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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Stainless steel fabrication Brisbane makes use of several techniques to turn basic steel into desired shapes to provide specific functionalities for a project. Steel fabrication has come a long way since steel metal was first harnessed in the 17th century for mass production. Advancements in steel fabrication technologies such as Computer Numerical Control (CNC) that monitor and control the movement of machines such as routers and welders has allowed for the most accurate fabrication results. The use of 3D modelling in steel fabrication Brisbane has made it easier to visualize even the most complex components and work on them with precision and accuracy. Manipulation techniques used in the custom fabrication Some common manipulation techniques used in custom steel fabrication Brisbane include the below ones: Shot blasting: Steel sections are blasted with shots to remove any impurities. The process provides a clean finish for ease of welding and surfaces rough enough to be painted. Shot blasting is used in a variety of industries including shipbuilding, construction, and steel structures such as silos, pipelines, and tanks. Bending: Modern steel architectures include more intricate steel shapes and elements that require the use of specialized tools and techniques. Applications such as passing a steel section through a roller bender a number of times to obtain an arc requires specific bending techniques. For straightforward bending, press braking is used by fab shops. Cutting: Steel metal is cut into sections so that it becomes easier to work with. Modern fab shops in Brisbane use many techniques for this purpose including plasma cutting, flame cutting and circular sawing. Coating: Galvanization is a popular steel coating method in which a steel surface is coated with zinc to prevent corrosion. Painting custom colours can also be achieved with the help of galvanization. Benefits of lean manufacturing Lean manufacturing has prompted much of the recent turnaround in the metal fabrication processes with the elimination of waste and unnecessary material handling. Software that tracks steel inventory has helped in optimizing the material use. The operator doesn’t have to guide the machine by inputting specific instructions, such as the size of the hole from the top to the end. The software takes this instruction from the part file and automatically programs the machine to make all the cuts to bring out a piece of the desired shape. Automaton goes a long way in eliminating the waste of defective parts as the design information, which covers multiple fabrication processes, is transferred directly to the equipment. This approach of transferring 3-D model information directly to the machine eliminates the possibility of incurring errors in the field. Custom stainless steel fabrication Brisbane Custom stainless steel fabrication Brisbane is used in a variety of steel structures such as tension, compression and beam members, open web steel joist, rigid frames, domes, trusses, cable-supported roofs, vehicle accessories, ducting and a lot more. You can approach a trusted custom metal fabricator in Brisbane who can help you with all your custom steel and metal fabrication needs. An advanced metal fabrication shop would use robotics to meet the needs of challenging fabrication projects. Robotics also means that there is less danger to human life and the fabrication process can be completed faster and with more accuracy. The fabrication shop should also be able to meet your various requirements in metal, wire and aluminium fabrication. Working from highly detailed drawings, the fabricators require extensive knowledge of the properties of steel. They also need to have extensive knowledge of the steel fabrication processes. Bringing your ideas to life Brisbane Metal Products has extensive capabilities in developing a wider range of stainless steel fabrication Brisbane profiles including pipe works, angled sections, tapered flange beams, channels, C-beams, rolled channel sections and a lot more. BMP has a broad steel fabrication Brisbane activities base with Australia-wide distribution and overseas distribution capabilities. The company installs fabricated steel and cladding to clients operating in a variety of industries including structural construction, plant maintenance, civil works, military and defence, and many more. Fabricators at BMP work closely with steel detailers and drafters that provide you with the detailed drawings and designs to bring your custom steel fabrication ideas into life. Design Strategy Elements for Cost-Effective Custom Fabrication With a Higher Productivity Rate11/4/2020 Custom metal fabrication is used in a variety of industrial applications involving sheet metal, precision tubes, laser cladding, architectural panels, structural beams, electron beam welding, artistic elements, etc. Fabricated metal parts are preferred for their broader range of mechanical properties. These parts are durable and offer high excellent structural strength and longevity. The machines used in metal fabrication Brisbane have high replicating capabilities that make it possible to produce parts at a low cost per unit. The fabricator works closely with the customer to take minimise the overall cost out of the broader process. It could include changes in component design and delivery schedules, among other things. Elements of design strategy Sheet metal fabrication involves a set of design strategies to develop a sheet metal product. Choosing a less expensive material in the design strategy, such as using aluminium instead of copper, would helps in keeping the fabrication costs low. Also, as stock sizes are anyways cheaper than metal sheets, the former should be chosen in the design strategy to keep the costs low. Take note that sheet metal parts start flat, so a common gauge should be used for all its features and functionalities. Care should be taken to design simple angled bends with a bigger radius as the bend angle becomes smaller while fabricating a workpiece due to an increase in strain on it. The hole size should also be kept larger than the thickness of the material as the cost of smaller holes is higher. Additionally, smaller holes may can also easily cause distortion during cutting. The design should be kept simple so that the conventional press brake can be used for forming and bending purposes. Choose a metal with a lower tolerance, it will have a lower defection rate while providing you with a higher production rate. Laser cutting for precise cuts Laser cutting is an energy-efficient technique used by fabricators that provides precise cuts in sheet metals. On the other hand, punch cutting is ideal for small size applications. Cutting is followed by forming or material deformation. The process includes rolling, spinning, bending, welding, and stamping. The prototyped parts are finished with an abrasive to eliminate all rough spots and edges to provide it the perfect finishing that may be followed by a finish progress process such as painting and anodizing. A variety of custom metal fabrication Brisbane approaches are followed by the fabricators,. Simple fabrication processes have a quick turnaround and a steady cash flow while complex jobs, such as those involving a nuclear facility or refinery may take months for the fabricators to plan, coordinate and complete a single job. Shifting technology focus on to custom fabrication Metal fabrication Brisbane may involve a narrow or broad technology focus, based on the requirements of the project. For example, a high-end prototyping project would require broader use of technology while a cutting and bending operation will have only a narrow use of technology. Still, some other custom metal fabrication Brisbane processes may involve broad technology mixes to accomplish tasks related to cutting, grinding, powder coating, complete assembly, and stamping. Custom metal fabrication Brisbane services may extend to private-label work wherein the fabricator handles all aspects of supply chain management, manufacturing and logistics, producing, assembling and shipping products directly to their customer’s customers. Achieving complex custom fabrication with robotics As a leading custom metal fabrication Brisbane provider, Brisbane Metal Products (BMP) makes use of the cutting-edge fabrication tools and techniques to fulfil the requirements of a variety of metal fabrication Brisbane projects. Considering the high variety of work they process, BMP has carried out robotics integration in its fab shop that which has provided it the capability to achieve complex fabrication tasks accurately, faster and in a cost-effective way. Sheet metal services offered by BMP include water jet, punching, laser cutting, grinding, CNC bending, metal stamping and a broad selection of metal fabrications Brisbane with all kinds of finishes and specialised requirements including standard, powder coating, anodizing and bead blasting. BMP has extensive capabilities in rapid prototyping to mass production to keep your metal fabrication Brisbane projects on track. Leveraging the capabilities of its experienced engineers and design experiences, BMP can provide you with the parts efficiency that you need. The advantage with Brisbane Metal Products is that the fab shop may offer you previously unheard of technology mixes to accomplish your custom fabrication requirements and provide you a competitive edge. |
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