A stainless steel fabrication process involves manufacturing pre-fabricated parts and components from stainless steel material, that is raw or stock. The fabrication methods used in different industries vary. It is common practice to roll-form, spin, deep draw, forge, bend, and fold with powerful forces due to the material’s high strength and hardness.
By Contributing Writer
Simply put, the steel manufacturing process involves the conversion of raw steel into products used to make products for building or assembly. Steel is a metal-containing alloy of steel or other metals. Fabricating with this metal is not the same as welding; fabrication is making something out of metal, while welding is done once the finished product is made.
Why Is Stainless Steel Fabrication Beneficial?
Each day, stainless steel demand grows, as does steel production. Even though this steel is expensive, the usefulness of it is hard to ignore, due to the fact that it does not rust, and is known for its high temperature resistance, among other factors. Stainless steel is also an excellent metal for recycling and repurposing. Something to consider is that the cost of purchasing new materials can be high, especially if something goes wrong during production. However, stainless steel fabricators have been making steel professionally for a long time, and therefore are able to produce quality results. Several raw elements are melted to produce stainless steel, including iron ore, nickel, silicon, chromium, and molybdenum. When mixed in the proper proportions, the metal’s numerous basic chemical components produce a robust alloy. Different varieties of steel are produced by varying proportions of its components. Each distinct combination of stainless steel is referred to as a grade. These are; 304 stainless, 316 stainless, and 420 stainless steel. With careful fabrication and welding, steel is less likely to change its chemical makeup. All of these factors are part of why stainless steel fabrication with a reputable company is important.
Stainless Steel Fabrication: The Process
The first step is to choose the stainless steel type and grade. Then, the stainless steel component ratio is determined by the manufacturing quality. The quality of every ingredient differs, and so do the proportions. When the raw ingredients have been obtained, the stainless steel production process can commence.
The fundamental procedures begin with melting the materials. The metal components are melted in the furnace. After melting, steel production can move on to the next phase, excessive removal of CO2. The metal is placed in an argon or vacuum oxygen system to remove unwanted carbon. The amount of carbon removed determines whether the metal is low or normal, which will affect the final product’s hardness and tensile strength.
The steel liquid is then agitated to disperse it and remove particles from the mix. This ensures the same quality and meets the needs of end users. When the steel cools, it is shaped in various ways. The first step is hot rolling to prevent crystallization. Stainless steel can also be cold rolled to produce metal blooms or billets. Then, it can be heated and annealed to minimize internal tension and change mechanical characteristics. Stainless steel is then laser-cut, bent, and shaped after annealing. A tube bending machine is then required to bend stainless steel, which can speed up production.
Shearing may be the next step, as it requires no heating and produces no waste in the form of chips. Rolling is best for reducing thickness and shaping. Steel sheets can be formed into standard structural sections or bespoke profiles. Furthermore, stainless steel has several properties that must be combined properly to provide faultless components. Therefore, Using CNC mills (Computer Numerical Control) is useful.
CNC machines are crucial in many industrial operations. Materials and components are created with CNC machines using computers. In other words, computers run the production line. Stainless steel is then sawed, sheared, or chopped with abrasive cut-off wheels.
Lastly, stainless steel is joined through welding. A surface must be cleaned and prepared before welding can take place. The gas used to shield is utilized in TIG and MIG welding. The welding gas can be disrupted, causing discoloration of the welding region or the heat-affected zone. A series of steps will be followed after the welds have been blended and levelled. Belts are utilized for alternate sanding and polishing as part of these steps. The product is now ready to be assembled. The assembly fasteners must be constructed from stainless steel like the plate, sheet, and bar stock, to help reduce the risk of rust.
Quality Control
With all of the steps mentioned to fabricate stainless steel, many wonder why it is important to use. However, stainless steel’s ability to withstand high temperatures makes it a great choice for fabrication projects. It can also be transformed into a metal that is resistant to extreme temperatures, making it a great choice for transportation and agricultural projects, among other industries. It has good corrosion and oxidation resistance, as well. This makes it a great choice for fabrication projects involving water, chemicals, or food.
The main principle behind stainless steel grade is that it may be categorized into three broad groups depending on the crystalline structure of its iron atoms: austenitic, ferritic, and martensitic. Each category is subdivided further into series and grades. The grades indicate the durability, quality, and temperature resistance of the specific alloy. The numbers stated after the grades pertain to the item’s chemical makeup, specifically the percentages of chromium and nickel.
In the metal fabrication industry, ‘quality control refers to the measures and standards put in place to maintain or improve the quality of the product and give customers the best product possible. There is always a strong emphasis on quality control in the metal fabrication industry as it reduces costs, keeps workers safe, and ensures standards are met. Businesses always have an in-house quality control program to keep serving their customers and get them to come back.
Quality control is an important part of the fabrication process because it helps keep things safe, productive, and legal. It also improves connection with customers. If you look at the big picture, keeping safety standards and quality control in place will only help. By doing this, the manufacturer builds a certain level of trust with the customer, making them more likely to buy from them for a long time.
Advantages of Stainless Steel
A great advantage is the lifecycle of stainless steel. Low-iron alloys are better for the environment than iron alone, but they often have other materials like zinc or aluminum that are not so good for the environment. A low-stress finish can be used, such as satin or matte, which is better for the environment than a high-gloss finish. Low-stress finishing is also a good choice for projects that need to be resistant to scale or stains, as it is better for the environment than high-gloss finishes.
To avoid accidents and injuries, employees who work directly on parts being made must be safe. Employees and people who run the machines should be taught about safety precautions and how to use the devices, among other things. It will make their job much easier. Safety can be increased by making prototypes that comply with standards, using OSHA-compliant materials, re-evaluating the designs, and making sure welders, tackers, and machine operators are qualified and education. Ensuring that the devices are shipped, handled, and stored properly is also an important consideration.
Running costs are high for a metal fabrication plant. In the same way that it is important to put the safety of employees first, it is also important to keep costs down without sacrificing quality or health. Using in-house engineers, picking the right materials, getting supplies directly from the mills, and other things can help cut costs.
Four Major Safety Considerations for the Metal Fabrication Industry
- Lack of protection. In this type of environment, being free from hazards is essential to keep a fabrication plant running. Employees need proper PPE, guards, and regular checks on all safety precautions.
- Lack of training. Training goes much further than initial qualifications – it has to be maintained, and continually renewed, on best practices, and refreshers of basic principles, to keep all employees up to date, and sharp on their knowledge.
- Lack of safety culture. Training can ensure employees are informed, but actually applying this knowledge depends on the culture of the workplace, and behaviour of other employees and managers.
- Lack of employee awareness. Burnout is also a common occurrence in this industry and needs to be monitored. Being mindful of one’s mental and physical state, as well as the overall moral of the workplace, will ensure safety and reduce risk of injury.
References:
- https://safestart.com/news/4-major-safety-issues-metal-fabrication-industry/
- https://www.abilityfab.com/
Conclusion
Stainless steel sheet metal has many benefits when it comes to making things. It is easy to work with, does not melt when welded, and lasts a long time. It is also resistant to corrosion and oxidation, has great resistance to scale and stains, is eco-friendly, surprisingly long-lasting, and has good corrosion resistance. Overall, it is a good choice for fabrication projects.