Sheet metal fabrication is a process of shaping and designing metal sheets in a cost-effective manner. Various techniques such as cutting, punching, bending, etc are used for the fabrication process which ensures production of robust fabricated materials with better metal finishes.

Today, all the major industries such as the automotive industry, aerospace industry, agricultural industry, medical industry, etc are benefiting after having switched to using fabricated sheet metals in their manufacturing processes.

Benefits of Sheet Metal Fabrication

Be it the automotive industry, electrical industry, utility industry, medical industry, or even agricultural industry for that matter, companies often prefer a custom metal sheet that perfectly suits their production requirement. Sheet metal can be cut, punched, bent, stamped, welded, rolled, CNC machined, and drilled to get the customized output.

A custom metal sheet helps them to scale up production at a low cost as there are fewer to no manufacturing challenges and the output is precise. Furthermore, companies can keep being innovative and create better designs as they know they can completely rely on custom sheet metal to replicate the designs.

Durability

Choosing the right kind of metal and giving it the right thickness, a customized sheet of metal increases the lifespan of the parts to a great extent. Add to that the property of metal sheets being corrosion, heat and rust-free and you get more out of your products than the set target. A great reason to shift to a custom sheet metal approach.

Fewer Limitations

There is no limit or restrictions when it comes to customizing a metal sheet as per the design requirement. The entire process of customization through cutting, drilling, welding, etc takes less time thus enabling a higher rate of production at a low cost. Furthermore, this can be achieved using any kind of metal thus providing the company’s flexibility to choose from the metal suiting their manufacturing requirement.

Faster Turnaround Time

With the usage of QBH technology and other automation tools, it is now possible to customize sheet metals with great precision in less time. This feature enables companies to roll out products quickly into the market and meet the growing demands of their customers.

Ease of Transport

Custom-made sheet metals can be customized in such a way that their weight is less as compared to a non-customized metal sheet. This option makes it easier to transport such metal sheets.

High Precision

The process of customizing a metal sheet can be streamlined to get the same output again and again with great accuracy and precision to suit the specific requirements of the industry. Thus companies no longer need to remain stuck with standard designs, instead, they can use custom designs and meet the market requirements at ease.

Easy Repair

More often than not, after say, 10 years or so old equipment tends to become of no use. This does not hold true for custom sheet metals since they can be easily re-engineered and be of use again. The old custom sheet metals can also be easily recycled thus they are environmentally friendly.

Steps Involved in Sheet Metal Designing

A lot goes behind finalizing a sheet metal design. Since precision and accuracy are the major fundamental advantage of using sheet metal fabrication, the designing part becomes one of the most important steps in the entire sheet metal fabrication process.

Finalizing the Idea

A lot of ideas are discussed and brainstormed to come up with the best possible design to meet the demands of the industry or the client. Often a 3D model is also created during this stage to have a better understanding of the process.

Creating a Blueprint

Once the design is greenlighted, the next crucial step is coming up with engineering drawings of the designs with all the specifications that would go into the final product.

Analysis

The design is then analyzed based on how feasible it is to be implemented based on factors such as available tools, budgets, labor, etc. In this phase, the design keeps getting reworked on to make it simpler, easier and cheaper to execute.

Building a Prototype

Once the design is finalized and the manufacturing requirements are in place, various sheet metal fabrication methods are performed such as cutting, bending, welding, etc to build a prototype of the metal sheet as per the design and the requirement.

Testing

The built prototype metal is then tested internally as well as in the closed group of end-users. This is the phase in which the prototype undergoes multiple evolutions and revisions based on the feedback received until the result is as per the set requirements.

Final Production

With the prototype model achieving the desired outcome, companies then go into full-scale production using sheet metal fabrication to build better quality products with better metal surface finishes.

Metals Used for Sheet Metal Fabrications

Steel: Steel provides great strength and durability.

Magnesium: Magnesium is used for its low density and stiffness.

Aluminum: Aluminum is very light compared to other metals and is thus used for ease of transport and it is also temperature resistant.

Bronze: Bronze has a low melting point. Majorly used in manufacturing household appliances.

Brass: Used in fittings because it is corrosion resistant and also lightweight.

Copper: Copper is a good conductor of electricity and can also be easily given any desired shape.

Apart from the above mentioned metals, there are some pieces of equipment that come handy in the sheet metal fabrication process. These equipment include fittings, plate metals, drillers, hammers, punching tools, casting materials, sectional and shaped metals, welding wires, clamps, etc.

Design Considerations for Sheet Metal Fabrications

Hole Size

Ensure that the hole size is equal to or larger than the thickness of the metal so that a situation such as breakage or damage does not arise. This ultimately benefits the output rate and reduces the cost.

Furthermore, working with metals generates a lot of heat and friction which may result in the tearing up of the metal in case the holes are at the edges or near the curls. In Order to avoid such a scenario, it is advised that the minimum distance between holes and edges should be at least three times the thickness of the sheet. Whereas, the distance between two holes on the metal surface should be at least six times the thickness of the metal sheet used.

Hole Diameter

For any sheet metal, the diameter of the hole should not be too small. Small holes mean more precision which translates into more manufacturing costs. Besides, small holes are also more vulnerable to getting damaged during the sheet metal fabrication process. Ensure that the diameter size is equal to or more than the thickness of the sheet metal used.

Bend Radius and Bend Orientation

All sheet metals have to undergo bending and in this bending process, they are subjected to a lot of strain. In the event that the strain exceeds beyond a point, it would result in cracks, damaging the metal sheet. The point beyond which a metal sheet should not be bent is known as the low bend radius. Ideally, this bend radius should be at least equal to the thickness of the material. The minimum bend radius varies according to the type of metal.

Uniformity of bends is another important factor that helps in standardizing the process and lowers the overall manufacturing cost. So, make sure that the bends in the same point are designed in the same direction.

Tolerance

Tolerance is often overlooked while designing a metal sheet which results in damaged products and also increases unnecessary costs. Keeping tight tolerance over hole diameters, radius, and distance results in more cost and low productivity. The tip here is to build only those features that are absolutely necessary.

Folds

Complications in the design translate into increased costs. The tip here is to keep the folds simple, the angles easy to blend so that the metal is easier to fold. It is recommended that the radius should be equal to or greater than the thickness of the material. If possible, avoid small bends on the thicker parts as it is not only expensive but also a difficult approach. So while complex is costly, remember that simple is cost-friendly.

Tabs and Notches

Another important tip is related to optimizing the design of tabs and notches. Notches should be placed about 1/8th inch away from each other and should not be closed to the edge. The width of the notch should be greater than or equal to the thickness of the metal used. The notch length should be up to five times the thickness of the metal.

Tabs on the other hand should not be longer than five times their width and should be greater than or equal to two times the metal’s thickness. Following these recommendations shall ensure there is no breaking and deformity during the designing process.  

Offsets

Offsets are the Z-shaped bends to be used as brackets and clamps. The important tip with using offset is that the bend radius should be uniform throughout the metal sheet and the parallel planes in the offset should be equal to or greater than twice the thickness of the metal sheet.

Curling

The edges on the sheet of metals tend to be sharp. Curling is the process in the sheet metal fabrication which makes the edge safe for handling. This process involves adding a hollow, circular roll to the edge of the metal sheet. Ensure that the outside radius of the curl is equal to or greater than twice the thickness of the metal.

Hems

The safe and strengthened edges that are established on the sheet of metal are due to hems. The important tip here is to avoid flat hems at all costs as they are prone to fracture and getting damaged. For open hems, ensure that the inside diameter is equal to or greater than the thickness of the metal. Lengthwise, maintain the length of hem to about four times the thickness of the metal. Closed hams on the other hand should be completely folded. For a teardrop hem, ensure that the inside diameter is equal to the thickness of the material.

Methods Used for Sheet Metal Fabrication

There are several ways and methods such as sheet metal laser cutting, sheet metal bending through which a sheet metal can be fabricated. However, the fundamental principle boils down to the sheet metal being formed or cut. In the recent years, there has been a rise in the usage of QBH technology and other kinds of automation tools to facilitate the sheet metal fabrication process as per the desired result.  Some of the predominantly used sheet metal fabrication methods are as follows:

Cutting

Cutting is one of the most basic methods to fabricate a metal sheet. One of the common ways of cutting is sheet metal laser cutting. Other than this, sheet metals can also be cut by sawing, shearing, using a high pressure water jet, etc to fabricate the sheet metal as per the specific requirement.

Bending

Bending is achieved by subjecting the metal sheet to hydraulic brakes that are set at certain angles. The metal sheet is then placed in the brakes and applied force to bend it at the specified angles.

Rolling

Rolling is either done using a hot-rolling process or a cold-rolling process. The hot-rolling method is used to create thin metal sheets whereas the cold-rolling method is used to make thick metal sheets.

Welding

Welding is an important method in the sheet metal fabrication process. Once the desired shape is attained, welding helps to retain that shape of the metal so that it does not get deformed and ensures it has better metal surface finishes.

Shrinking and Stretching

Shrinking is done to smoothen out the edges and other irregularities in the shape of the metal. Stretching on the other hand is done to stretch a metal sheet and get the desired shape.

Fastening

Holding tools like nuts, screws, etc are used to hold the metal sheet tightly during the sheet metal fabrication process.

Hydroforming

Hydroforming is a method in which the metal sheet is subjected to high pressure fluid to give it the desired shape.

Punching

Punching is done to give the metal sheet a uniform shape throughout and remove any holes in the sheet.

Stamping

Stamping is somewhat similar to punching but in stamping, there is no need to remove the material from the sheet metal. Stamping is used to outline, draw and emboss the material.

Assembling

Assembling is often the last step of customization and is achieved by welding, binding and bending to get the desired outcome. Fasteners, bolts, screws, etc are used to complete the assembling process.

As compared to other manufacturing methods, companies can easily implement sheet metal fabrication in their manufacturing process and derive accurate and precise results and that too on a large scale and at a much lesser cost.  Sheet metal fabrication also gives companies the license to innovate and keep improving their designs which can be easily met through sheet metal fabrication.

Thus it is not at all surprising that sheet metal fabrication is extensively used in multiple industries such as aeronautics, electronics, energy, agriculture, and healthcare among others.

Hot and Cold Rolled steels are popular materials used in almost all the products we use in our daily lives. These are crucial components of the manufacturing industry, and each has unique benefits to offer. Each material has its own strengths and is best suited for specific applications.  

Here we explore both the types, their manufacturing processes, differences, uses, and much more in detail!

Hot Rolled Steel Vs. Cold Rolled Steel-An Overview

Hot and Cold Rolled steels are two distinctive types of metals because of how they are manufactured. Hot Rolled Steel is treated at a high temperature of 1700℉ (930℃), which alters its material properties.

Contrary to this Cold Rolling process comes after this and is done below the recrystallization temperature of steel. It involves applying mechanical stress to steel by passing steel billets through the rollers at ambient temperature. Here are we have jotted down some key features of both types of steel.

	Hot Rolled Steel (HRS)	Cold Rolled Steel (CRS)
Manufacturing
Temperature	1700 ℉	80-90 ℉
Re-crystallization Temp.	Above	Below
Process	Steel is heated at extreme temperatures where the material properties are altered. Hardening and other mechanical processes improve its strength and characteristics.	After HRS, the steel is cooled down. It undergoes mechanical stress by passing it through pair of rollers. And due to strain hardening, the strength of steel is further enhanced.
Appearance
Texture	Scaled Finish, Rough surface	Smooth Finish, Oily surface, round edges
Color	Bluish hue	Silver hue
Material Properties
Yield Strength	~310 MPa  (45000 Psi)	~482 MPa  (75000 Psi)
Tensile Strength	~462 MPa   (67000 Psi)	~586 MPa  (85000 Psi)
Advantages	Good Strength, Higher workability, i.e., can easily be shaped at high temperatures. Less expensive	High strength. Better dimensioning. Smooth texture.
Disadvantages	Poor finish. Lesser strength, Residual stress after cooling.	Expensive. Lower malleability, Hard to Machine.
Examples:	Construction, Industrial machinery, Railroad Track, Pipe, Fittings, Agricultural Equipment, etc.	Household and Kitchen appliances, cabinets and metal furniture, precise industrial equipment, Aerospace components, etc.

What is Cold Rolled Steel (CRS)?

Cold Rolled Steel- in simpler terms, is a type of steel processed at room temperature. It is much finer and has better material properties than its counterpart Hot Rolled Steel. Here we are going to discuss it in detail.  

How is Cold Rolled Steel Manufactured?

Steel at first undergoes the hot rolling process at extreme temperatures. This is done to temper the steel bars and improve strength. The finished product is left to cool at room temperatures, also known as Annealing. During this, the steel goes through significant change in its material characteristic.

Once the steel is cooled below its recrystallization temperature,  it now undergoes the cold rolling process. Steel billets are then pushed through rollers and undergo compression. This mechanical stress alters steel properties and increases strength by almost 20%. The process can be done multiple times to achieve the desired thickness.

The CRS also has to go through a metal surface treatment called pickling, which removes impurities from the metal. The final product is now ready for machining and can undergo Roughing and Finishing.

What is Cold Rolled Steel used for?

Cold Rolled steel is a much finer and strong material, used for a wide variety of applications. The oily finish and smooth texture make it more visually appealing. You may see it in Household appliances, Kitchen utensils, steel furniture, and cabinets.

In the outdoors, the garage Gates, Sheds, and Fences are made of cold-rolled steel. In industry, high precision equipment is made using this because it offers exact dimensions and better material properties.  

Material Characteristics

Although it’s more brittle, Cold Rolled Steel has better material properties than Hot Rolled Steel (HRS). The reason is that it goes through an extra mechanical process that further enhances material characteristics.

Mechanical stress does strain hardening, which directly affects the steel strength. Here we have listed some essential characteristics for you to get an idea of.

Keep in mind Cold Rolled Steel is not a specific type or grade of steel that is usually determined by the chemical composition of the material.

Cold Rolled Steel (CRS) -Material Properties
Tensile Strength	85000 Psi
Yield Strength	70000 Psi
Brinell Hardness	167

What does cold-rolled steel look like?

Cold Rolled Steel has the following characteristics:

1. Cold Rolled Steel has a smooth, silky finish and is grayish.
2. Its unique texture comes from its manufacturing process, altering its material properties.
3. CRS has well-rounded edges and precise dimensions.
4. You may find it shinier than other steels, and it’s easily recognizable.  
5. The surface is straight without any roughness.

Advantages of Cold Rolled Steel

Every steel type offers unique advantages, and Cold Rolled steel has its own set of benefits. Some common advantages are:

1. Smooth Finishing
2. High Tensile strength and Yield Strength. 20% harder than Hot Rolled Steel.
3. Better and precise dimensioning.
4. Reduced roughness.
5. Corrosion-resistant properties.

What is an advantage of Cold Rolling over Hot rolling?

Cold Rolled Steel has many advantages over Hot Rolled Steel.

• For instance, CRS has superior material strength than HRS, roughly 20% more.  
• CRS has finer finishes
• CRS has more precise dimensions than HRS.

Disadvantages of Cold Rolled Steel

Nothing is free from negative aspects, and CRS is no exception. Let’s see in what areas the Cold Rolled Steel lack.

1. Low Malleability:  Due to its high strength, it is less malleable.
2. Brittle: It is prone to break under high stress. But due to its high yield strength, it is less likely.
3. Expensive: Since it involves extra processes during manufacturing, it takes more money to make.

Can Cold Rolled Steel be CNC Machined?

Cold Rolled Steel can be absolutely machined by CNC machining. CRS is a harder metal, requiring lubricant and extra care during machining. CNC machines are capable of machining cold-rolled steel with high precision and the least tolerances.

One thing you should keep in mind about Cold Rolled Stress is that it has a lot of stress stored up in them due to mechanical compression. It may result in the deformation of metal parts during machining. Experienced machinists always consider this fact.

Which is more expensive: hot rolled or Cold rolled steel?

Cold Rolled Steel is more expensive than Hot Rolled Steel. Because CRS is made after an extra process of applying the pressure via pair of rollers, these rollers are powered by powerful motors that can withstand the pressure.

This usually adds up to the cost of manufacturing. Industrialists prefer Hot Rolled Steel due to its reduced price, but it usually depends upon the application.

What is Hot Rolled Steel (HRS)?

Hot rolling is a common process in metalworking used to strengthen metals. Steel that has been worked at a temperature of over 1700°F is called Hot Rolled Steel. Working here means rolling or pressing metal into desired shapes.

The recrystallization temperature of steel is 750°F to 1300°F, depending upon grade. Above this temperature, steel becomes softer and easily workable. This allows for cheaper and faster manufacturing of products.

How is Hot Rolled Steel manufactured?

Steel arrives at manufacturing plants as slabs or billets. These billets are heated to high temperatures to make them malleable. Malleable steel is then easily rolled into the desired shape and thickness.

At this point, scales start forming on the hot steel. Scales are a direct result of the oxidation of iron. The now rolled steel goes through a descaling process before finishing. Descaling only removes the scales from the steel surface. It does not affect the Finishing or appearance of the steel.

Hot rolled steel is initially processed at 1700°F to 2000°F, but the steel is finished at a lower temperature. This is typically under 1700F but still above the recrystallization temperature. Finishing involves rolling the steel one last time to get to the final dimensions of the product.

Hot rolled steel is left to cool down at room temperature. This is in opposition to cold-rolled steel, which requires heat treatment and quenching.

What is Hot Rolled Steel used for?

The process of hot rolling steel is easier, thus making it cheaper. As such, the primary use of hot-rolled steel is in the construction industry. Construction requires large quantities of material and precise dimensions are not a necessity.

Hot Rolled steel is also used for,

• Railway Tracks
• Sheet Metal
• I-Beams
• Automotive Frames & Wheels

What are the characteristics of Hot Rolled Steel?

The strength and quality of steel are determined by its grade. Different AISI-grade steel will have different properties. Hot Rolling or Cold Rolling are additional processes that augment the strength of the steel.

AISI Grade for steel is usually a 4-digit number. The first two digits determine the alloy metal used in steel. The second two digits represent the percentage of carbon contained in the steel. Using 1018 steel as an example,

Hot Rolled Steel (HRS) – Material Properties
Tensile Strength	67,000 psi
Yield Strength	45,000 psi
Brinell Hardness	137

Hot rolled steel is lower in strength in comparison to cold rolled steel. This, however, is only valid when using the same grade of steel. Different grade materials will yield different results. Caution is advised when comparing direct values.

What does Hot Rolled Steel look like?

Hot rolled steel has a distinct physical appearance. Which makes it easier to identify simply by looking. Hot rolled steel has:

• a rough surface finishing.
• A scaly grey look, which is a side effect of cooling from high temperatures.
• Rounded corners and edges this is due to shrinkage during cooling.
• mild distortions or warping. (In some cases)

Hot rolled steel is preferred for practical application, where aesthetics isn’t a factor.

Advantages of Hot Rolled Steel

Hot rolling is a relatively cheaper manufacturing process. This is mainly due to heated metal requiring less work to shape and deform.

 From a manufacturing perspective, hot rolled steel is;

• Easier to manufacture.
• Cheaper compared to Cold Rolled steel.
• It has little to zero internal stresses due to cooling being done at room temp.

Disadvantages of Hot Rolled Steel

Although hot rolled steel is easier to manufacture, it also has a less desirable finish. Cooling steel from high temperatures causes shrinkage of the final shape. Hot rolling steel can cause,

• Imprecise dimensions, primarily due to shrinkage.
• Rough texture and Finishing.
• Mild distortions and Even warping.

Can Hot Rolled Steel be CNC Machined?

Yes, Hot rolled steel can be machined using CNC machines. Hot rolled steel is softer compared to cold rolled steel. And as such, most CNC machines have no problem dealing with Hot Rolled steel. Typically, cold-rolled steel is preferred for CNC Machining due to its higher strength. However, for precision parts where a high degree of strength is not a criterion, hot rolled steel can be used.

Which type is suitable for you? 

Hot Rolled or Cold Rolled, it really depends on your plans for your business. Before jumping to any conclusions, you have to consider the following factors. This will help you choose better raw materials for the project.

Application:

For any industrial setup which does not require high Finishing, HRS is the best. It is cost-effective. CRS is better for manufacturing more refined products and precise dimensions like sensitive equipment. CRS is suitable for household appliances where aesthetics is an important factor.

Investment:

HRS is less expensive, whereas CRS has a higher purchasing cost.

Conclusion 

In conclusion, Cold and Hot Rolled steel both have their unique applications. By understanding the key differences stated above, you can utilize this knowledge to make a better decision. This will save your time and resources and can increase your business manifold.

Whether it’s Hot rolled Steel OR Cold Rolled Steel, CNC machining can make the best of it. Here at QBH Technology, we provide high precision, reliable and efficient CNC machining services parallel to none. Our team of professional machinists, engineers, and workers is highly experienced.

Do you require the best quality CNC machining? Want a custom CNC machining project? Best Prices?

Then do not wait! Contact us NOW! And get the best offer.

QBH Technology uses Welding or Riveting when creating something that needs the joining of two metals. Permanent connecting procedures such as welding and riveting are both widespread.

Welding and riveting both have advantages and disadvantages when creating a long-lasting product.

What Is the Process?

The head is a hemispherical dome, while the tail is a smooth cylindrical shaft. When we smash the tail’s substance into a flat shape, a new head forms on the tail’s side, secures the rivet in place and binds the metal components together.

We refer to the distorted one as the “shop head,” while the “factory head” is the name given to the original charge. If you want high-quality manufacturing solutions, visit QBH Technology.

Welding vs. Riveting: What’s the Difference?

Even though these are metal joinery procedures, they have very little. Welding uses heat to melt the metal, whereas riveting uses mechanical fastening (rivet).

What do we mean by Welding?

When it comes to joining metals, welding is the most used manufacturing process. Welding is another method for joining two components together, and we may do it either by hand or by a CNC machine.

Rather than relying on an internal heat source to melt the metal components as we join them, welding utilizes an external source of high heat to do it.

Welded joints are usually more efficient than riveted ones.

Welding always provides a smooth, pleasing structure. It is also comparable in strength to a rivet.

Welded buildings are less weight than riveted structures. It is because gussets are not utilized in welding, reducing weight.

In contrast, there is no way to make changes or additions to the welded structure once we insert a rivet.

Welding has certain drawbacks, such as inconsistent heating and cooling. This component may inhibit extra strains on the metal.

It takes longer to check for flaws in weld structures. It is because of the heating and cooling process, which means extra work for the fabricator.

Welding Benefits:

Especially when compared to riveting, welding has several benefits. These benefits are in strength, durability, and flexibility.

Welding is a very efficient process that can sustain enormous loads if constructed. Besides, the procedure is quite adaptable.

We may use the welding technique on various materials, from stainless steel to titanium. We can also use it for projects of all sizes, from tiny to large, heavy to light.

Welding metal joints seal them and prevent any liquid, gas, or solid from passing through the seam.

It is a significant consideration compared to Riveting, welding is a more versatile, useful, and metal joining method.

What do we mean by Riveting?

CNC riveting fastens geometric forms, from simple to complicated. Rivets feature a dome-shaped head on a cylindrical metal shaft or mandrel.

When linked through the hot drilled holes, these fasteners form a watertight seal.

The rivet compresses as the metal cools, fusing the two pieces. Riveted constructions tend to be heavier than welded. Aluminum, stainless steel, and copper are a few metals that might enjoy blind rivets.

Once we drill the hole, we insert the rivet into the hole. When the machine reaches its predetermined max force, the mandrel of the rivet bursts off. It results in a “blind” or flush-looking rivet inserted.

No one can under-torquing rivets, which is one of the major benefits of riveting.

As long as we choose the diameter and grip range of the rivet, it will always install. As one of the oldest technologies, we may tract riveting back to before World War II.

We may use Machine-controlled riveting may in various applications. These applications are constructing airplanes, manufacturing tiny electronics, recreational vehicles, and even submarines.

Faster turnaround times are possible by CNC riveting machines built for production lines.

Riveting Benefits:

The key advantages of adopting the riveting method for metal joinery are:

• The huge financial savings.

• The reduced skill requirements.

• The ease with which we may join thinner or different metals.

Riveting metal costs less than welding, so it is more popular. For example, you may buy a rivet gun (or riveting equipment) for as little as $5USD. You can also get high-quality rivets for a few pennies each.

We need to make Predrilling holes across a metal joint, insert the rivet into the gun, and then release the trigger.

The metal has now welded together in a secure junction. Welding necessitates using a TIG or MIG welding machine, a shielding gas, filler material, equipment, and much time. Riveting is simpler and more cost-effective.

Riveting is a better option than welding. It is better for joining thin materials or materials with differing properties (such as stainless and carbon steel).

These materials demand a lot of expertise, patience, understanding, and more specialized welding gear to weld them well.

A simple method for riveting a variety of various metals is the same regardless of their thickness. Predrilling the hole and inserting the rivet are the only steps required compared to welding.

Rivet Strength vs. Weld Strength!

Riveting vs. welding is a subject that many individuals ask themselves at some point in their lives. Knowing the difference will help you select the best method for the task at hand.

Have you ever taken notice of how many rivets there are on an airplane’s wing?

When working with metals like aluminum, which is difficult to weld, riveting is the method of choice.

It’s more suited to installing a car bumper than welding since it’s better suited to lighter and thinner materials.

The most common riveting methods are a rivet gun or a hammer and a mechanical squeezer.

We may use welding to fix everything from a motorbike exhaust pipe to a shattered engine block.

Welding may not always be the best option. As strong as the base metal, a welded seam is. Weld joints are more susceptible to faults when correct post-welding processes are not followed, which is an issue.

While welding is difficult to examine and test for strength, riveting provides a safe means.

It provides a safe means to combine metals in essential applications like bridge construction.

Common Rivet Types!

When we assemble a product or workpiece, we use a rivet to hold it in place. They have a bolt-like shape with a broad head attached to the shaft.

Its tail grows up to one-and-a-half times in diameter when hammered into a product or workpiece. But, the manufacturing sector uses various rivet types. We have listed some of them below.

Type#1: Solid Rivets

With some instances reaching back to the Bronze Age, solid rivets, sometimes known as round rivets, Rivets are in use for centuries. They’re made up of a shaft and ahead. After driving in the rivet, producers use a crimping tool to distort and extend the shaft. It helps in creating a more robust rivet.

Type#2: Rivets for Steel Structures

Structural steel rivets are like solid rivets. They are particularly engineered for use in high-stress commercial buildings.

Before installation, we heat structural steel rivets in a furnace to soften the metal. This procedure makes it simpler to work with.

Type#3: Split Rivets

When it comes to split rivets, we split the shaft into opposing directions. As with a wall anchor, the shaft of a split rivet expands in opposing directions when driven into a product.

Split rivets comprise soft materials like plastic or wood. They are appropriate for usage in items and workpieces made of these materials.

Type#4: Blind Rivets

Blind rivets, also known as pop rivets, consist of a rivet and a mandrel.

Type#5: Flush Rivets

After installation, most rivets stick out of the product or workpiece. Contrary to their namesake—which is that they sit flush with their surroundings—flush rivets do exactly what their name implies:

For industrial applications where aerodynamics are a consideration, flush rivets. Flush rivets are, also known as countersink, or countersunk rivets come into use.

We may improve Aerodynamics as a result of their proximity to the product.

Type#6: Friction Rivets

For a Friction Rivet to stick, we must insert the shaft far enough into a product or workpiece.

For this reason, you should only use friction rivets when they are well-used in the product.

Types of Welding!

Flashdance was a popular movie in the 1980s. Many individuals got the idea of working as welders due to the film’s female heroine, Jennifer Beals. She worked in a Pittsburgh steel factory.

Even though the movie and Jen’s welding talents were both blasted by the reviewers, the actress Jennifer managed to make welding appear gorgeous.

Jen was eager to perform a poor job at welding. The director wanted more sparks on camera despite having studied the craft for two months before filming. She’ll be exempt from prosecution.

Welding is, in fact, a serious job, despite what movies would lead you to believe. It is a skilled technique employed to put metal components together. For example, what are the many forms of welding?

Type#1: MIG Welding

Beginners will have an easier time mastering the art of MIG welding. MIG welding is, in fact, a two-step process.

It is possible to fuse thin metal sheets using bare wire MIG welding. A rotating central point because MIG welding does not need a flow meter or a gas source. We may use it outdoors.

Hobby welders who can’t afford high-end equipment turn to MIG welding. It becomes their primary method of joining metals.

Type#2: Stick Welding

Old-school Arc welding, or stick welding, is the only welding technique. This skill is more difficult to learn than MIG welding, but we can do it at home with low equipment costs. Stick welding makes use of a welding rod with a stick electrode.

Type#3: TIG Welding

Although TIG welding is one of the most difficult procedures to master, Lincoln Electric TIG welders are some of the best in the business.

TIG welding necessitates the use of two people. While holding a TIG flame in one hand, the welder feeds the rod with the other.

We may use TIG welders to weld Steel, stainless steel, chromium, aluminum, nickel alloys, and even gold.

Bike frames, lawnmowers, and fenders are examples of items that can enjoy the TIG welding process.

Type#4: Arc Plasma Welding

In-plane applications where metal thickness is less than 0.015 inches, plasma arc welding is a typical method of precision welding. An engine blade or an air seal might be an example of this.

Compared to TIG welding, plasma arc welding utilizes ionizing gases within the arc to generate heat instead of the electrode.

The shielding gas comprises argon plus 2 to 5 percent hydrogen, with argon serving as the plasma gas.

It decreases the current rating of the nozzle when using helium as plasma gas since it is hotter than the other gases used for plasma.

So, you’re interested in learning more about plasma welding. Check out this post for more information.

Type#5: Laser and Electron Beam Welding

We may achieve a precise, high-energy weld with electron beam and laser welding processes.

We may use electron beams or lasers when welding the tiniest of implantable medical devices. These devices need to offer the power necessary to weld huge spaceship components.

Welding using an electron beam is a flexible, powerful, and automated technique. Welds may be stunning from both a metallurgical and aesthetic standpoint.

Type#6: Gas Welding

TIG welding displaces gas welding as the preferred method of joining metals together.

We need Oxygen and acetylene for gas welding equipment, which we may carry anywhere. Even now, they’re still employed to reassemble broken pieces of automobile exhaust.

Young individuals who want to pursue a career as a welding technician will have several options for employment.

It is because of the severe lack of qualified welders in the U.S and throughout the world. You can use the services of QBH technology if you want high-quality fast solutions.

Final Thoughts

There are a variety of ways to attach your sheet metal components. However, welding and riveting are the most common processes. It’s important to note that each has its own set of perks and drawbacks. As a result, making a decision may be difficult.

When it comes to your project, you may require an expert’s opinion on which method best suits your needs. As a result, if you have any questions about the benefits and drawbacks of welding or riveting, don’t hesitate to get in touch with QBH Technology.

Precision manufacturing methods and a committed workforce are at the core of QBH Technology’s commitment to producing high-quality prototypes and parts.