5 Must-Have Features in a sheet metal penang

In modern engineering, sheet metal serves as the foundation. It's all around us, from cars and machines to house facades and furnishings. This has led to there being various options of sheet metal material available in the market, which is why it is important to select the right one for your project. The choice of sheet metal during the product design process will impact the sheet metal component of the design, manufacturing process, cost, and performance.

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Before embarking on any project that involves sheet metal, engineers must first have a basic understanding of sheet metal to utilise it to its maximum potential. This includes standard measurements, materials, production differences, and various forming techniques.

So, let's dive deeper into the factors you need to consider when selecting the ideal sheet metal material.

Factors when selecting the right sheet metal material

When selecting a material for your construction project, there are several things to consider&#;for example, lowering costs and utilising simple manufacturing techniques. When considering these, you should choose a material that is long-lasting, efficient, and best suited to your project.

Here are some things to think about while choosing a fabrication material:

• The shape of the components that need to be created
• The intended purpose of the developed material
• The dimensions of the product you are creating
• The finishing techniques you can use on your product

Advantages and Disadvantages of Different Sheet Metals

Before you head off to get your materials, here are some of the different types of sheet metal and their advantages and disadvantages. 

Alloy steel

Alloy steel, as the name implies, mixes various components to provide a customisable set of characteristics. Carbon steel serves as this material's primary element. Other components are included, such as:

• Tungsten: This component increases the heat resistance of the alloy steel, which raises the melting point. It also improves the structural composition of the steel.
• Chromium: Just a small amount of chromium 0.5% to 2%) can aid in the alloy's hardening, while larger amounts (4% to 18%) can offer an additional benefit of corrosion resistance. 
• Manganese: When combined with trace levels of phosphorus and sulphur, the steel alloy becomes less brittle and is easier to hammer. 
• Vanadium: This element can improve grain structure, strength, and heat resistance with just 0.15% of its content. The steel alloy hardens when combined with chromium while keeping its formability.
• Nickel: This alloying material will increase the strength of the steel by up to 5%. It offers remarkable corrosion resistance at levels over 12%.

Aside from its adaptability, alloy steel is also incredibly affordable.

Advantages of Alloy Steel

Alloy steels can offer a variety of advantageous features with additional heat treatment, such as:

• Higher resistance to corrosion
• Increased durability
• Increased hardness and strength

Disadvantages of Alloy Steel

The following are the drawbacks of alloy steel, which include

• Low machinability
• Lacks weldability 
• Low flexibility

Stainless steel

Stainless steel is a metal alloy made up of iron, chromium, and nickel. Due to its high corrosion resistance, magnetic properties, ability to tolerate high temperatures, and ease of machining, it is the most widely used material in the world.

Additionally, stainless steel is common for many different reasons&#;one of them being that it is rust resistant. Hence, you can use it in your kitchen without worrying about contamination because it doesn't react with food. Furthermore, it is durable and suitable for usage in extreme heat.

Advantages of stainless steel

Here are some of the other advantages of stainless steel

• Low maintenance: Stainless steel has long-term benefits that surpass the initial cost. However, you can concentrate on an ideal process and outcomes when you choose a material like stainless steel that requires minimal maintenance.

• Sustainability: Stainless steel can be recycled. Using stainless steel is an excellent approach to lessen the environmental impact of your production processes and merchandise. 

• Temperature resistance: Stainless steel is a good choice for applications where temperatures may be more intense, such as boilers, valves, feed water heaters, and other heat exchangers.

Disadvantages of stainless steel

While there are a lot of advantages to stainless steel, there are certainly a few disadvantages that stainless steel has, such as:

• Price: Stainless steel is not the most cost-effective metal. Due to its difficulty in manufacturing, stainless steel is frequently expensive.

• Difficult to weld: Although stainless steel's high melting point can be a significant asset in some situations, it also makes the material challenging to weld, which places restrictions on the types of building projects that can include it.

Carbon steel

This sheet metal substance has iron alloyed with carbon to give it a high level of durability. A manufacturer can select steel with low, medium, or high carbon content levels based on the specific requirement.

Low levels of carbon produce a highly adaptable material that is most frequently used in commonplace items like fences and gates. Steel with a medium carbon content is commonly used in appliances and automobiles. Higher carbon content produces a more fragile product, perfect for delicate things like cables.

Advantages of carbon steel

• Malleable: Carbon steel has the advantage of being able to be bent, cut, and twisted to form the necessary shape more easily than other metals. 

• Affordable: Carbon steel is the perfect material for minimising project costs. However, since mild steel is generally less expensive than other metals, you must consider the possibility that you will need to treat it to minimise corrosion.

Disadvantages of carbon steel

• Durability: Carbon steel is ideal for mechanical engineering and general fabrication. Due to its strength, it is an excellent material option for applications where severe stress won't be placed on it.

• Limitation to heat treatment: The carbon content of carbon steel may change when treated with heat. Steel is frequently subjected to heat treatment to alter its features. However, after heat treatment, there are no noticeable alterations to the original fabrication once it has cooled off in the mill.

Tool Steel

Tool steel is a strong alloy with 1% carbon that is incredibly versatile. Like alloy steel, tool steel consists of various elements in different types and ratios, depending on the intended use. This is why tool steel is resistant to abrasion and operates well in severe temperatures. Due to its characteristics, this sheet metal is perfect for making tools like hammers, punches, dies, and blades.

Advantages of tool steel

Several advantages that tool steel can offer include:

• Durability
• Resistance to deterioration
• Hardness
• Resistance to heat

Disadvantages of tool steel

Tool steel metal sheet comes with some disadvantages as well, which are:

• Low hardenability
• Tendency to overheat

Galvanised steel

Electro-galvanised sheets and hot-dipped metallic-coated sheets are the two types of galvanised steel commonly found in construction. Steel that has been cold rolled and annealed makes up electro-galvanised sheets. Without any zinc spangle, it is coated entirely in zinc.

On the other hand, hot-dipped metallic-coated sheets are made up of cold-rolled strong steel plates with an iron-zinc alloy and pure zinc coating applied to them. Compared to electro-galvanised sheets, this galvanised steel is slightly cheaper and has better corrosion resistance.

Advantages of galvanised steel

• Durability: Steel becomes strong through the galvanisation method. Its strength can therefore be enhanced.

• Rust resistance: Steel is protected from corrosion by being galvanised, which contributes to preventing rust.

• Protected from contamination: Since other chemicals and dangerous substances won't contaminate galvanised steel, its performance level will be unaffected.

Disadvantages of galvanised steel

• Welding limitation: The inner substrate's surface has improved coating density and a comparatively high manganese content. As a result, the aluminium-zinc coating cannot be joined by welding under normal circumstances and must instead be joined by other means, such as rivets.

• Galvanising process is not suitable for all types of steel: While most steel materials can be galvanised by being submerged in a zinc bath, some very large or small products cannot go through the process.

Aluminium

Aluminium is an ideal choice for applications where a lighter material is needed. Even without a finish, this kind of sheet metal has a high level of corrosion resistance. In addition to being sturdy, aluminium is also suitable for laser cutting, welding, and machining.

Advantages of aluminium

• Recyclable: Aluminium is regarded as a sustainable material. One important characteristic is that it can be recycled while maintaining its original features. 

• Corrosion resistance: A thin layer of aluminium oxide forms on the surface of aluminium when it is exposed to air. When exposed, this layer shields the aluminium from corrosion.

• Lightweight: The strength and longevity of aluminium in designs are other advantages. This material can withstand a sizable weight without making the finished product too heavy.

Disadvantages of aluminium

• Price: If you are taking on a significant project, you will want to save money wherever possible. Unfortunately, aluminium is more costly than other materials, like steel.

• Welding duration: Specific techniques must be used to weld aluminium, which might be more expensive, time-consuming, and messier than other methods.

Select the right sheet metal material to achieve the desired results 

There are several grades of sheet metal materials available on the market nowadays. The material is chosen in accordance with the needs for the product's functionality and the available budget.

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So, if you're looking for a sheet metal contractor in Malaysia, visit us at Choong Ngai Engineering today to speak to our experts. We at Choong Ngai Engineering have years of experience and knowledge to answer your doubts or concerns, and we ensure to provide you with the quality solution you're looking for. Call us now!

Making the right decisions for your business project involving sheet metal fabrication can feel like a challenge, especially if this is your first project. Worry not! Let us show you how.

The Basics of Sheet Metal Fabrication

Sheet metal fabrication is the process of drawing, forming, and bending sheet metal according to the desired specification. Many industries, including the construction, automotive, aerospace, and consumer goods sectors, rely heavily on sheet metal fabrication. Because sheet metal is so versatile, the possibilities are endless. The variety of end products can range from vehicle parts, watering equipment, kitchen appliances, and elevators, to household items like screws and caps.

Milestones in the sheet metal fabrication process:

As we move through the key milestones of a sheet metal fabrication project, we will discuss the different types of raw materials, surface finishes, and several useful tips.

Step 1: Project Planning

Project planning is the first and most important step in metal sheet production. The three key components to consider at this stage are design, schedule, and budget. The design process begins with a blueprint outlining the product&#;s characteristics and dimensions. At this stage, it is crucial to set reasonable goals for cost and schedule with the metal fabrication team.

Step 2: Material selection and acquisition

Material selection and sourcing are essential steps before manufacturing. Once acquired, raw materials will go through several fabrication steps to form the final product. Before we go into the specifics of sheet metal materials, here are some general considerations:

Yield strength: The greatest amount of stress that a material can withstand before permanently deforming. The yield strength indicates the elastic limit of a material.

Tensile strength: Unlike yield strength, tensile strength measures how much the metal can be stretched and pulled before it breaks.

Hardness: A measure of how well a metal can resist localised deformity, scratches, or indentation from other actions.

Weldability: This reflects how easily your metal can be welded (melted with heat and joined together) without cracking.

Corrosion resistance: Some metals are more likely to react to the oxidation and moisture of their surroundings. So, it is important to consider how exposed your project&#;s metal products will be.

Machinability: The ease and speed of cutting a metal depends on its machinability.

Next, we&#;ll discuss some common sheet metal materials, each of which has its unique qualities.

Hot-Rolled Steel (HRS)

A steel bar or slab known as a &#;billet&#; is first heated to temperatures above its recrystallisation point (between 720 and degrees Celsius). The recrystallisation point is the high temperature that rearranges iron atoms, making it easier to work with. Next, the metal passes through a series of high-speed rollers to achieve its final dimensions.

It is then spun into a coil and left to cool. Steel contracts slightly as it cools, hence controlling its final shape is more difficult.

Pros:

• More affordable, and suitable for mass production.
• Less manufacturing time, easier to work with.
• Minimal internal stresses. Internal stresses are forces we keep in check to prevent undesirable dimension changes. 

Cons:

• Uneven surface or scaled appearance.
• Less durable than cold-rolled steel.
• Distorted or unrefined shape.

Common applications: Metal construction, railroad tracks and parts, agricultural equipment, pipes, and tubes.

Cold-Rolled Steel (CRS)

Cold-rolled steel is simply a more refined form of hot-rolled steel that has gone through further processing to produce harder and stronger metal sheets. &#;Cold&#; refers to heating the metal below its recrystallisation point. The first step is similar to hot-rolling, where the metal gets its initial shape.

Then, it goes through more grinding and polishing to achieve more precise measurements and a better surface finish. In contrast to hot-rolled steel, cold-rolled steel undergoes a process called &#;hardening&#; at a lower temperature, making it harder and sturdier.

Pros:

• Excellent surface qualities (smoother, shinier, more attractive).
• Stronger and harder than standard hot-rolled steel.
• High precision, refined shape.

Cons:

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• More expensive.
• Longer processing time.
• Stress can lead to warping or distortion.

Common applications: Metal containers, fan blades, water heaters, cabinets, and furniture.

Spring steel 

Spring steel, also known as &#;all-purpose&#; steel, is available in several alloy combinations with manganese and varying carbon content. What makes it &#;all-purpose&#;? Spring steel is highly versatile because of its excellent resilience, yield strength, and malleability. It is also the best raw material for making springs since it can withstand extreme bending and twisting without deforming.

Pros:

• High yield strength, retains shape with repeated twisting and compression.
• Decent hardness and elasticity.

Cons:

• Overheating can lead to breakage.
• Requires tempering to relieve material stress.
• Tempered or hardened state spring steel is harder to work with.
• Not all spring steel sheets are suitable for welding.

Common applications: Clutch and brake springs, valve springs, coil springs, blades, and washers.

Aluminium

Aluminium easily alloys with other metallic elements such as copper, manganese, silicone, and magnesium. Besides being non-toxic, non-magnetic, and non-combustible, aluminium has excellent electrical and heat conductivity. The high workability and low corrosion of this material make it ideal for a wide variety of applications.

Pros:

• Easy to fabricate&#;highly formable and weldable.
• Corrosion-resistant, decent surface finishing.
• Heat conductivity, non-combustible, and reflective.
• Lightweight
• Non-toxic, suitable for food handling and other specialised industries.

Cons:

• More costly than standard steel.
• Steel is preferred for strength when weight is not an issue.
• Can affect the taste of food in cooking applications.

Common applications: Automotive and aircraft parts, window frames, food packaging, electrical products, and lighting.

Stainless steel

Known for its excellent surface properties and corrosion resistance, stainless steel sheet is available in various grades to suit multiple applications. The grades vary, depending on the compositions of steel with chromium, carbon, and other alloy materials. The 300-series is the most popular type of stainless steel.

For instance, the nickel content in SS304 contributes to decent corrosion resistance and durability. While SS316&#;s molybdenum content provides superior corrosion resistance, with additional protection against seawater corrosion, it comes at a higher cost.

Pros:

• Corrosion-resistant finish.
• Durable, good balance of strength and hardness.
• Available in several grades for different purposes.
• Easy to fabricate: soldering, welding, riveting.

Cons:

• Higher set-up cost.
• Chipping can occur during processing.
• Risk of corrosion at thick welding points.

Common applications: Building structures, food processing equipment, vehicle parts, storage containers, agricultural watering systems, marine.

Step 3: Fabrication process

Transforming metal sheets into the desired shapes and dimensions is the most fascinating part of a sheet metal fabrication project. You can learn more about the common metal fabrication processes&#;forming, cutting, and joining&#;here. The pricing for metal fabrication procedures can differ widely depending on the design complexity and the production method.

For example, the cost of a project is likely to increase if it calls for customised tools or a lot of manual labour. In comparison, automated metal manufacturing using conventional tools will be cheaper.

Step 4: Finishing

Two main reasons for applying finishing to sheet metal items are corrosion prevention and aesthetic appearance. It usually happens before installation to save time and money. Here are some examples of common sheet metal finishing methods:

Standard finishing: This involves cleaning and smoothing the edges. It is also known as the &#;basic finishing&#; of ready-to-use material. For a natural look, we can sometimes opt for the standard finishing. A classic example is stainless steel.

Bead blasting: Compressed air propels thousands of microscopic abrasive particles like sand or glass onto the sheet metal surface. When these beads hit the sheet metal, they smooth it out and leave a matte finish.

Using this method, you can give metals like steel, stainless steel, aluminium, and brass incredibly attractive surface treatments. Surfaces with these finishes last a long time and do not react to chemicals. Unfortunately, this finishing method, while beautiful, is pricey and time-consuming for most small projects.

Powder coating: A specialised dry powder that is thermoplastic and thermoset is used instead of conventional liquid paint. It is applied electrostatically and heat-cured for a thick, homogeneous surface with no drip marks. Unlike traditional paint, powder coating requires no solvents and cures faster.

Another reason for its popularity is its tougher, more durable finish. However, due to its high price tag, powder coating is not as practical for thin film or large component coating operations.

Electrophoretic coating (E-coating): This process involves immersing metal parts into a water-based bath solution that contains paints, resins, or pigments. An electric current is applied to the metal to allow these particles to deposit on the metal surfaces.

Adjusting the electronic voltage will decide the coating thickness. Then, heat curing follows. E-coating is suitable as either an undercoat or a topcoat to guard against corrosion.

Anodizing: Anodizing is useful for improving corrosion and wear resistance in aluminium alloys. This procedure involves immersing the material in an electrolytic acidic solution. The solution covers the metal with an aluminium oxide coating, which is much tougher and more resistant to abrasion than pure aluminium. This method works best for aluminium alloys that spend a lot of time in seawater.

Passivation: Passivation decreases the reactivity of a metal&#;s surface. An acidic solution is typically used on stainless steel to eliminate free iron from the surface, leaving behind corrosion and rust-resistant components. But since this process isn&#;t permanent, a product may need to go through several passivation cycles throughout its life.

Electroplating: Electroplating involves applying a thin layer of another metal to a metal surface, such as nickel, silver, or other metals. Immersing both metals in an electrolyte solution leads to electrochemical reactions. Sheet metal serves as the cathode, while the outer coating metal acts as the anode.

The finished sheet metal surface will be more durable, attractive, and resistant to corrosion. Depending on the outer coating metal, electroplating can improve the conductivity or radiation resistance of metal parts. Although popular, this method incurs a higher cost.

Step 5: Delivery, assembly, and installation:

The finished items&#; delivery, assembly, and installation conclude a sheet metal fabrication project. The final products require careful handling to avoid potential damage. Thus, it is good to have someone perform a quality check and supervise assembly to ensure everything runs smoothly. This will make it possible to inform the metal fabrication team about any flaws or potential problems.

Cost-saving tips:

1. Simple designs save production time and money. However, complex designs are difficult to achieve and raise production costs.
2. Right raw materials matter. For final production components, use the least expensive metal that can carry out the function well.
3. Common sheet metal gauges are standard-sized thicknesses. They are readily available and hence more affordable than unique gauges.
4. The choice of finishing must depend on the function, aesthetic requirements, and environmental conditions of use. Sometimes, it would be wiser to spend more on an anti-corrosion surface that lasts longer.

Top tips for choosing the right sheet metal fabricator partner

Finding a reliable metal fabrication team is a key factor in completing a successful project. When looking for a sheet metal fabrication expert, consider these points:

Portfolio: Studying the portfolio of a potential metal fabrication specialist will give you a good idea of their product range, experience, production capabilities, and work quality. You can see if there are any design similarities between your project and their previous work, or if there are any alternative approaches that might work better.

Professional team: Find an informed and skilled team offering information about current products and services. A skilled metal fabricator will be able to provide you with a realistic price quote and timeframe for your project after a discussion of the details.

Production capabilities: A metal fabrication team&#;s production handling capacity is heavily influenced by several factors. This includes the equipment and technology they use, the range of stock available, the number of workers, and their level of experience. It is vital because you want a metal fabricator who can meet your budget and timeline.

Certified production facilities: Working with certified manufacturers gives you more confidence and peace of mind. This ensures that your sheet metal manufacturing project meets quality standards by using the right tools and standard operating processes.

Location: Long-distance logistics can contribute to hidden costs in your metal production project. Your metal manufacturing partner should thus be located close to your facility for both logistical and communication purposes.

Conclusion

Every entrepreneur&#;s goal in their sheet metal fabrication project is to create a fair and sustainable balance of cost and product quality. Knowing the design requirements, materials, and finishes of sheet metal fabrication is a great advantage.

A good partnership between the client and the metal fabrication expert is the foundation of every successful project. Because communication is crucial, selecting a sheet metal fabricator who knows your project and its requirements is critical.

With over 30 years of experience in the metal fabrication industry, we have amassed many loyal customers from a wide range of industries. Contact us if you have a sheet metal fabrication project in mind.

References:

https://eziil.com/custom-metal-fabrication

https://kneesengineering.co.uk/news/sheet-metal-fabrication-a-complete-guide/

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