Metal fabrication

People make things from metal.

First, they cut the metal. They can use saws or torches. Next, they bend the metal into shapes. They use tools to push it.

Then, they join the pieces together. They might use heat to weld them. They can also use screws.

This makes parts for cars or planes. It can even make jewelry. Metal shops build many big things.

Metal fabrication is a way to make metal parts.

People use this to build machines and big structures. A shop that does this work is called a fab shop.

First, workers must cut the metal. They can use saws or chisels. Some use a torch to burn through steel. They can also use CNC cutters. CNC means a computer controls the tool. These tools use lasers or water jets to cut.

Next, they use forming to change the shape. This turns flat metal into 3-D parts. They use force to bend the metal. This does not add or remove any metal. They may use a press brake to bend sheets.

Finally, they use assembly to join the pieces. Welding is a main part of this. A welder uses heat to join metal parts.

Sometimes, heat can make the metal warp or bend. Workers might use sand to help it cool. They can also use a torch to straighten it. After the work is done, they may paint the metal. This makes the final product ready to use.

Metal fabrication is the way people make metal structures. It involves cutting, bending, and joining pieces together. This process turns raw materials into useful machines and parts. A shop that does this work is called a fab shop. These shops often win jobs by bidding on engineering drawings. They use many different steps to add value to the metal.

There are many ways to change metal. First, workers must cut it into the right shapes. They can use saws, chisels, or even handheld torches. Some shops use CNC cutters, which are controlled by computers. These machines might use a laser, a torch, or a water jet. Next, they use forming to change the shape of flat metal. This uses force to turn flat sheets into 3-D parts. This step does not add or remove any metal.

Different types of workers have helped with this for a long time. Blacksmithing has always involved making things from metal. In the past, boilermakers specialized in making large boilers. Millwrights used to focus on setting up grain and saw mills. Today, ironworkers or steel erectors use parts made in fab shops. They take these segments to building sites to put them together. These workers help build the world around us.

Fab shops use many specific materials and tools. They work with plate metal, tube stock, and structural steel. Welding wire and rods are used to join pieces together. For cutting, many shops use a shearing method. Some use a burn table, which is a computer-operated torch. These tables often use natural gas to power the flame. High-end tables might even use a carousel of punches.

Assembling the parts is a very important step. Welding is the main way to join metal pieces. Workers might use fasteners, rivets, or even strong glues. Sometimes, the heat from welding makes the metal warp. To fix this, a welder might use an oxyacetylene torch. They apply heat in a slow sweep to straighten it. Once the metal is cool, they might sandblast or paint it.

Metal fabrication is the technical process of creating metal structures. It involves cutting, bending, and assembling various raw materials. This is a value-added process because it turns simple materials into complex machines or parts. A shop that performs this work is called a fabrication shop, or a "fab shop." These shops usually win contracts by bidding on specific engineering drawings.

The fabrication process begins with cutting the raw material into specific shapes. Workers can use manual tools like saws, shears, or chisels. They can also use handheld torches, such as plasma or oxy-fuel torches. Many modern shops use numerical control (CNC) cutters. These computer-operated machines use lasers, water jets, or mill bits to cut with high precision. Some shops use burn tables, which are CNC torches powered by natural gas. In advanced setups, robots move the cutting head in three dimensions around the metal.

After cutting, the metal undergoes forming to change its shape. Forming converts flat sheet metal into three-dimensional parts. This process applies force without adding or removing any material. To do this, machines use tools called punches and dies. The force must be strong enough to cause permanent deformation. Most metallic materials are ductile, meaning they can bend without cracking or breaking. This allows fabricators to create repeatable shapes for industries like aerospace, automotive, and construction.

Assembling is the stage where individual pieces are joined together. Welding is the primary method used in steel fabrication. To prepare, workers might tack-weld parts in place and check them for accuracy. They may also use a fixture to hold multiple parts in the correct position. Other joining methods include riveting, using threaded fasteners, or using adhesives. Some pieces are joined by further bending, such as creating crimped seams.

Welding introduces significant heat, which can cause metal to warp. This warping is a common challenge in creating weldments, which are products produced by welding. To prevent warping, workers might use staggered welding or a stout fixture. They might even cover the metal in sand while it cools. If the metal does warp, a skilled welder can use an oxyacetylene torch to straighten it. They apply heat in a slow, linear sweep to make the steel contract. Some parts, like engine blocks, may also be annealed in a low-temperature oven to relieve stress.

Fabrication overlaps with several other metalworking specialties. Machine shops focus on machining, which is the removal of material from a metal block. They use lathes, mills, and drills to create solid components like gears, bolts, and screws. While machine shops and fabrication shops have overlapping skills, fab shops focus more on preparation and assembly. Other specialties include blacksmithing, which has always involved fabrication. Historically, boilermakers specialized in making boilers, while millwrights focused on setting up grain and saw mills. Today, ironworkers, also called steel erectors, use prefabricated segments from fab shops to build structures on-site.

Fab shops work with a wide variety of standard materials. These include plate metal, checker plate, and tube stock. They also use structural steel, casting, and expanded metal. To join these pieces, they utilize welding wire, welding rods, or flux. The finished product is often cleaned through grinding or sandblasting. Finally, it may be primed and painted before being inspected and shipped.