Steel Fabrication

Fabrication of steel involves melting down raw materials and mixing them with steel. The steel is constructed into the desired shape after the raw materials have been melted and mixed. As part of the process, a skilled technician must take raw materials and turn them into marketable products, and there is often little room for error. Everything from vehicles to household appliances is made by steel fabrication facilities Purohit Pipe Industries.

Here is a brief overview of each of these methods of fabrication: cutting, burning, forming, machining, and welding.

• Machining: 

Some of the tools that are involved in this process include lathes, mills, and drills, which are used to shave off pieces of metal to transform them into the desired shape.

• Cutting: 

Water jet cutting uses high-pressure water to cut virtually any material with high precision and without distortion. Learn more about the benefits of water jet cutting.

• Welding: 

During this process, welds are used to bend or combine pieces into one piece. Check out this blog post to learn more about MIG and TIG welding differences. CT welding contractors use Pulsed welding machines to control the heat put into a part, minimize distortion, and enhance the quality of parts manufactured by us. We specialize in welding steel, stainless steel, and aluminum with MIG and TIG.

As part of steel fabrication, machine operators need to determine the original shape of the raw material, which could be in the form of a flat plate, reshaped channels, pipes, or any other form. The fabricator must determine the shape of the steel after it has been processed. This outcome is influenced by two factors, namely the software package and the machine shop’s equipment. For this reason, most metal fabrication companies use cutting-edge technology to maintain efficiency and track the operation.

In order to fabricate metal, quite a few raw materials are required. If workers know which materials to keep on hand, they will always have a complete supply of what they need, which will speed up the fabrication process. Many metal fabrication projects require the following basic materials:

• Plate Metal: 

The fabricators use this to shape the pieces that they are working with in order to have a wider range of options.

• Fittings: 

Creating and completing pieces often require these

• Castings:

Keep them on hand so you can speed up the creation process by adding visual interest.

• Formed and Expanded Metal:

Because expanded metal is grate-like, it works well for outdoor furniture that needs to drain moisture.

• Sectional metal: 

There are many types of sectional metal, including “L” beams, Z shapes (they resemble the letter Z), bar metal, and rod metal.

• Flat metal: 

It is easy to fabricate flat metal like sheet metal and plate metal and add them to designs to add visual interest and texture. These are also well suited to making shapes.

• Welding Wire: 

It’s imperative to keep various types and thicknesses of welding wire on hand so that metal pieces can be joined together during fabrication.

With the latest 3D CAD/CAM software, CNC machinery, and highly skilled employees, CAM Metals services manufacturers and OEMs throughout New England with metal fabrication, CNC machining, waterjet cutting, and welding. When Al operated as a one-man operation, he focused on quality work and timely delivery, and these are the same principles that drive us today.

DIFFERENT PARTS OF STEEL FABRICATION

The fabrication of steel consists of melting raw materials, mixing melted materials into steel, and forming the desired shape with that steel. In order to operate the entire process correctly, someone with specific skills is needed, and it is very complex, leaves little room for error, and has little to no room for error. For example, steel fabricators commonly use this process to make all kinds of steel parts and details, including:

• Bar joists;
• Ladders;
• Grating;
• Skids;
• Universal beams;
• Pipe racks;
• Platforms;
• Universal columns;
• Industrial equipment, and more.

Several different methods and approaches can be used for steel fabrication. Here are some examples:

• Cutting – 

Cutting specific parts of a metal piece can be done in several different ways:

• Shearing

This is also an option, and it’s easy to use – the raw material is placed between two parts of a die, the higher of which is referred to as the punch, and it’s the simplest method so far. Using a punch, a single piece of raw material can easily be separated into several smaller pieces by pressing it against the punch.

• Band saws

Because shearing covers the majority of use cases when cutting steel plates and sheets, these methods are mostly used for cutting entire steel parts. To size a material piece, you use a band saw, which is either an abrasive disk or a band that turns against the material.

• Cutter torches 

As well as being used for cutting large cross-sections of steel, they are quite common. Although their speed is impressive, they do require extreme temperatures in order to perform the cut, so the cutting areas are treated as heat-affected zones. In choosing a cutting tool, keep in mind that the cooling style for all parts cut with this tool will affect some of the steel’s properties, so it’s important to keep that in mind.
Furthermore, these torches can be controlled by computers (CNCs) to make the process even faster. Additionally, a laser can be used to cut steel parts, and the torch is typically powered by natural gas.

• Water jet cutting 

A high-pressure water jet can also be used as an alternative to cutting torches, but it doesn’t cause material distortion and can cut practically any material precisely without overheating as regular cutting torches do.

• Bending –

Changing the shape of steel by applying massive force to it is usually done by hammering or by using press machines. Press brakes and/or tube benders are used in the bending process to achieve the desired angle. When it comes to bending as a process, it is imperative to consider the amount of stress applied to the raw material since excessive force can deform the material in question, requiring additional operations later on to correct it.

• Welding –

Fusion fabrication is a relatively common way to fabricate steel that involves either joining or bending pieces of steel or other materials using the fusion process. As a result of the fusion process, steel parts are heated to an extreme, joined or bent while they’re hot, and then cooled. It’s a very straightforward operation in principle. Lasers, electric arcs, and gas flames are the most commonly used heat sources for welding.

• Machining – 

The name of this process is derived from a large amount of machinery used to shave away metal parts of a specific shape, using tools such as drills, lathes, and mills.

The original raw material can exist in a number of shapes before the fabrication process, and the person supervising the process needs to take into account the original shape. Several other processes can also be considered to be supportive of the steel fabrication process, including:

• Steelwork erection;
• Surface preparation;
• Corrosion protection, etc.

It is believed that heat treatment is the most important of all of these processes. In order to create finer grains in steel for better properties, heat treatment involves three steps: soaking, heating, and cooling. There are specific heat treatment mechanisms.

If the original state of the steel prevents it from being shaped in a certain way without deforming, annealing can be used as an alternative to hardening it. In addition to heat treatment procedures, several other operations can also be performed on specific types of steel.

Because it is quite common for products to be ordered in advance, steel fabrication facilities specialize in making specific parts or details. Fabrication shops are facilities that focus on fabricating a specific part or model for which technical drawings are available.

As long as several different types of machines are needed for the fabrication process, fabrication shops can easily possess them. Both manual labor and machine work are used in the fabrication process – the demander can easily control the process and the number of pieces. In the first place, it is easier to control the process because a single fabrication shop performs a wide range of production processes within a single facility.

Almost every fabrication shop has a quality control procedure, which is why quality control exists for pretty much every shop that makes steel. There are two main ways to approach quality control for steel fabrication – semi-automatic and manual.

Various techniques are also available for detecting leaks via non-destructive tests. It is important to clean up the surface in question thoroughly before performing non-destructive tests and to check for welding failures to prevent disasters. Non-destructive tests include magnetic, ultrasonic, and radiography.

Since Purohit Pipe Industries is a steel fabrication company that utilizes the fabrication design throughout the whole process, an understanding of the design is essential. To make the drawing comprehensible and complete, all size markings must be included. In addition to the design of the piece, engineering also influences the different production parameters, such as the mechanical properties, which affect the overall quality of the product.

The steel fabrication services offered by Purohit Pipe Industries include a wide range of steel products that can be customized to meet the needs of clients.

In order to minimize the chances of making a mistake, there is strict quality control during the entire fabrication process. Additionally, the company provides an abundance of different features, such as steel structure creation, sheet metal cutting operations, and more.

Purohit Pipe Industries’ experience is evident in their client list which includes companies from Germany, Belgium, North America, Japan, and so on. Level supports the entire project lifecycle and keeps the client informed throughout.