal, but focus primarily on the machining of parts on machine tools. Some firms
do both fab work and machining.
 Blacksmithing has always involved fabrication, although that term has not always been used.
 Welder-produced products, often referred to as weldments, are examples of fabrication.
 Boilermakers originally specialized in fabricating boilers, but the term is now used more
broadly.
 Millwrights originally specialized in setting up grain mills and saw mills, but now perform a
wide range of fabrication.
 Ironworkers, also known as steel erectors, also engage in fabrication. They often work with
prefabricated segments, produced in fab shops, that are delivered to the site.

Raw materialsEdit

Standard metal fabrication materials are:

 Plate metal
 Formed and expanded metal
o Tube stock
 Welding wire/welding rod
 Casting

Cutting and burningEdit

A variety of tools are used to cut raw material. The most common cutting method
is shearing.
Special band saws for cutting metal have hardened blades and feed mechanisms for
even cutting. Abrasive cut-off saws, also known as chop saws, are similar to miter
saws but have a steel-cutting abrasive disks. Cutting torches can cut large sections of
steel with little effort.
Burn tables are CNC (computer-operated) cutting torches, usually powered by natural
gas. Plasma and laser cutting tables, and water jet cutters, are also common. Plate steel
is loaded on the table and the parts are cut out as programmed. The support table
consists of a grid of bars that can be replaced when worn. Higher-end burn tables may
include CNC punch capability using a carousel of punches and taps. In fabrication of
structural steel by plasma and laser cutting, robots move the cutting head in three
dimensions around the cut material.
FormingEdit
Forming converts flat sheet metal into 3-D parts[4] by applying force without adding or
removing material.[5] The force must be great enough to change the metal's initial
shape. Forming can be controlled with tools such as punches and dies. Machinery can
regulate force magnitude and direction. Machine-based forming can combine forming
 and welding to produce lengths of fabricated sheeting (e.g. linear grating for water
drainage).[6]
Proper design and use of tools with machinery creates a repeatable form that can be
used to create products for many industries, including jewelry, aerospace, automotive,
construction, civil and architectural.

MachiningEdit
Main article: Machining

Machining is a specialized trade of removing material from a block of metal to make it

a desired shape. Fab shops generally have some machining capability, using
metal lathes, mills, drills, and other portable machining tools.
Most solid components, such as gears, bolts, screws and nuts, are machined.

WeldingEdit
Main article: Welding

Welding is the main focus of steel fabrication. Formed and machined parts are
assembled and tack-welded in place, then rechecked for accuracy. If multiple
weldments have been ordered, a fixture may be used to locate parts for welding. A
welder then finishes the work according to engineering drawings (for detailed
welding) or by their own experience and judgement (if no details are provided).
Special measures may be needed to prevent or correct warping of weldments due to
heat. These may include redesigning the piece to require less welding, employing
staggered welding, using a stout fixture, covering the weldment in sand as it cools, and
post-weld straightening.

Straightening of warped steel weldments is done with an oxyacetylene torch. In this

highly specialized work, heat is selectively applied to the steel in a slow, linear sweep,
causing the steel to contract in the direction of the sweep as it cools. A highly skilled
welder can remove significant warpage this way.
Steel weldments are occasionally annealed in a low-temperature oven to
relieve residual stresses. Such weldments, particularly those for engine blocks, may be
line-bored after heat treatment.
Final assemblyEdit
After the weldment has cooled, it is generally sandblasted, primed and painted. Any
additional manufacturing is then performed, and the finished product is inspected and
shipped.
SpecialtiesEdit

Many fabrication shops offer specialty processes, including:

 Casting
 Powder coating
 Powder metallurgy
 Welding
 Machining