The global metal fabrication market is booming, with a value of USD 20 billion in 2021. This figure is expected to reach USD 29.46 billion by 2029. The sharp growth reflects the increasing demand for metal products across various industries, highlighting the importance of understanding welding and metal fabrication. So, join us today as we explore the fundamentals of these two processes and the differences between them.
Metal Fabrication Process
Metal fabrication refers to the entire manufacturing process, from design to finished products. Every fabrication job involves multiple steps, each of which relies on the others for success. There are three primary parts of the process:
Bidding
The bidding stage starts the process. During this stage, the end-user outlines the scope of work and details the product’s purpose and the required quantity. The accuracy of bids depends on the details provided by the client to the contractor. Competitive bidding sometimes creates an adversarial environment, which may hinder the goal of securing quality manufacturing at the best price.
Companies submitting bids for metal fabrication projects have to evaluate their capacity to handle the work based on their resources. Some have full in-house capability, while others may rely on subcontracting services for specific needs.
Planning
Engineers and designers collaborate with the client to understand the project’s concept, specifications, and purpose. This teamwork helps them choose the best techniques and materials for the project. Project managers are important, as they ensure input from task-oriented experts.
Production
Once a contract is awarded through a competitive bid or design/build approach and the planning stage is done, the real work of fabrication begins.
Fabricators source and shape raw materials using different techniques, from simple shearing to high-tech laser cutting. Then, they bend the cut materials for assembly. Welding is part of the process, but it plays a key role. Let’s move to the next section to explore the welding job in detail!
Welding Process
Welding refers to the process of joining metal pieces together using pressure and heat. Although it’s just a step in the larger metal fabrication process, welding requires a lot of effort.
There are two main types of welding: fusion and solid-state. Fusion welding aims to join metal parts by heating them and adding filler material to create a unified bond. In contrast, solid-state welding achieves the same goal without using any additives. Here are some key welding techniques commonly employed in metal fabrication:
Shielded Metal Arc Welding (SMAW)
SMAW is the most frequently used form of welding, often called stick welding. This fusion technique utilizes an electric current along with consumable welding rods, which serve as filler material to join the surfaces together.
Oxy-Acetylene Welding (OA)
This technique combines oxygen and acetylene tanks through a torch nozzle. The flame generated heats the metal, while a filler rod facilitates the fusion of the metals.
Tungsten Inert Gas Welding (TIG)
TIG welding is the most refined method due to the exceptional quality of the welds it produces. This technique requires a two-hand process that utilizes a non-consumable tungsten electrode to form the weld.
Gas Metal Arc Welding (MIG)
MIG welding is a wire-feed technique using a consumable rod drawn from a spool of electrode wire. This method works best for thin materials and sheet metal joints.
What is the Difference between Welding and Metal Fabrication?
Metal fabrication refers to the whole manufacturing process, while welding is one part of the fabrication process. Here are some significant differences between them:
Different Tools
Metal fabrication includes many tasks and requires different cutting machines, such as laser cutters and mechanical saws, along with heavy machinery. In contrast, welding calls for specialized equipment such as clamps, power sources, consumable electrodes, welding machines, and torches. Welders must use safety gear to guard themselves against harmful gasses and fumes.
Different Skill Sets
Metal fabrication involves various machines shaping and molding metal, while welding relies more heavily on manual skills. Welders must go through rigorous experience and training to achieve the ideal metal joints.
Different Techniques
Fabrication includes tasks like bending, scraping, joining, and cutting metal parts. On the other hand, welding focuses on one task with different welding techniques.
Welding and Metal Fabrication Essential Tools
Both welding and metal fabrication require specialized tools. They share tools like:
- Angle grinders
- Chipping hammers
- Benders and breaks
- Shears
- Vices and vice grips
- Computers and CAD software
- Welding clamps
- Adjustable wrenches
Besides, since welding and metal fabrication tasks are complex, employees should wear safety equipment when handling the machines. Here is a list of Personal Protection Equipment (PPE) commonly used:
- Respirators
- Eye protection
- Safety-toed footwear
- Face shields
- Goggles
- Aprons and gloves
- High-visibility clothing
Welding and metal fabrication are increasingly automated and optimized. Companies like Fischer ASIA have invested in modern technologies to provide comprehensive solutions, from mold design to final product assembly. Check our solutions to see if they are what you need:
Maximize Efficiency and Quality in Metal Fabrication with Fischer ASIA
Welding and metal fabrication are two different processes. Welding focuses on joining metal parts, whereas metal fabrication covers a broader range of tasks.
If you need a consultation and exceptional solutions for your metal fabrication needs, contact Fischer ASIA today for more information. Our experienced team is ready to assist you with anything!
FAQs
1. What’s the hardest type of welding?
Tungsten Inert Gas (TIG) welding is the most difficult because welders must control many factors such as gas cooling, current, and heating. Plus, contamination is more likely to occur during the process.
2. What metal cannot be welded?
Material combinations like aluminum-steel, titanium-steel, and aluminum-copper cannot be welded.
3. What is the easiest metal to weld?
The easiest metals to weld are mild steel, stainless steel, aluminum, nickel, copper, cast iron, and bronze.
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