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fabrication

Metal fabrication is a value added process that involves the construction of machines and structures from various raw materials. A fab shop will bid on a job, usually based on the engineering drawings, and if awarded the contract will build the product.

Fabrication shops are employed by contractors, OEM's and VAR's. Typical projects include; loose parts, structural frames for buildings and heavy equipment, and hand railings and stairs for buildings.

Standard raw materials used by metal fabricators are;

  • plate metal
  • formed and expanded metal
    • tube stock, CDSM
    • square stock
    • sectional metals (I beams, W beams, C-channel...)
  • welding wire
  • hardware
  • castings
  • fittings

Fab shops will generally have a limited machining capability including; metal lathes, mills, magnetic based drills along with other portable metal working tools.

Welding is the main focus of steel fabrication. The formed and machined parts will be assembled and tack welded into place then re-checked for accuracy. A fixture may be used to locate parts for welding if multiple weldments have been ordered.

The welder then completes welding per the engineering drawings, if welding is detailed, or per his own judgment if no welding details are provided.Welding Process

Special precautions may be needed to prevent warping of the weldment due to heat. These may include; welding in a staggered fashion, using a stout fixture, covering the weldment in sand during cooling, and straightening operations.

Straightening of warped steel weldments is done with an Oxy-acetylene torch and is somewhat of an art. Heat is selectively applied to the steel in a slow, linear sweep. The steel will have a net contraction, upon cooling, in the direction of the sweep. A highly skilled welder can remove significant warpage using this technique.

Steel weldments are occasionally annealed in a low temperature oven to relieve residual stresses.