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Articles tagged with "steel"
Results: 90
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Using plasma arc cutting to clean-cut stainless steel sheet and plate: Variables to considerTo clean-cut stainless steel sheet and plate, fabricators first must choose the right CNC cutting equipment and then set the correct process-related variables. Precise machine motion controls, torch-to-material distance control, and the correct plasma and assist gases all are crucial to producing weld-ready plasma-cut edges on all stainless steel thicknesses.
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Plasma pleases plentyTechnological developments in lasers are positioning them as an attractive alternative to plasma. But fabricators are still sticking with plasma cutting for many applications where speed and cost-effective operation are concerns.
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Cutting through the obstacles: The challenges of sawing structural tube, pipe, and solidsOf all the materials that can be cut on industrial band saw machines, structural steels—such as pipe and tubing, plate, angle and channel iron, and I beams—are all among the most common and challenging.
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What is your facility cut out for? Circular and band saw purchases depend on application requirementsWhat cutting equipment you buy depends very heavily on what area of industry you are supplying, throughput requirements, and, not least, finances. Don't let preconceived notions prevent you from making the very best possible decision.
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Take the old with the new - Selecting saw blades with new technologies in mindNew methods for cutting tube and pipe have been introduced to welding shops in the last few years—methods designed not only to cut metal, but also to cut costs.
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Exploring complementary cutting methods: Comparing capabilities of laser, plasma, EDM to waterjet technologyThe various cutting methods available to fabrication shops today can be both a little daunting and very beneficial. Choice is good--learn how to make the most of the diversity all your choices offer to you.
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Taking the pain out of paint - Finishing—Part 2: Applying paint to structural steelThis article highlights two of the accepted industry specifications, which are provided by the American Institute of Steel Construction (AISC) and the Society for Protective Coatings (SSPC). It covers many of the more salient topics, point by point, and explains them in detail.
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Fabricating technology advancements drive new plate finishing trendsThe same industry forces of nature—globalization, economic conditions, quality demands, and safety and environmental regulations—that are pressuring metal fabricators to do more, better, and faster with less are blowing no less forcefully on finishing fabricators.
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Using hydroforming aluminum components versus steel stampings: The contender gains points, but the champion is still in the fightThis article examines two transitions that are occurring in the automotive industry—the change from stamping to hydroforming, and the substitution of aluminum where steel was used previously.
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Pressure-sequence and high-pressure hydroforming: Knowing the processes can mean boosting profitsPressure-sequence hydroforming can form complex parts as well as forming most ductile metals, including high-strength, low-alloy, and stainless steels with sharper corners, thick-walled tube, and other difficult features.
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Eliminating final trim shearing of hydroformed tubeThe most common way to establish tube length after hydroforming is by cutting or shearing the tube to a specified dimension; however, cutting out this step can reduce scrap. A new method designed to eliminate this step combines forming the end of a tube to resemble its final form with using a hydroform die to correct end position variations off the bender. While this approach eliminates the final shear trim operation, it also presents new challenges.
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Tube Hydroforming Design Flexibility—Part IV |
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Hydroforming heats up: New techniques and equipment push industry forwardHydroforming was one of the fastest-growing metal forming technologies during the 1990s. Most of U.S. industry cooled down during and after the recession of 2001, but things have been heating up lately, and the world of hydroforming is no exception. The North American Hydroforming Conference and Exhibition (Sept. 29 – Oct. 1 in Dayton, Ohio), which was sponsored by the Tube & Pipe Association, International® (TPA), and the Society of Manufacturing Engineers (SME), showcased new techniques, equipment, and applications that are moving the industry forward.
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Handling appliance steel: Tips for processing surface-sensitive materialsSavvy stampers are purchasing new equipment or modifying and retrofitting existing equipment to include prefinished materials features. By paying close attention to equipment, tension practices, material processing methods, and material handling, stampers can participate in the market for surface-sensitive materials.
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Big steel on the ropes: Consolidation looms for a troubled industryIntegrated steel mills in the U.S. are feeling the heat of foreign competition, pricing problems, and bankruptcies. How long will it be before consolidations start narrowing the field?
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Interaction of chemicals used in forming and fabricatingKnowing how chemicals tend to react with one another and how each type of lubricant and coolant commonly used during steel processing tends to behave is a boon when you're trying to fabricate products properly.
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Mixed Metals Reactions: Danger in the ductworkUnder controlled conditions, aluminum and steel powders can be mixed to create a chemical reaction to produce heat for welding. If you mix these materials under uncontrolled conditions, you will want to call the fire department.
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Welding cold-rolled steel to cast iron |
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Predicting the service life of galvanized steelZinc, which has been used to hot-dip-galvanize steel for 250 years, provides 50 to 75 years of corrosion protection in many environments. Empirical data collected about hot-dip galvanized (HDG) steel field performance from 1940 to 1980—in environments ranging from industrial to marine to suburban—indicates that zinc can prevent base steel corrosion more than other surface treatments. Because of zinc's long-lasting protection, projects require no maintenance and therefore no maintenance costs.
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Stretching metal's forming limits with HSP lubricants: Forming aluminum, high-strength steel without tooling upgrade |
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Phases, structures, and the influences of temperatureWhen you heat or cool a piece of metal to a specific temperature, that metal goes through what's called a phase change, in which its crystal structure changes. Sometimes the change is obvious. For example, when a piece of metal melts, it goes through a phase change when the crystal structure breaks down and the metal goes from solid to liquid. When it solidifies it's also a phase change, as the structure re-forms from liquid to solid.
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Considering thermal processes for dissimilar metals: Joining steel to aluminum in heat-intensive applicationsKnowing how to weld dissimilar metals is becoming more and more important. One reason is that it's often impossible for one material to provide the optimum chemical, physical, and mechanical characteristics needed for an application. For this reason, as well as cost efficiency, technology specialists are experimenting with different joining processes to weld bimetal joints optimally.
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Making steels strongerWhen it comes to modifying a steel's strength and hardness, it's important to not confuse hardness with hardenability and remember that hardenability characteristics are important because they help identify how much a specific steel will harden during welding.
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Keeping pace with today's punching requirements: Advancements in tool design, metallurgy lead to more accurate holes, improved part qualityThis article provides the basics on how the punch, die, and stripper work; how to perform material thickness calculations on various materials; how different applications affect punching quality; how fully guided tooling counters lateral forces; and how metallurgy, coatings, and maintenance affect tooling.
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Punching tips: The easiest solution to slug management is to keep the tooling in good conditionThe author discusses what not to do to manage slug ejection. He mentions several tooling maintenance errors that he has made over the years, as well as what machine operators can do if they want to experience slug ejection difficulties. He concludes by stating that the easiest solution to slug management is to keep the tooling in good condition and to use the correct die clearance for the material.
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How important is sheet and plate steel flatness?: Fabricators are specifying temper-passed, leveled steel to remove coil memoryThis article examines flatness of steel, discussing the outcome of combining temper passing and leveling in the same line. It also provides the outcomes of experimentation on steel that has been leveled, temper passed, and both. Furthermore, it gives a few real world examples of who is using this process and what they are saying about it.
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Roll formers look for a win: Industry players hope to score with customization, better technology |
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Selecting the right materials for roll forming—Part 2: How mechanical properties affect productionThis is the second part of a two-part article. Read Part I. If you examine the mechanical properties of several materials, including carbon steel, alloyed steel, stainless steel, as they relate to roll forming, you'll gain an understanding of the influence of some primary metal processes on roll forming.
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One system does not fit all: Ventilation equipment becomes more specific to improve the welding environmentVentilation systems come in a variety of types for different types of welding processes and varying fabrication facility setups. The emphasis on proper application of these systems and best use of the components used in them comes from an increased interest in cleaner air for the welder.
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Man of Steel: FABTECH keynote speaker Ferriola discusses harnessing change in steelNucor Corp., recycler and manufacturer of steel products, is using new technology, such as the HIsmelt® process and the micromill, both of which are allowing them to start out with thinner steel strip to more efficiently process steel for its customers. John Ferriola, executive vice president of the Sheet Mill Group at the company, will address these technologies and how steel industry changes can positively affect steel consumers.
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Maximizing your scrap's value: Diligence in preparation and tracking pays offThe more uniform and contaminant-free that scrap is when fabricators provide it to recyclers, the more fabricators can benefit. This article addresses the two principles for selling scrap to recyclers: know what you're selling vs. what you're getting paid for, and incorporate sorting & cleaning into your production stream.
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Applying the theory of constraints in a structural steel plant: How keeping busy can be a BAD ideaMerely staying busy is not a determinant of success.
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Huge possibilities, tiny tools Nanotechnology--the science of small--could change the metals industry in a very big wayNanotechnology is just beginning to blossom as a practical topic of interest for the manufacturing industry. Just how big an impact will nanomaterials have in our lifetimes? We're sure to find out soon.
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Longer slabs, lower costs: Long-span composite decks could offer designers new flooring optionsUnshored, deep steel decking that spans 20 feet—it's a good concept on paper, but can it serve customers in the real world? At least one engineer is convinced it can, and he's taking his message to the masses.
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Family business going strong after 100 yearsThe average lifespan of a family-owned business is 24 years, and 60 percent of family-owned businesses do not have a clear succession plan. Tell that to the Peddinghaus Corporation and you might be in for a big "Oh really?" In business for 100 years and with a Peddinghaus still at the helm, the family-owned manufacturer of steel construction industry equipment clearly is a statistical exception.
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What now? Every facet of steel industry watches, waits as change sweeps inThere's no telling just what the steel industry will look like even in the next few months as the federal government mulls its options for protecting a domestic steel industry suffering through perhaps its most threatening slump ever.
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Consolidation talk picks up speed: As steel industry founders on the rocks, big players look at pulling togetherAs No. 4 steelmaker LTV prepares to liquidate, the integrated steel industry's heavy hitters are finally taking a serious look at consolidation
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The new face of manufacturing on the Net: Interviews with some survivorsMaking the Internet pay has proven more difficult than a lot of first movers in the metals business made it sound in the late '90s. Thefabricator.com talked to a few people trying to capitalize on the lessons learned from all those no-brainers that turned into no-gainers.
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Metals outlook mixed: Two different metals industries adapt to a challenging economySteel is looking at some uncertain times, to say the least, but aluminum industry professionals see a little more to smile about if general economic conditions improve.
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Mac's Muse: One potato, two potatoes, three potatoes ... gone! As U.S. steel industry gets its lunch eaten, many parties can share blameA lot of parties can share the blame for what's happened to the North American steel industry, and its going to take effort from them all to pull the industry out of its quagmire. Can it be done? Time will tell.
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Canada sighs, strategizes: Steel industry dodges tariffs, wards off backdoor importsThe exclusion of Canadian steel producers from restrictions on imports to the U.S. was a relief after months of uncertainty. The Canadian steel industry wants to ensure that the Canadian market does not become a back door for imports into the U.S. Keeping the industry strong by opening new markets, developing lighter, stronger and more corrosion-resistant steel products, and working closely with the automotive industry is vital to that goal.
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Steel industry anything but status quo: Next generation of distributors set to lead wave of changeAs the market demands change, the steel distribution industry will take up the gauntlet and change with the times. Contrary to some speculation, the steel manufacturing industry is neither going away nor reluctant to embrace the innovations necessary to survive.
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Changing the way they do business: Bridge, structural fabricators have to think about process choicesDealing with work loads, delivery schedules, and many other responsibilities doesn't leave managers with much time to consider factors that justify equipment improvements.
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Looking to the future: Steel supplier designs facility based on regional current, future needsA growing manufacturing base in the Southeast spurred Thompson Steel in the mid-1990s to research what type of equipment to purchase for its new facility in Fountain Inn, S.C. The steel supplier had been shipping coils of slit steel from its plants in Baltimore; Franklin Park, Ill.; and Rome, Ga., almost daily to several customers in the area.
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Protecting surface-sensitive materials in coil processing: ArrayArray
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Handling the RushThink delicate: an antique vase, velvet gloves, the sweet sound of string music.Then imagine a typical stamping operation: bam-bam, metal on metal, all day long.
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Increasing stamping press productivity in the appliance industry: Advances in press technology and materials leave their markAn appliance plant with 80 to 100 presses in opeation is likely to buy new presses regularly. Under these circumstances, it makes good sense to pursue aggressive productivity goals inch by inch through steady advances in such prosaic concerns as machiner ergonomics, prventive maintenance, tooling efficiency, and material quality.
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Designing high-strength steel stamped parts for formabilityThe use of high-strength steel to manufacture automobiles and other transportation vehicles has increased dramatically. The material's strength allows manufacturers to reduce vehicle weight substantially and increase fuel efficiency, without sacrificing performance.
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Predicting springback in air bending, straight flangingAll businesses tied to the metal forming industry are scrambling to find areas in which they can lower costs without sacrificing quality. Adding to this burden are a tight cash flow and a lack of financial resources to invest in process improvement equipment. Therefore, the savings must come from doing more with less.
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Key design principles for successful deep drawingSuccessful deep drawing depends on many factors. Ignoring even one of them during die design and build can prove disastrous.
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Sharpening for a longer life: Maintaining the cutting edge on punch and die componentsRoutine maintenance—grinding, using surface treatments, sharpening ejector pins, and minimizing potential grinding damage—can extend tool life and save you a lot of headaches.
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Part nesting and die design tips for reducing and utilizing scrap in stamping operationsYou might be able to gain a competitive edge by learning how to reduce the amount of engineered scrap, or that material that was inteded to be scrap rather than scrap created because of defective piece parts.
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Resisting cracking, deformation, and premature wear: Powder metallurgical steels provide an alternative to conventional tool steelsWant to know how powder metallurgical tool steels are produced and how their properties provide the material's toughness and wear resistance? Read on.
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Cutting die-related costs: Where to look to save moneyDemands for cheaper, better, and faster tooling for stampings and the pace of business continue to escalate. This trend is not going to reverse itself.
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Tooling tricks of the trade: A few tips for extending die life |
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Improving blank edge conditionsA blank, stamped in the first station of a progressive stamping operation, usually is subject to subsequent forming processes to form a designated part. If the blank is subject to straining, deformation, bending, stretching, or lateral expansion in later stations, its edge condition should be carefully examined.
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Choosing the proper steel to minimize abrasive adhesive tool wearThe most disruptive type of failure in any tooling application is when the tool cracks. To prevent this type of failure in cold-work applications, it's important to select the correct steel.
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Investing in lubricants: Increasing your profits 7 percent by changing metalsAll businesses tied to the metal forming industry are scrambling to find areas in which they can lower costs without sacrificing quality. Adding to this burden are a tight cash flow and a lack of financial resources to invest in process improvement equipment. Therefore, the savings must come from doing more with less.
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Rolling bolsters bolster productivityTo thrive and experience growth and healthy profits, a stamping company must have systems in place that allow flexible manufacturing and minimize press downtime. Changing from one job to the next in the least amount of time possible is one of the primary factors impacting productivity and a company's ability to adjust to the changing needs of customers quickly and efficiently.
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Gaining from friction and formability data: Beating rising steel prices and offshore competitionAs steel prices rise and offshore competition increases daily, steel and overhead optimization are driving U.S. metal stamping and forming companies. Companies that survive and thrive are taking a different approach to managing change and cost and are discovering savings in areas never seriously considered before.
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Magnetic pulse welding for tubular applications: Discovering new technology for welding conductive materialsA review of how magnetic pulse welding works, in what applications it can be used, and what considerations users must take to perform it properly.
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Selecting the right temporary coating: Choices abound for tube and pipe applicationsTube and pipe manufacturers should consider carefully environmental laws, cost, quality, and the cost of a coating line before deciding on a temporary coating for their products.
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The wrinkle-wiper for tube bends: How to choose and use wiper diesA wiper die is a piece of tooling used in tube bending that helps keep the bend from wrinkling. While there are many reasons and ways to use a wiper die in a tube bending maching, you should also know what types are available, their differences, and how to choose the right one for your application.
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Getting a handle on work-related hand injuriesThe hand is one of the most complex parts of your body. It enables you to execute simple or complex jobs that cannot be performed by any other part of the body. Without your hands, it would be extremely difficult to do even those routine tasks that we take for granted every day.
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Taking tubular aluminum scaffolding to new heights: Taper, aesthetics, elevated design for monumental structureFor the company that broke the world record for building the tallest freestanding structure with a 320-foot scaffolding (the Statue of Liberty restoration project in 1984, see Sidebarat bottom of page)designing and constructing the scaffolding for the Washington Monument restoration project was just a natural next step.
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Tooling, the key for mill productionThis article discusses three main criteria that govern tube mill tooling—design, materials used in their construction, and alignment of tooling on the mill. Discusses advancements in design due to CAD technology; experimental use of ceramic and plastic materials for making tooling; and the use of subplates and interchangeable components to ease tube mill alignment.
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Laser welding of stainless pressure tubesNot all laser welded tubes are created equal. Know what to look for in the final product to ensure that you're buying quality and not just an imposter.
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Inline gauge control in welded tube production: Reducing conversion lossesReducing scrap when converting strip to finished tube is a huge step in bettering your bottom line.
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Choosing a GMAW machine for occasional aluminum welding |
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GMAW vs. FCAW for beginners: Choose the best process for your small operationThere are several pros and cons to using the gas metal arc welding process versus the flux cored arc welding process in compact applications.
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Secrets of Using GTAW for Tools and Dies: One retired fabricator share the basics of how he added this services to his shopTool and die welding can be a very lucrative service for a fab shop. However, tool and die welders are about as rare as brain surgeons because of a general lack of knowledge about the process and because of the extra expense it brings to a shop. This article offers a basic understanding of what's needed to add this service to your fab shop.
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Examining the GTAW environment: Choosing the right electrode and booth for your applicationThe author outlines basic components of a welding booth suitable for GTAW, and offers possible solutions to a decline in availability of the thoriated tungsten used in a GTAW electrode. He also offers ideas for providing a clean air supply for the GTAW operator.
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The fundamentals of gas tungsten arc welding: Preparation, consumables, and equipment necessary for the processLearning the fundamentals of the GTAW process will increase the welder's ability to produce quality weldments. Knowing the correct consumables, equipment, and preweld preparation necessary will help the welder troubleshoot welding problems.
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Found art: Welding artist finds inspiration in industrial, natural formsWatching the sparks fly as his dad welded a temperamental posthole digger mesmerized Derek Arnold. "I found the immediacy of something so permanent absolutely fascinating," he said. "I knew I wanted to weld."A hands-on welding education on the family farm drove Arnold to take his skills and creativity to the next level. In 1993 he graduated from the Maryland Institute College of Art in Baltimore. "I've been welding regularly since my freshman sculpture class," he said.
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Washington women weld at the 'Y': Students learn by doing in their community |
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The blades of Don Fogg—a cut above |
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Robots and dials and knobs—oh my!: GMAW power sources have evolved over timeIn the late 1950s, the U.S. Navy wanted to find a way to join heavy aluminum structural sections used to fabricate motor torpedo boat hulls.
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Shielding gas consumption efficiency-- Part I: Spend a penny, save a dollarInstalling a bulk delivery system in your welding shop is perhaps the best way to save money
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Making the most of the daily grind: How to choose and use abrasives for welding and fabricating applicationsThe article divides grinding equipment into three application categories: welding/heavy metal removal; metal fabrication and construction; and light metal removal, finishing, and sharpening. It also discusses grits and grains and operator safety.
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Selecting a shielding gas for joining stainless steel: The right choice is critical for success |
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Three optional techniques for beveling: Understanding the advantages and drawbacks of eachMany fabricators use standard plasma cutters and abrasives to create beveled edges. Along with these traditional methods, welders also have the option of using three alternative beveling techniques: punch and nibble, peeling and shearing, and milling and routing. Each has advantages and drawbacks.
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Design tips for sheet metal: Bend relief, small holes, hole distortion near bends, and minimum flange widthsThe article discusses making small holes and when to use a punch or laser cutter, inside radius measurements and how they differ depending on whether you are coining or air bending on a press brake, and adding bend relief to prevent tearing material.
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Discovering the limits of press brake toolingOne of the most important aspects of press brake forming is tooling selection. What are the tools capable of? What kinds of loads can they withstand?
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Hot spots for U.S. metal fabricated exportsIncreased global competition for customers on their home turf has driven U.S. metal fabricators to throw their nets wider to international markets. With this in mind, fabricators should look at the lists of the countries purchasing the most U.S. metal fabricated tools, machinery, products, and partially assembled goods as a road map to export opportunities.
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The challenges of laser cutting: Overcoming some common obstaclesLasers can be used to process expensive alloys as well as traditional materials such as stainless steel. However, knowing the strengths and weaknesses of laser processing is the key to determining whether or not a laser is the right choice for cutting.
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Predicting the outcomes of laser thermal forming: How process simulation brought this technology to industry |
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Turning up the power: Using lasers to cut thick plateThe most common power levels ranged between 1,500 and 2,000 watts. However, a statistical survey conducted by the AMT Laser System Product Group indicates a steady increase during the last 12 months of installations for high-power 3,000- to 4,000-watt laser systems and a decline in sales of lasers with power levels less than 2,000 watts.
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Job shop reduces costs, improves laser's output: Laser regulator minimizes gas contaminationToday's job shop market is characterized by unrelenting competitive pressure for laser processing services. Job shops are expanding into niche services such as multiaxis laser processing and thick plate applications to differentiate themselves from their competitors. Others are performing additional services such as forming, welding, painting, and assembly to add value.
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Laser and waterjet: friends or foes?: Capabilities make these technologies complements, not competitorsKnowing the capabilities and drawbacks of laser and waterjet machines is the key in determining which is best for a particular application.
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Láser y chorro de agua: ¿amigos o enemigos?: Sus capacidades hacen que estas tecnologías se complementen y no que compitan entre sí |
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