Article
August 1, 2009
Warm forming aluminum magnesium components
In all applications, being able to form complex features and details in a single step is an advantage. In addition, for automotive applications, improved forming characteristics open the possibility for more use of aluminum and magnesium to reduce vehicle weight.
In the 300- to 500-degree-C... Read more...
Article
July 1, 2009
Counting on the combo
Figure 1 Boon Edam produces a variety of revolving doors that have some unique fabrication requirements. Next time you enter a downtown hotel or office building, push the revolving door—then look up. There you'll see what the door industry calls ceiling pies, wedge-shaped pieces... Read more...
Article
June 30, 2009
Welding aluminum
Selecting an appropriate filler alloy for welding aluminum differs from selecting a filler alloy for welding steels. In the case of steel, selection is primarily a matter of matching the tensile strength of the filler metal to that of the base alloy. For aluminum, many variables come into... Read more...
Article
March 24, 2009
Age before welding in T6
In the last Aluminum Workshop, you talked about improving the welded strength of 6061 by welding in the T4 temper and aging after welding. But what happens if we weld in the T6 temper and age after welding? Does the weld get stronger, or does the extra aging cycle overage the T6 base material... Read more...
Article
January 27, 2009
Don't rule out plasma for cutting aluminum
Plasma cutting isn't new. But like any technology, it has its share of new developments. In any discussion about how to cut metal, it's right up there with laser and waterjet. The technology gets a bad rap, though, when the discussion turns to cutting aluminum.
Plasma cutting has been... Read more...
Article
November 25, 2008
Don't get stuck wondering about composites
Adhesives distribute stress
evenly along the bond line.
Photo courtesy of Henkel Technologies.
With the price of metals increasing, manufacturers are modifying their designs to offset their rising costs. At the same time, more consumers want to purchase vehicles based on gas... Read more...
Article
September 16, 2008
What's up with scrap (besides price)?
At today's elevated prices, scrap is almost considered a precious metal. In some cases, scrap is double its value only a few years ago. Scrap metal is one of the U.S.'s largest exports and the main component in electric arc furnace (EAF) steel production; therefore, its export has become a... Read more...
Article
April 15, 2008
The right trace at the right time
Whenever a laser is used in an industrial setting, a safety enclosure is usually required. To eliminate the expense of setting up an expensive enclosure room for use of its MeccoMark 20-W, fiber-delivered ytterbium laser marking system, Ford and MECCO engineers developed a safety snorkel on... Read more...
Article
January 15, 2008
Stamping 101: Die basics
Piece parts stamped in transfer dies are transferred via traveling rails mounted within the boundaries of the press.Image courtesy of Batesville Tool & Die, Batesville, Ind. Processing, designing, and building a stamping die can be very complicated. This broad overview of stamping... Read more...
Article
December 11, 2007
Festivus poles for the rest of us souls
With a dull, lusterless finish, an aluminum pole becomes the symbol for this country's favorite non-holiday holiday—Festivus. Not too many metal fabricators can say they are a supplier of not only metal product, but also a piece of pop culture. The Wagner Companies of Milwaukee can.... Read more...
Article
December 11, 2007
Why is it Dieology, not Dieologism?
Note: Before I begin with the technical portion of Die Science, I would like to thank all of my loyal readersand wishyou a happy holiday season. I am looking forward tocontinuing this column in 2008. If you have anytopics that you would like to have covered, please contact me. As a dieologist,... Read more...
Article
December 11, 2007
These aren't your grandparents' wheelchairs
Although it's called "wheelchair rugby" or "quad rugby"—it's played by quadriplegic athletes in wheelchairs—neither term really captures the sport's speed or intensity as does its original name: murderball. Nor do the athletes fit the stereotypical image of quadriplegics, and... Read more...
Article
November 6, 2007
Protecting magnesium alloys from corrosion
Magnesium is the lightest of all structural metals, weighing 35 percent less than aluminum and 78 percent less than steel.
Lightweight characteristics and wide availability make magnesium alloys suitable for mass production of components in cars and light trucks. However, the percentage... Read more...
Article
November 6, 2007
Piercing, cutting aluminum sans slivers
I have had a few consulting jobs in which the primary focus was on cutting aluminum. Slivers and burrs were the main problems. To address metal stamping problems such as slivers and burrs, the process engineer, tooling designer, or troubleshooting technician must have a reasonably good... Read more...
Article
October 9, 2007
Finding, addressing the root cause of die galling failures
As a consultant, I spend a great deal of time answering questions about die galling failures: What's the best tool steel I can use to prevent this galling problem? How can I prevent these punches from breaking down? What's the best tool steel coating? The truth is that there is no single... Read more...
Article
September 11, 2007
Stamping aluminum
Figure 1 Depending on the type, aluminum has a good strength-to-weight ratio and is well-suited to the deep-drawing process, as well as multiple draw reductions. I remember distinctly my very first experience with building a die that was supposed to draw a sheet of aluminum into a deep,... Read more...
Article
September 11, 2007
Minimizing weld cleaning stripes
I'm fabricating toolboxes for pickup trucks using gas metal arc welding (GMAW) and polished aluminum tread plate. The cleaning stripes along each side of the weld are wide and detract from the appearance of the toolbox. Please don't tell me to wire-brush the weld because this stands out even... Read more...
Article
July 10, 2007
To weld or not to weld Alclad
I have some aluminum sheet that I would like to use to fabricate a project. The only marking on it is "Alclad." Other than that, I have no idea what alloy it is. Can you tell me what filler metal to use to weld it? Whether you realize it or not, you have seen Alclad sheet hundreds of times. The... Read more...
Article
May 8, 2007
Aluminum Workshop
I have a fabrication project involving 5454 aluminum plate, and I was told to weld this alloy using 5183 filler wire. Is this correct? If you check any of the charts showing the recommended filler metals for the various aluminum alloys, you will find that 5554 is the recommended filler wire... Read more...
Article
October 10, 2006
Luminous aluminum makes light work
Hapco had to design and fabricate aluminum light posts to replicate the art deco, Empire State Building period look of cast-iron poles made 70 years ago as part of a Triborough Bridge renovation project. The paint color had to be custom-blended to resemble cast iron. Special mounting bases... Read more...
Article
October 10, 2006
Aluminum pipe pioneer streamlines tube mill welding
Hastings Irrigation Pipe Co., Hastings, Neb., blazed a trail in the late 1940s by manufacturing irrigation pipe out of a material that was not used commonly at that time: aluminum. Five decades later Hastings and that unusual material are both field-tested and proven for manufacturing... Read more...
Article
October 3, 2006
Warm forming magnesium, aluminum tubes
Research shows that in forming lightweight materials such as aluminum and magnesium alloys, the formability increases as the temperature increases, especially in the range from 200 degrees C to 300 degrees C (392 degrees F to 572 degrees F).1-5 The Center for Precision Forming (CPF, formerly... Read more...
Article
August 8, 2006
Feed to registration
Figure 1 In the mid-1980s service centers attempted to create coils slit in a scroll pattern to reduce scrap. When processing round or nested parts, most stampers use one of these three methods with varying degrees of scrap rates: Conventional coil stock feeding into a one-out... Read more...
Article
July 11, 2006
Innovation rides the waves
U.S. Air Force security police use this response boat to conduct sea trials. Bellingham, Wash., has a long tradition of seafaring sailors and boat-builders. During the 1800s many full-rigged ships hauled lumber to places like California and Hawaii. During World War II wooden mine... Read more...
Article
June 13, 2006
A closer look at self-piercing riveting
The current vehicle market demands structural weight reduction to decrease fuel consumption and to improve vehicle performance. As a result, automotive manufacturers are required to use aluminum alloys and other advanced materials, but the conventional joining methods, such as resistance spot... Read more...
Article
May 9, 2006
Choosing a gouging method
In recent years environmental and quality issues have taken center stage in the welding industry. This increased emphasis on safety and health often is accompanied by reconsideration of how certain tasks are performed, for example, cutting and gouging metal. Gouging—a requirement... Read more...
Article
April 11, 2006
Die Basics 101: Part VII
Previous articles in this series focused on stamping dies and production methods. This article discusses stamping materials—both ferrous and nonferrous. To process, design, and build a successful stamping die, it is necessary to fully understand the behavioral characteristics of the specific... Read more...
Article
March 7, 2006
The need to feed aluminum
Aluminum, especially thin-gauge, presents unique welding obstacles. Gas metal arc welding (GMAW) in particular presents challenges in wire feeding and selecting the right type of filler metal and equipment. However, several options can aid in effective aluminum welding. In its pure form,... Read more...
Article
March 7, 2006
Anodizing aluminum
In anodizing, dyes are absorbed into the aluminum oxide layer's porous structure. Anodizing, the electrochemical oxidation of aluminum, is widely used throughout the world for a variety of functional and decorative applications. In anodizing, a thin film of aluminum oxide forms on the... Read more...
Article
October 11, 2005
Welding aluminum piping
Aluminum piping is test-welded in a laboratory. A large number of fabricators manufacture carbon and stainless steel piping systems, and in general, the welding procedures and techniques for manufacturing them are well-known. But few fabricators manufacture aluminum piping systems,... Read more...
Article
June 14, 2005
Fatigue Failures
Figure 1 Fatigue is the progressive formation and propagation of cracks in a metal subjected to repeated or alternating stresses (from cyclic loads or forces) not exceeding the material's static yield strength limit. The final failure occurs when the remaining section—the part... Read more...
Article
May 10, 2005
Is this Round 2?
The year is 1966, the race is the 24 Hours of LeMans, and the Ferrari® team has little to fear. It has won this race six times in a row. Oh, sure, Ford Motor Co. has entered its showcase racing car for a third time, but this isn't as much about racing as it is a flamboyant publicity... Read more...
Article
November 9, 2004
Challenges and considerations in joining exotic materials
The company fusion- and resistance-welds 300 and 400 Series stainless steel, CRES A286, nickel alloys 625 and 718, titanium, and aluminum to produce sheet metal and machined V-retainer couplings, mated flanges, band clamps, and strap assemblies. With expertise in seven metal groups in... Read more...
Article
June 8, 2004
Dangerous curves
Provocative lines and innovative materials are the hallmarks of luxury car manufacturer Jaguar Cars Ltd. Jaguar has reaped the benefits of aluminum since 1922, when the company, then known as the Swallow Sidecar Co., designed sidecars out of lightweight aluminum panels. Since then the... Read more...
Article
January 29, 2004
Article
January 13, 2004
Hydroforming heats up
Hydroforming at Higher Temperatures The majority of hydroforming knowledge is based on steel. Steel's characteristics make it a favorable choice for many products, and steel has been the dominant material in many industries, especially automotive, for decades. Lately, though, hydroformers are... Read more...
Article
January 13, 2004
Structural tube on campus
A Sculptor and an Architect Carpenter specializes in large-scale public installations, including architectural sculptures and infrastructural items. He studied architectural glass art under artists in England and Germany, and this experience is reflected in his use of glass and light,... Read more...
Article
December 11, 2003
Taking tubular aluminum scaffolding to new heights
Photo courtesy of Fred R. Tannery Photography, Brooklyn, N.Y. Universal Builders Supply, a temporary-structures company with headquarters in Mount Vernon, N.Y., designs and constructs scaffolding, hoisting, and platforms—big ones. It was the company's proposal for a unique... Read more...
Article
October 23, 2003
Tube Hydroforming Design Flexibility—Part IV
Material selection is a very important aspect of design flexibility when striving to fulfill part functionality requirements. Choosing the correct material is fundamental to making the part effectively and efficiently.
The way a material is formed and the conditions it needs to withstand for... Read more...
Article
September 25, 2003
Choosing a GMAW machine for occasional aluminum welding
I want to buy a small gas metal arc welding (GMAW) machine, preferably one that runs from 120-V input power. Most of my welding will be steel, but I would like to weld aluminum occasionally. Can these machines really weld aluminum? I've heard a lot of different opinions. Some companies claim... Read more...
Article
September 25, 2003
The wrinkle-wiper for tube bends
Figure 1 Here's a quick quiz for you to take: What "wipes" the wrinkles from the bend in a tube and is one of the five pieces of tooling in a die set? If you guessed wiper die, you're right. A piece of tooling used to keep the inside bend of a tube from wrinkling, a wiper die... Read more...
Article
August 28, 2003
Inverter versus transformer power supplies for aluminum GTAW
I'm looking for a new GTAW power supply for AC aluminum welding. I had intended to buy a conventional transformer unit, but several people have told me to buy an inverter-based power supply. Which one is better for my application? Inverter-based power supplies do have some advantages over... Read more...
Article
August 28, 2003
Considering thermal processes for dissimilar metals
This joint has dual characteristics—a brazed joint on the steel side and a welded joint on the aluminum side. A reliable method of joining the two most commonly used metals, steel and aluminum, would make it possible to make these joints in several applications. On one hand,... Read more...
Article
July 24, 2003
Welding aluminum with inverter-based power supplies
Direct Current All welding power supplies transform relatively high-voltage, low-current incoming power to lower-voltage, high-current welding output using a transformer. In the past the transformer operated directly from 50- or 60-hertz incoming alternating current (AC). At these... Read more...
Article
July 24, 2003
Improving blank edge conditions
Blanking—like piercing, parting, notching, and trimming—basically is a shearing process. Sheet metal that is sheared undergoes a predictable process and yields a predictable cross-sectional profile. Typically during shearing, as the punch initially engages the sheet metal, it... Read more...
Article
July 10, 2003
Article
July 10, 2003
Hot spots for U.S. metal fabricated exports
Canada is a virtual U.S. export paradise. It is, by far, the leading importer of U.S. exports in the categories reviewed by The FABRICATOR® staff. In some cases, Canada outspent the second-place export purchaser, Mexico, by 10 to 1. Some surprising newcomers have been added to... Read more...
Article
June 26, 2003
Laser-integrated robotics for assembly
Recently a cell phone manufacturer set out to be the first to develop an all-aluminum flip-type package for its ultracompact cell phone. Conceptually, the manufacturing seemed feasible, except for the joining of the materials.
Overlooking the Obvious
In the early phase of... Read more...
Article
June 12, 2003
Stretching metal's forming limits with HSP lubricants
The trend in metal stamping is to use more and more aluminum and other lightweight materials, such as advanced high strength steel (AHSS). The need for technology to help improve metal flow of these materials in deep-drawing applications also is increasing. In many cases, a stamper's original... Read more...
Article
May 29, 2003
Batter up! Turning an aluminum tube into a baseball bat
Although wooden bats still are the only type used in professional baseball, aluminum bats are used extensively in nonprofessional baseball and softball leagues. In fact, nearly 95 percent of all baseball bats used in the U.S. are made of aluminum. Hillerich & Bradsby Co. (H&B),... Read more...
Article
April 24, 2003
Cutting exotic alloys
But sometimes this common process can be puzzling, especially when the fabricator is cutting titanium or other alloys. Tubing may be cut successfully in one production application, but the next time the result is galling and extremely short blade life. If an operator understands why this... Read more...
Article
April 10, 2003
How to recognize, minimize weld smut
When I weld any aluminum alloy, I see a covering, light gray to black in color, over the weld. I see it when I gas tungsten arc weld (GTAW), but it's worse when I gas metal arc weld (GMAW). What is it? Does it affect the mechanical properties of the weld? How do I get rid of it? A common... Read more...
Article
April 10, 2003
Mixed Metals Reactions
Why, you may ask, would anyone want to start an uncontrolled chemical reaction that is really hard to stop? Well, our shop did not want to, but we did anyway, and I hope you learn from my lesson. Actually, they are lessons (plural) because we repeated the disaster twice, although with some... Read more...
Article
February 27, 2003
Choosing tungsten electrode type, size for aluminum GTAW
I've heard different opinions about which size and type of tungsten electrode I should use to gas tungsten arc weld (GTAW) aluminum. Could you clear up this subject for me? As you know, we use direct current electrode negative (DCEN), or straight polarity, to weld steels and stainless... Read more...
Article
February 13, 2003
Aluminum stands tall as a structural metal—Part 2
The whole Palm House roof had to be fabricated off-site, then lifted and set on the support structure, so it had to fit perfectly. The accuracy of the measurement and fabrication of all of those aluminum members in the roof was critical. The new roof was transported to Washington, D.C.,... Read more...
Article
November 7, 2002
Aluminum stands tall as a structural metal—Part 1
Exterior view of aluminum-framed structure Scienceland, Shanghai, China.
In appearance, aluminum sometimes is difficult to distinguish from other rust-free structural metals such as stainless steel, magnesium, and even galvanized steel. However, its properties are very different. Even... Read more...
Article
November 7, 2002
Fanning production rates
While a worker prepares to remove parts from a dual-pallet laser at Hartzell Fan, Piqua, Ohio, the machine is cutting the next job. The company was able to replace an older laser and a plasma cutter with this new machine. The space saved contributed to better flow of material from the... Read more...
Article
November 7, 2002
Lubes and the new materials: It's a different game
The draw bending of these materials requires special lubrication expertise. As a manager, you should understand what changes in production and process control are necessary to achieve productive and profitable fabrication. The Right Stuff Properly chosen lubricants can profit tubemakers... Read more...
Article
October 10, 2002
Deep drawing aluminum—not as hard as it looks
Figure 1
Aluminum unfortunately often gets a bad rap.
For those manufacturing operations that revolve around the deep drawing of steel, the sheer mention of aluminum brings out a grimace. It is universally known for its inability to stretch, its abrasive nature, and its tendency... Read more...
Article
September 26, 2002
Preparing, testing bend samples
Almost all welding codes require bend tests for welding procedures and welder qualifications. These tests can cause more problems in aluminum than in steel. In bend testing, a 1 1/2-inch-wide sample is cut so the weld is running across the width of the sample. Then the sample is bent around a... Read more...
Article
March 14, 2002
Article
February 28, 2002
Steering toward aluminum Trends in the automotive industry
Exciting ideas, new applications, and experimental joining processes for welding automotive aluminum drove conversations and presentations at the 22nd annual Automotive Aluminum Design and Fabrication Seminar in October. Sponsored by The Aluminum Association's Automotive & Light Truck... Read more...
Article
February 2, 2002
Design rules for forming aluminum stampings—Part 2
Figure 1: Addendum types enable or improve the stamping of a sheet metal part. A draw wall, for example, connects the trim line and the punch opening line. Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM),... Read more...
Article
February 2, 2002
Design rules for forming aluminum stampings—Part 1
Figure 1: In deep drawing, if the die clearance is too large, the component forms a cone instead of a cylinder. Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State University, Professor Taylan... Read more...
Article
January 10, 2002
Metals outlook mixed
As the U.S. economy continues to slow, steel and aluminum producers are looking for the bottom of the market. While gross domestic product (GDP) growth was exhilarating in recent years, we all knew it was unsustainable, and market results are bearing out those fears. However, low commodity... Read more...
Article
November 29, 2001
Making the most of the daily grind
The design and production of abrasives have kept pace with other advances in the welding industry, making grinding and finishing products more effective than ever in helping fabricators to lower costs and improve productivity. Grinding equipment and accessories for this industry are available... Read more...
Article
November 15, 2001
Using hydroforming aluminum components versus steel stampings
As the name implies, hydroforming is a metal forming process that uses water as a forming medium. In the case of tube hydroforming, a tubular workpiece is placed between two mating die halves. The tube is sealed, normally by metal mandrels inserted under pressure in each end of the tube. Water... Read more...
Article
October 25, 2001
Article
September 13, 2001
Selecting the right materials for roll forming—Part 2
Alloyed Steel In addition to carbon, large varieties of metallic and nonmetallic elements are used to achieve the desired mechanical properties and corrosion resistance. The most frequently used alloying elements are manganese, cobalt, chromium, copper, molybdenum, vanadium, nickel, zirconium,... Read more...
Article
September 4, 2001
Exploring complementary cutting methods
Diversification is the linchpin of running a successful business. The key to producing quality work and investing in equipment wisely is knowing which cutting method—laser, plasma, electrical discharge machining, waterjet, or another—to use for a particular application. While... Read more...
Article
July 26, 2001
Article
July 12, 2001
Plasma cutting stainless steel and aluminum
Figure 1
The plasma cutting process may be used to cut any conductive material, including carbon steels, stainless steels, aluminum, copper, brass, cast metals, and exotic alloys. Each of these materials behaves differently when subjected to the intense heating and cooling of the... Read more...
Article
April 24, 2001
Preparing for aluminum GTAW
Even if you are experienced in welding steels, aluminum welding can present quite a challenge. Aluminum's oxide coating, higher thermal conductivity, and lower melting point easily can lead to welding problems unless you know how to prepare for welding and set up the equipment. Though many... Read more...
Article
March 5, 2001
The basic elements of tubular hydroforming
Tube hydroforming has been well-known since the 1950s. However, with recent advancements in computer controls and high-pressure hydraulic systems, the process has become a viable method for mass production, especially with the use of internal pressures of up to 6,000 pounds per square inch... Read more...
Article
February 19, 2001
Article
February 19, 2001
Auto industry demands shape the future of stamping
Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State University, Professor Taylan Altan, Director. As we face the 21st century, the stamping business continues to be driven primarily by the automotive... Read more...
