Achieving excellence in aluminium and heavy metal fabrications with industry-leading practices11/20/2020 Aluminium alloys made with zinc, copper, magnesium silicone and manganese are commonly used in fabrication methods. These are normally supplied as semi-finished products such as extrusions and sheets, which are then fabricated into finished products.
The corrosion resistance of aluminium is due to a tough oxide layer on its surface that must be removed through chemical, electrical, or mechanical means. The oxide layer should also be prevented from reforming before the welding is completed. However, care should be taken not to overheat the metal as it has a higher thermal conductivity compared to other metals such as steel. Welding aluminium alloys Aluminium alloys can be easily welded through spot resistance or MIG and TIG welding methods. Spot welding is most suitable for assembling sheet parts while MIG welding is suitable for a plate thickness of more 6 mm. It allows for high current density with deep penetration. There is less total heat input and hence lesser chances of distortion. TIG welding is suitable for lighter gauge material with larger section thickness ranging from 0.8 mm to 12.5 mm. Both TIG and MIG welding processes electronically removes the oxide layer with a higher melting point from the aluminium surface. Welding aluminium with dissimilar metals Large differences in properties such as thermal conductivity, melting point and thermal expansion make it difficult for heavy fabrication services Brisbane to weld aluminium with dissimilar metals such as steel. As such, explosion bonded transition joining method is used by aluminium fabrication Brisbane to join aluminium with dissimilar materials. This method to join dissimilar material with aluminium uses a cross-section of the bimetallic strip with an appropriate aluminium alloy on one side and dissimilar material on the other side. It creates a filler bridge between the dissimilar metals with each metal welded directly to the corresponding metal. Spot, seam, flash, and wire resistance welding methods are commonly employed by heavy fabrication services Brisbane that result in excellent joints. Resistance welding is more suitable for high-strength heat-treatable alloys. Cutting aluminium workpieces Aluminium can be cut by many different methods by fabrication services Brisbane, depending upon its shape and form. Its plate can be cut with laser, plasma, or water jet to produce intricate shapes. The advantage of water-jet cutting is that it lacks heat, so there is no alteration of its properties. Aluminium extrusion and tube are usually cut with a carbon-tipped circular saw blade on which a stick wax may be applied for lubrication. Imparting additional strength to aluminium alloys While working on non-heat treatable aluminium alloys, additional strength is achieved by heavy fabrication services Brisbane by work hardening the metal and softening it in an annealing stage until the desired properties are achieved. For heat-treatable alloys, additional strength is achieved through heating followed by rapid cooling, which is known as quenching. Deep drawing Deep drawing is a valued method used by aluminium fabrication Brisbane to produce seamless products such as cans. The process uses extremely high forces to push a sheet into a female draw cavity with appropriate lubrication. 3003, 5005 and 5952 aluminium grades are best suited for the deep drawing process. Bending methods The below four bending methods are used in heavy fabrication factories for aluminium fabrication Brisbane: Three-roll bending: A central roller is gradually depressed on the workpiece until the desired radium is achieved. Wrap and mandrel welding: Formers and support tools are used to bend aluminium to tight radii while minimizing buckling at the same time. In wrap bending, the former moves around the section, while in mandrel welding the section moves around the former. Three-point bending: The bending process is used on strong sections that involves gradual or impactful application of load. Stretch forming: The process involves working with a section tension wrapped around a former to minimise compression failure. Brisbane Metal Products (BMP) provides aluminium and heavy metal fabrication services using the latest tools and techniques of metal fabrication. Their expert fabricators use published bend radii tables before bending a workpiece for the most precise results. BMP has also implemented robotic practices in its aluminium fabrication Brisbane processes to automate and speed up the process. The fabricators can be approached for all types of cost-effective solutions for heavy fabrication services Brisbane with industry-leading practices.
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