Stainless steel is an alloy of iron and chromium with improved resistance to corrosion and heat. Its enhanced mechanical properties make it suitable for custom metal fabrication for use in a variety of applications. Stainless steel is widely used in fabrication processes as it is malleable enough to be machined, folded, bent, spun, or deep drawn.
A wide range of fabrication techniques are currently available including work hardening and machining. Compared to other varieties of steel, stainless steel work hardens quickly, however, a custom metal fabrication process should consider matching the steel grade with a treatment that is best suited for use in a specific application. For example, austenitic steel work hardens faster than carbon steel which makes it a favourite of many custom metal fabrication processes in Brisbane. Faster work hardening rates make austenitic and martensitic stainless steels appropriate for use in projects that require corrosion resistance and strength. Work-hardened stainless steel Work hardened stainless steel also exhibits a higher magnetic capacity after treatment. In some instances, stainless steel can be cold worked up to 1,000 MPa. When cold-drawn, it can reach tensile properties of 2,000 MPa. However, this high tensile strength is usually limited to fine wires and thin sections. Achieving high tensile characteristics from cold-drawn stainless steel becomes unsuitable due to the rapid work hardening rate of larger surfaces. While working with work-hardened stainless steel, some high-speed forming processes may need to be slowed down to enhance efficiency as it undergoes greater deformation at slower forming speeds. Moreover, Grades 303, 430, 410 and 416 have manganese sulphide that limits their machining applications. High sulphur levels result in reduced ductility and forging. More options in steel fabrication Laser cutting is another custom metal fabrication technique used by stainless steel fabrication Brisbane. A laser-cutting machine is used to make a perfectly smooth and stress-free cut in the metal. Laser machines are often used in place of CNC punching as less stress is exerted on the metal surrounding the hole so the sheet metal remains considerably stronger. The metal brake bending technique applies several tons of force to the sheet metal to quickly achieve the bend of the desired angle. Welding stainless steel Most stainless steel fabrication Brisbane processes can weld stainless steels, but the degree of efficiency depends on the grade. For example, Grade 2205 has a low thermal expansion and as such is welding-efficient, while ferritic stainless steel is less suitable for welding as it has low ductility and sensitization. Only a stainless steel fabrication Brisbane facility with state-of-the-art welding equipment can weld all types of stainless steel as they use a welding machine to make faster and accurate welds than what a human welder can achieve, minimizing burns and spatter. TIG and MIG welding TIG welding uses a non-consumable tungsten electrode to produce the weld. A constant-current welding power supply is used in TIG welding which produces electrical energy to be conducted across the arc. The technique is commonly used to weld thin sections of stainless steel and non-ferrous metals. Another welding technique, known as MIG welding, uses a solid wire electrode run through a welding gun to join the sheets of metal. The equipment used in TIG welding automatically regulates the electrical characteristics of the arc. MFDC welding technique Some fabricators use a computer-controlled welding machine that takes advantage of Medium Frequency Direct Current or MFDC to provide welds with fewer deformities compared to the TIG or MIG Welds. The control and power supply system takes alternate current as input and converts it into an inverted higher power output. The process allows for welding 30 times faster than an AC welding machine. Achieving resistance to chipping Some grades of stainless steel achieve resistance to chipping when alloyed with manganese sulphide. The chipping problem can be overcome by selecting machinery with less vibrations, making the cutting edge sharp, and maintaining light cuts and feeds. More than 50 stainless steel grades are available in Australia for custom metal fabrications. Austenitic steel grades 304 and 316 exhibit improved machinability. It is produced through a process that has a sufficient chip breaking effect that provides it excellent mechanical properties related to formability, weldability, and resistance to corrosion.
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Gain tangible improvements in heavy fabrication and wire straightening with innovative solutions10/23/2020 Traditionally, heavy fabrication has relied on the people, cranes, and manipulators to manoeuvre large and weighty pieces. Manufacturing large parts, such as equipment for agriculture, defence, construction, and mining are limited by their ability to move these parts quickly and safely through traditional fabrication methods. Some fabrication activities, such as making bends required for laboriously moving the parts several times at a press brake, make the whole process cumbersome and slow.
However, of late, heavy fabrication services Brisbane have undergone a technological transformation with the increasing use of robotic automation. Robots have opened up the doors for manufacturers and metal shops with their versatile capabilities. For example, the manufacturing of the high-capacity lift trucks requires the moving of many heavy components and bending to create large flanges. It also requires the collaborative efforts of the operator, equipment, and technicians to remove, flip and return a part to the press brake for accurate positioning. Use of robotic automation in heavy fabrication Flipping a large part also requires clearing around the machine for workers which takes up precious floor space. Labourers also become fatigued due to constant heavy lifting. The use of a robotic system in heavy fabrication services Brisbane not only significantly increases productivity but also reduces scrap. A robotic arm can be used to quickly feed, flip and reorient the large forklift parts. It will make more use of the vertical space, so less area needs to be cleared around the machine. Intuitive robotic programming Use of robotic automaton in heavy fabrication services Brisbane also frees up the valuable production time of your workers. The fabricators can employ their workers in more rewarding jobs so that they work with more commitment towards the team’s success. Robots stand to make a large impact on heavy fabrication services Brisbane with their increased capabilities, the versatility of functions and extremely safe operations. With intuitive robotic programming available today, technicians in the fab shops can quickly learn program touch-ups after just a few hours of training. Wire straightening solutions Often you need a straight wire for your project but all that you have is coiled up or bent wire. Typically, wire is straightened by manipulating it through rolling and rotary styles. In rolling straightening, the wire is made to traverse a course around roll bearings. It is bent past its elastic point and then redirected to a straightened state. In the rotary style, straightening rolls are used to rotate the wire around it as it is pulled through the device. To obtain good results from the rotational point, the following four points should be considered carefully:
Additionally, the below considerations should be kept in mind for wire straightening projects: Wire line: The wire should travel in a straight line as far as possible once is paid off from reel, spoil, or coil through the straightening device. Pulling force: Jerky forces should be avoided, and the pulling force should be as consistent as possible. Back tension: The wire should always be pulled through the straightener device even if the back tension is applied on it. Lubrication: Lubrication should be used in all applications to get a consistent friction value from the straightening device. The benefit of the roll straighteners is that they can be configured with multiple planes that are less expensive. Roll straighteners can be set up easily and operated at speeds into the thousands of feet per minute. Multiple approaches to wire straightening solutions Many approaches to wire straightening continue to be used by heavy fabrication services Brisbane to meet the evolving needs of the modern wire forming and straightening applications. Precision wire straighteners with multiple planes can be used to get the utmost straightness and functionality. Roll style straighteners can be configured to form multiple shapes such as hex, triangle and diamond. A typical 2-plane style approach is good for breaking cast and general straightening of low tensile wire. 4-plane approach works well on the higher tensile wires and the projects that require more critical straighteners. However, a roll style straightening device may not be as effective as tensile strength approaches 300 ksi. Approach a trusted fabricator in Brisbane who can provide you with the best solutions for all your wire straightening and heavy fabrication services Brisbane, utilizing robotic automation and the latest innovations. |
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November 2020
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