Metal is one of the world’s most versatile and essential materials, found in everything from construction frameworks and vehicles to electronic devices and jewellery. But what is metal made of, and how does it go from raw material to finely crafted metal objects?
In this guide, we’ll explain the composition of metal, the types of metals used in fabrication, and the metal fabrication process. With these insights, you’ll be well-equipped to make informed decisions about metal fabrication and ensure that your projects meet the highest possible standards.
What Is Metal Made Of?
Metals are composed of elements from the periodic table, often combined with other elements to create alloys that offer specific properties.
Most metals are found naturally in the earth’s crust, where they form in combination with non-metal material.
This raw ore is refined through smelting, removing impurities, and mixing with alloying elements to create a more stable and usable product.
Metals can be broadly categorised into two main types based on their composition:
Pure Metals
Pure metals are relatively unaltered and often extracted directly from raw ore. These metals, such as pure copper and pure iron, have a simpler composition with fewer additional alloying elements.
Pure metals are highly valued for their lustrous appearance, corrosion resistance, and chemical properties, making them desirable for industrial and decorative applications.
Metal Alloys
A metal alloy is formed when combining two or more metallic elements to create other metals with enhanced properties.
These alloys can be customised to meet specific needs, like increased strength, chemical reactivity, or corrosion resistance. Due to their durability and versatility, alloy steels, stainless steel, and bronze are widely used in metal fabrication.
Types Of Metal Used In Metal Fabrication
Choosing the right types of metal for fabrication is essential to achieving the best results for your project. Here are some of the primary metals and metal alloys used in fabrication:
Ferrous Metals
Ferrous metals contain iron and are typically robust and durable, making them optimal for structural applications. Here are some of the most common ferrous metals used in metal fabrication:
- Cast Iron: Known for its high carbon content, cast iron is strong and used in heavy-duty construction.
- Carbon Steel: This type contains carbon to improve strength and durability, making it good for structures.
- Steel Alloys: These types of steel combine iron with other elements, such as nickel and manganese, to enhance strength and corrosion resistance.
Non-Ferrous Metals
Non-ferrous metals do not contain iron, which makes them lighter and rust-resistant. Here are a few non-ferrous metals that are commonly used in fabrication:
- Copper: Copper is employed in electrical wiring and plumbing due to its outstanding conductivity and malleability.
- Aluminium: Known for its light weight and strength, aluminium is popular in the aerospace and automotive industries.
- Precious Metals: This category includes gold and silver, prized for their lustrous appearance and resistance to tarnish and often used in decorative or electronic applications.
Stainless Steels
Stainless steel, an iron alloy with chromium, is known for its corrosion resistance and durability, making it a top choice for kitchens, medical equipment, and outdoor structures.
Base Metals
Base metals like copper and aluminium are the foundational materials in various metal alloys. They are widely available and used in applications across many industries.
The Metal Fabrication Process Explained
Once metals are extracted and processed, they are fabricated to be shaped and refined for their intended application.
This process involves multiple stages to create custom products that fit specific needs, including cutting, bending, and assembling.
Step 1: Extraction And Refinement
The journey of metal fabrication begins with metal extraction. Raw materials like iron ore are mined from the earth’s crust and undergo a purification process to isolate and refine the metal.
In the case of iron, for example, the ore is heated in electric arc furnaces to separate non-metal material and produce pure iron or pure copper.
Extracting the purest possible metals ensures the quality and performance of the final product. Precise heating and refining remove impurities, yielding a base metal ready for further enhancement.
Step 2: Metal Alloy Manufacturing
Once the molten metal takes on a pure form, manufacturers may introduce alloying elements like carbon, nickel, or chromium to enhance the properties of the extracted metals.
This mixing process produces metal alloys with enhanced properties suitable for advanced applications.
Step 3: Cutting And Shaping
Once the metal or alloy is prepared, it’s time to shape it. During the cutting and shaping phase, metals are transformed into thin sheets, rods, bars, or specific forms using high-precision machinery.
Techniques like laser cutting slice metals accurately, while methods like bending and pressing give the metal its required contours.
Step 4: Assembly And Joining
The assembly phase combines multiple fabricated metal pieces to create a final, functional product. This step can include welding, where metal pieces are joined through melting.
These joining techniques allow for the creation of complex, sturdy structures that can withstand significant loads and stress, perfect for vehicle manufacturing, construction, and machinery applications.
Step 5: Finishing And Coating
Once assembled, the fabricated metal undergoes finishing to improve its durability, resistance, and aesthetic appeal.
Finishing can involve applying chemical baths to remove surface impurities, powder coating to add a layer of protection, or even polishing to achieve a specific finish. The coating also protects against corrosion, ensuring the product’s longevity.
Frequently Asked Questions
How do you ensure the quality of metal fabrication?
To make sure your metal fabrication meets the highest quality standards, consider these strategies:
- Material Selection: It is essential to choose the right metal substances and alloys for your project. Ensure the selected materials meet industry standards and are suitable for the application.
- Quality Control Testing: Implement materials science testing, such as chemical reactivity tests and corrosion resistance analysis, to verify the metal’s quality before fabrication.
- Skilled Metalworkers: Experienced metalworkers bring precision to cutting, welding, and assembling, which is critical for achieving reliable, top-quality results.
- Inspection And Certification: Regular inspection and certification of fabricated products ensure that all safety and quality standards are met, providing peace of mind for you and your clients.
How long does the metal fabrication process take?
The overall duration of the metal fabrication process varies depending on the project’s complexity, the types of metals used, and the specific techniques required.
Simple projects might take a few days, while more intricate or large-scale projects could take weeks. Working closely with your fabricator can help set realistic timelines based on your project’s requirements.
What are some applications of fabricated metals?
Fabricated metals are used in various applications, from construction (structural beams, supports) to manufacturing (machinery parts, automotive components) and consumer products (appliances, furniture). The versatility of metals and alloys makes them suitable for various industries and environments.
Unlocking The Potential Of Metals For Your Specific Needs
Now that you understand what metal is made of and the metal fabrication process, you can select the optimal materials and methods for your project.
By working with skilled metalworkers and implementing quality control measures, you can ensure the highest standards in metal products, from stainless steel components to precious metals in decorative items.
Whether you’re designing structural frameworks, custom equipment, or intricate metal details, having a solid understanding of metal fabrication enables you to achieve impressive and durable results.
With the right materials and processes, you can create custom solutions that meet your specific requirements, ensuring that each project is as strong, functional, and visually appealing as possible.
If you’re looking for top-quality metal fabrication tailored to your unique needs, our expert team is here in Melbourne to help. From selecting the right materials to ensuring precision at every step, we bring skill and dedication to each project.
Contact Star Sheetmetal today at (03) 9000 0280 to discuss your requirements, and let’s turn your vision into a reality.
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Ogbonna OS, Akinlabi SA, Madushele N, Mashinini PM and Abioye AA (2019) “Application of MIG and TIG Welding in Automobile Industry,” Journal of Physics Conference Series, 1378(4):042065, doi:10.1088/1742-6596/1378/4/042065.
Sabhadiya S (n.d.) 20 Different Types Of Metals And Their Properties, The Engineering Choice, https://www.theengineeringchoice.com/types-of-metals/, accessed 29 October 2024.The Editors of Encyclopaedia Britannica (2024) “Stainless Steel,” Britannica, https://www.britannica.com/technology/stainless-steel, accessed 29 October 2024.
