Heavy vs. Light – Types of Metal Fabrication
Fabricating metal is an intricate process which requires understanding of different techniques and products. Metals come in a wide variety of shapes, sizes, and colors, and are used for a wide range of applications; machining methods vary depending on the metal type, with heavy metals like steel, aluminum and titanium requiring more intensive procedures than lighter metals like brass. This leads to two types of metal fabrication – heavy and light, which have different manufacturing styles, applications etc. So, what is the distinction between these two fabrication techniques and how are they adding value to the manufacturing industry? This blog will look to address some of these points.
Heavy Metal Fabrication – Factsheet
- Processes: Any engineering technique performed on metal components thicker than one inch is considered heavy metal fabrication. Special methods are required to cut and shape “heavy” structural materials as compared to methods used on lighter metals. An example is gas metal arc welding (GMAW) which is efficient on a metal sheet plate.
- Materials: Ferrous metal (which has iron as a major component) are exceedingly hard and durable and make for good heavy metal fabrication applications. Steel and, in some cases, stainless steel are mentioned while discussing the necessity of strength involved in developing heavy metal fabrication products.
- Products: Large-scale agricultural machinery and equipment, as well as access walkways, are other good examples, along with tanks and gantries. In fact, just about any produced structural element might be considered heavy fabrication.
Light Metal Fabrication – Factsheet
- Processes: Any engineering technique performed on metal components thinner than one inch is considered light metal fabrication. Examples are turret punch used for generating sheet metal shapes and press for forming. Resistance welding and alloy processing are also applicable while working on light fabrication operations.
- Materials: Steel, copper, aluminum, brass and bronze are considered to be “light” materials which are applicable for cutting, shaping and assembling various metal components. Very tensile materials are not suitable for light fabrication.
- Products: Products like RV parts, brackets, toolboxes etc. are instances of end products of light fabrication. These are usually smaller architectural components, and hence are more manageable in size.
Steel in the “Heavy Metal” world
Steel fabrication is hugely popular with regard to heavy metal fabrication, e.g. steel fabrication has many applications in the mining industry. It is easy to see why, especially as we consider the following advantages it offers:
- Tensile strength: The material is an alloy, typically consisting of very strong materials that actively prevent dislocation on an atomic scale. Steel’s reliability as a building material is unmatched.
- High Resistance to Wear and Tear: Steel is a very tough material. It can withstand heat, flame, moisture, and wind, and it can be protected from rust and corrosion. Even termites and other wood-boring insects won’t damage it.
- Consistency and efficiency: These benefits have been realized as heavy steel manufacturing technology has advanced, allowing heavy steel fabrication companies greater consistency in steel construction. Steel is precisely made to specifications, which means it arrives at the construction site ready for installation.
- Environmental friendliness: Steel is widely recognized as one of the most eco-friendly building materials available. Over ninety percent of structural steel is recycled material, demonstrating the widespread nature of steel recycling. Furthermore, it may be remelted and reused indefinitely without degrading in quality.
Closing Remarks
It can thus be seen that heavy metal fabrication typically involves more complex machinery like lathes or mills, while products made from light metal stock can be molded using only hand tools. Welds and heat induction bending services are susceptible to severe strain when working with heavy metal fabrications and require regular testing to check durability. Steel, due to its malleability and widespread favor among architects and designers, is the material par excellence of contemporary building. Thus, while “heavy metal” may be the flavor for large scale manufacturing, “light metal” reigns supreme with regard to smaller and lighter products!