Metal fabrication Archives

Fabrication Of Steel And Its Various Applications

April 21, 2022

Fabrication of steel is a technique of creating a variety of components and items that we utilise on a daily basis. It’s a method of converting raw steel into a set of items that can be used in building projects. This procedure entails taking crude ingredients and forming them into the desired shape. You can contact bharat steel suppliers in Chennai for high-quality steel supplies.

The natural resources are cooled down and converted into completed steel products before being formed into various shapes in this manner. Steel production necessitates highly skilled personnel with prior expertise converting raw materials into marketable products.

The application of steel fabrication is determined by the end-use of the produced product. However, steel fabrication falls into three main categories,

Structural fabrication

Metalworking that is employed as part of the construction process is referred to as structural fabrication. Typically, stores, manufacturers, buildings, and skyscrapers use structural manufactured steels purchased from reputable steel dealers in Chennai.

Commercial fabrication

Fabrication for Business technique creates consumer-oriented commercial products. The greatest examples of businesses manufacturing are appliances and automobiles, as well as steel parts.

Industrial fabrication

Fabrication in the workplace creates components that are employed in the development of other machinery. The greatest examples of workplace fabrication are bandsaws and iron working machines.

Steel manufacturing process

Steel’s main features include stiffness, resistance to corrosion, and longevity. Punching, folding, cutting, machining, stamping, shearing, welding, and casting are the most common ways for producing steel. You can rely on steel suppliers to get it done according to your necessity. Here’s a quick rundown of how each of these steps works:

Punching

Punching is indeed the process of making an opening in a metal piece by placing it under a die and drilling it through. To fasten the latches on each other, wells are created into a plate of steel in most situations.

Folding

Folding requires manipulating steel into a certain shape and is one among the most challenging tasks. In this method, the steel panels are pleated at a right angle or at various degrees to make the product somewhat blunt.

Cutting

Dividing the steel plate into halves, thirds, or smaller parts is the most often used steel production method. Typically, the sheets or bars are chopped and reshaped into new shapes. Laser beams and fusion flames are used to cut them, resulting in a more complicated and high-tech sculpture.

Machining

This is the process of dismantling the parts of a metal object. The procedure is commonly carried out on a lathe, which revolves the steel along equipment which trim the rough edges to shape the item.

Stamping

This is a fabrication method for forming plain metal pieces into specific forms. It’s a sophisticated procedure that includes blanking, punching, bending, and piercing, among other metal forming techniques.

Shearing

This is a metal fabrication technique that involves cutting alignments on a plain steel plate. An upper blade and a lower blade are built near with a little gap between them during this procedure. The blades are normally fixed. Shearing of steel can be done on layers, strips, bars, plates, and even angular metal stock.

Welding

This process involves the joining of two separate metal parts. The parts used in this process include sheet, panels, bars or any other shaped steel. They are joined together through numerous methods and machines that result in finished usable products.

Casting

Casting is a method of pouring molten metal into a mould that contains a hollow cutout of the required shape. After the molten metal has solidified, it is taken from the furnace, showing the finished result, also known as the “Lay up Form.” Casting is appropriate for a wide range of intricate shape-making since it is one of the most adaptive ways of metal fabrication. Jewellery, sculptures, and weaponry are some of the most common examples. Steel is utilised in a variety of applications, from staplers to plane parts. It comes in a variety of grades with different chemical compositions. At Bharat Steels, we give you high-quality steel that is long-lasting and reliable.

Metal Extrusion And Its Advantages In Various Industries

February 4, 2022

The various characteristics of the metal products have to be kept in mind before manufacturing. The steel suppliers and manufacturers should consider multiple techniques to get the desired result. Metal extrusion is one of the manufacturing processes where the raw steel materials are converted into desired shapes and sizes. So, the raw materials can be in the form of billets or a bar which is subjected to a machine that has a hollow cavity, high-force hydraulic press, and predefined cross-sectional profile. Thus, the resulting output is called extrudates. These extrudates can be any shape ranging from bars, cylindrical, longitudinal, and even steel or aluminimum based products. Thus, metal extrusion is one of the ideal manufacturing processes which yields products ranging from basic to complex at required cross-sections. Metal extrusion and its advantages in various industries are plenty that are used in commercial, industrial, and retail sectors. If the steel has undergone a galvanization process, then extrusion adds a layer of strength that makes the steel even more resistant to corrosion. Hence, listed are the advantages of using extrudates.

Flexibility:

The foremost advantage of using steel products processed from extrusion is they offer higher flexibility. As we all know, steel is one of the versatile metals and can be transformed into any shape. Similarly, steel is the ideal example of flexibility and it can undergo maximum strain and stress. For example, in motorcycles, you can see the steel spring in the shock absorber undergoes compression and returns to its original shape within seconds. Just imagine for a normally galvanized steel, the flexibility is higher than extruded steel. The reason for the extruded steel product’s higher flexibility is due to the cross-section in respect to the design. That is the reason why many industries like agricultural, automobile and even HVAC industries use extrusion processed steels for their products. Even extruded MS chequered plate is best for industrial flooring and grating over the gutter.

Precision:

Another benefit of using extruded steel is they have higher precision because of its cross-sectional profile. Precision is the most important factor in every industry or project from protecting the smallest component to complex heavy machines. For example, you need to seal the non-seamless pipes with steel products that are of accurate dimension. So, the pipe fittings undergo the metal extrusion process which offers greater precision and prevents leaks and damage during major problems. The metal extruded SAIL TMT bar are used for construction purposes due to their flexibility and precision.

Reduces welding:

Thirdly, the metal extrusion process eliminates the high-intensive process like welding. Welding is tedious and requires a lot of manual work. Sometimes you may end up wasting the material to get the desired shape. Thus, by the dedicated cross-section extrusion process, many manufacturers and JSW steel dealers in Chennai are creative in the process of the products with interlocking patterns.

Hence, these are the processes in metal extrusion that benefits every steel manufacturer out there. Bharat steel – is the best MS steel suppliers in Chennai to help their clients to get the desired extrudes.

Different Types Of Metal Fabrication

January 29, 2022

Every building or structure that you see today is nothing without steel. Steel is one of the essential construction materials that stands stable for the years to come. But have you ever thought about how steel is fabricated into the desired shape before reaching your hands? Hardly, right? However, the steel we use as tubes and pipes undergoes various fabrication processes to meet the construction requirements. So, we can say that metal fabrication is a process where the raw materials are created into desired structures by various processes. The steel suppliers in Chennai consider the different types of metal fabrication as a value-added process because it is where they are created, developed, and assembled. So, the metal fabricators work with a wide range of raw materials which includes plate metal, welding cast metal, wires, and rods. Thus, let us see the various processes involved in fabricating steel and other metal products.

Cutting:

The foremost process involved in metal fabrication is cutting. You can say that the cutting process is one of the earliest fabrication processes and most of the MS steel suppliers in Chennai follow this method. So, typically a cutting process is used to cut the unwanted pieces despite being a ferrous or non-ferrous metal. The cutting process can include machines from basic to complex. The metal fabricators name these final metal products depending on their cuts. The cutting tools involved in the metal cutting process are backsaw, hacksaw, and coping saw. Similarly, sometimes for complex metal fabrication, metal fabricators use power tools like drilling and grinding.

Metal stamping:

Next, a popular metal fabrication process is metal stamping. This process is more beneficial if the raw material is in the sheet format. So, the process involves transforming the flat sheets into desired shapes. These metal sheets are punched, bent, and pierced to obtain a specific shape. These stamping processes are ideal for metals, like carbon steel, stainless steel, aluminium, bronze, MS chequered plate, and various alloys. Thus, metal stamping finds its application in the automotive industry to design components like wheel hubcaps, trunk lids, firewalls, doors, and other vehicle-related parts. Another reason why metal stamping is used in the automotive industry is to customize the design as per the client’s requirements.

Welding:

Thirdly, steels surely undergo the welding process because of high usability. Welding is a fabrication process where two or more steel or metal parts are joined together under high heat and pressure. This process includes equipment like shielding gas, consumable and non-consumable electrodes, fillers, flux, and welding machines. As there are various welding techniques involved and the most common methods are Gas Tungsten Arc Welding, stick welding, and Gas Metal Arc Welding (GMAW). These methods are used in fabricating steel pipes, SAIL TMT bar, automotive manufacturing, steel-building, and bike-making.

These are the prominent and different types of metal fabrication that are used in making components suitable for industrial sectors and everyday life. Bharat Steel is the best JSW steel dealers in Chennai for high-quality steel products that are ideal for customization and match the user’s preference.

Methods Involved In Metal casting

December 2, 2021

As we all know, steel is the essential core metal that every building includes. But have you ever thought about how steel gets its defined form? Metal casting is the process that transforms the steel into its desired shape or form. The molten form of the metal that is steel is poured into the desired mold. It is then allowed to cool and harden to obtain the desired shape. Hence, many MS steel suppliers in Chennai use numerous techniques to cast the metal as per the requirements. So, there are two types of molds used by various industries, and they are reusable and expandable molds. The reusable molds can be used numerous times, and the mold won’t melt in the process, whereas the expandable molds can’t be reused. Hence, in this post, let us know the methods involved in metal casting.

Permanent mold casting:

This type of casting comes under reusable molds or permanent molds. It is a simple process where the molten steel is poured into the mold. Then it is allowed to solidify to obtain the desired shape. The only thing to remember in this process is that the mold must have a higher melting point than the molten steel that is poured. Hence, metals that have low melting points like aluminium, zinc, copper, and tin are preferred in permanent mold casting. In some cases other than the specified alloys, iron casting is also done in this mold. Many steel dealers heat the permanent mold before pouring the molten metal. The high temperature causes the molding to break if precautions are not taken.

Semi-permanent mold casting:

Another type of steel casting is semi-permanent mold casting that comes under reusable molds. This mold consists of two halves with a sand core in the center. The molten steel is poured into the mold cavity surrounding the sand core. Then, after cooling them for a while, the casting is removed with sand core leaving a passage in the casted product. This type of mold casting is suitable for alloys and metals because the mold can be reused. But ensure that the sand has to be changed each time for casting. Hence, the term is called semi-permanent mold casting. This type of casting is used to make valve bodies, torque converters, MS chequered plate, blowers, and many more.

Slush mold casting:

It is also a steel metal casting that comes under reusable molds. The slush mold casting is also suitable for alloys and metals to create a hollow cast in the center. The molten steel is poured into the mold cavity and allowed to cool. The steel hardens over time and starts to form a shell-like structure. Finally, the remaining liquid is poured out to form a hollow shell. This type of molding is used to make low-weight steel casting.

Similarly, the construction industry uses the SAIL TMT bar for building bridges, flyovers, and many more. In some places, Cast iron TMT bars are used to meet the requirements. Hence, depending upon needs and purpose, steels are fabricated by various casting methods.

All you need to know about Metal Fabrication!

May 21, 2021

There is a significant trace of metal fabrication in every object that you see in real life. From the smallest of the kitchen appliances to the moving car, from the smallest of the nuts and bolts to the grand architectural creations—Everything has undergone varying levels of fabrication. You might not even recognize them. You would be oblivious to the elaborate process they have gone through to attain the current state.

Metal fabrication is an integral part of the construction industry. All Steel Suppliers play an important role in metal fabrication by supplying the best quality steels to the fabrication companies and workshops. The output of the fabrication process weighs heavily on the strength and quality of the steel as much as the skills of the fabricators.

What is Metal Fabrication?

In simple terms, metal fabrication is altering the form of sheet and flat metals like MS chequered plate to fit the requirements. Generally, no materials will not go along with the other components in the construction as it is. The dimension may be larger than expected. The shape may not be compatible. Therefore, any metal goes through a certain degree of fabrication or modification to comply with the specifications of the project.

The metals go through cutting, welding, casting, and other processes depending upon the material and its purpose. These activities are carried out by specialized metal fabricators who can slice any metal to perfection. We will look at this in detail in the following section.

The different facets of fabrication

1 – Cutting

This is the most basic fabrication process followed to bring the material into use. Out of the whole, certain portions in the desired dimensions are cut out. They may be cut to a certain shape or size based on the necessity of the project.

2 – Cast

The hot, liquid metal is poured into a predefined mold. Later, when the liquid cools down and the mold is removed, the metal retains the shape of the mold. This process is easy to achieve intricate designs rather than cutting them.

3 – Folding

High pressure is applied to the surface of the metal. It allows for a fabricator to bend the material to a certain degree as needed. It is a complex process and may need the latest technologies to perform this process effectively. For example, a SAIL TMT Bar is bent accordingly to form the desired shape.

4 – Welding

This is also one of the most commonly used fabrication processes. Any two or more metal components are fused together by using a considerate amount of heat. It makes all the independent jell together as a single unit.

Applications of Metal fabricated products

The use of Metal fabricated products is never-ending and prevalent across all industries. Hence, metal fabrication contributes a lot to the construction industry, even though its presence is hidden from the naked eye.

The complexity in the construction process and the time has significantly reduced in recent years. Thanks to structural frames. Fabricated products make up the skeletal structure for the buildings no matter their size or scale. Beams and MS plates along with other fabricated materials make the structure of the building. Since the MS plate price in chennai is fairly economical, therefore they are one of the widely used materials in the process.

Fabrication plays an important role in the Ship-building industry because they are known to be the largest consumer of steel. Fabricated materials are essential for the whole structure to stand firmly.