Category: Metal Fabrication

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What Metals Are Used For Welding?

metal fabricator

From an outsider’s perspective, the metals used in welding and fabrication all look the same. Apart from color and luster, there really isn’t much an average person can do to discern from different types of metals and alloys – and even those criteria are difficult to distinguish from one another. Because of that, many people fail to predict how much money they actually have to pay for metal welding services. One of the main factors that contribute to the cost of the services of a welding company is the type of metal that will be used for the project. Different metals vary in difficulty when it comes to welding and fabrication, and some are expensive to procure as well. This blog addresses that concern by providing a simple distinction between the common types of metal used in welding and fabrication.

Choosing the Correct Metal for Fabrication

Metal fabricators work with all sorts of metals, and it is important to know the distinction between each and every one of them. In terms of practicality, there are three factors that distinguish these metals from each other: strength, weight, and resistance to corrosion.

  Aluminum

aluminum welding

The most abundant metal and the third most abundant element on the earth’s crust is aluminum. However, because of its highly reactive property, it is rarely found in its purest form. The main source of aluminum in the world is bauxite, a mineral that is found in places like Australia and South America. It is lightweight, non-corrosive, and is a good thermal and electrical conductor. But most importantly, it is cheap and easy to fabricate.  Its only real downside is that it is prone to warping and bending due to stress. TIG welding and shielded metal arc welding are suitable techniques for aluminum welding. If you have a metal project that you want to be done, the welding services in Albury, can help you out.

Stainless Steel

stainless steel welding

Arguably among the most important alloys in the modern age, stainless steel can be found in almost every nook and cranny in the world where there are people around. Its strength and flexibility make it suitable for structural fabrication, but what truly sets it apart is its resistance to corrosion. Stainless steel contains an element known as Chromium which creates a protective oxide layer over the metal that prevents it from rusting. It is easy to weld material, and is usually cheaper than alternatives with similar properties. Utensils, window frames, roofs, and awnings are common objects found in a house that are partly or completely made through custom stainless steel fabrication.

Carbon Steel

carbon steel

Carbon steel is a high-strength alloy with a broad range of uses, particularly in the construction of buildings and other large structures. It is stronger than both aluminum and stainless steel, but lacks the resistance to corrosion. In order to prevent it from rusting, a zinc coating is usually applied. There are three main types of carbon steel, categorized based on their carbon concentration. Mild steel contains 0.05% – 0.25% concentration. Medium carbon steel contains 0.25% – 0.7% concentration. Finally, high carbon steel has a carbon concentration of 0.7% – 1.5%. Carbon steel is also used to build pressure vessels, but are far more difficult to weld compared to stainless steel and aluminum.

Titanium alloy

Often found in rockets, armor plating, aircrafts, and shipbuilding, titanium is an exceptionally strong metal but light welding metal that boasts high heat resistance, corrosion resistance, and tensile strength. Despite being the fourth most abundant metal in the earth’s crust, it can be notoriously expensive. In some cases, titanium is also used for biological implants because it does not react with the human body. Gas metal arc welding (GMAW) and TIG welding are both compatible welding techniques metal fabricators use for this alloy.

Cast Iron

cast iron

Cast iron is also an iron-carbon alloy, but contains a much higher concentration of carbon than carbon steel. It is commonly found in the kitchen as frying pans and metal pots. It is a hard metal, but that comes at the expense of ductility and tensile strength. Besides the aforementioned, cast iron is used to build fences, gates, farm equipment, beekeeping equipment, and mining equipment. Shielded metal arc welding is one of the popular methods of welding this alloy, making it even more cost-efficient to work with when other factors are not important.

How TopWeld Can Help With Metal Fabrication Services in New South Wales

Topweld General Engineering is a metal fabrication and welding company offering high-quality custom metal fabrication services for a diverse range of clientele all across the state. Having been in the industry for over 2 decades, we have ample experience working with different industries such as housing, agriculture, manufacturing, and automotives. Regardless of the scope of a project, our talented craftsmen work diligently to produce impeccable results. Our specialties include stainless steel welding, aluminum welding, and sheet metal welding.

FAQ

What 3 metals are commonly welded?

Aluminum, stainless steel, and mild steel are metals that are commonly used in welding and fabrication. They are cheap, strong, and in the case of aluminum and stainless steel are resistant to corrosion.

What metal rod is used in welding?

Mild steel electrodes such as 7018, as well as 6013, 6011, 6010, 7014 are some of the most common rods used for welding and metal fabrication. 

What are the 3 main fabrication techniques

There are three main welding techniques used in metal fabrication: shielded metal arc welding (stick welding), metal inert gas (MIG) welding, and Tungsten inert gas (TIG) welding.

What is the difference between welding and metal fabrication

Welding is a term used to refer to the process of joining two pieces of metal together by applying heat. Metal fabrication involves the cutting, bending, and assembly of metal which also involves welding to affix the pieces together.

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What Are The Signs Of A Bad Weld? Tips From Griffith’s Finest

Welding is a core process in metal fabrication that can quite literally make or break a metal product. It is the best way to join two metal pieces together with our current technology, and likely will be so for many more decades to come. It is not just important for structural engineering. Metal products at home and urban structures rely on welding, making it a crucial factor in evaluating the quality of metal fabrication. But how exactly does one tell if a weld is done well or not? That’s what we at Topweld, Griffith’s top aluminum and stainless steel fabricator, are here to share with you.

How Does Welding Work?

The main idea of welding is very simple. We use heat to melt the surface of two or more metal pieces and then join them together in the form we want before they cool and harden once more. This began in the middle ages with blacksmiths hammering hot metal pieces together and in the present, we have various welding techniques available to fit different kinds of works, the most widely-used being arc welding in industrial work. Under this category is Metal Inert Gas (MIG) welding, Shielded Metal Arc Welding (S.M.A.W. or Stick) welding, Tungsten Inert Gas (TIG) welding, and Flux Core welding. These techniques may vary in terms of the tools they use or the specific manner in which they move along the workpiece, but the fundamental steps in welding remain the same. As such, they may share similar signs of a bad weld.

Uneven Size and Shape

A uniform and robust weld is ideal, while a weld bead that looks like spray-painted string on the corner means the welder went too fast or had a low wire feeder speed.The implications of welds like these are less overall durability and incomplete penetration. It is a huge red flag to structural inspectors who find these in critical load-bearing components.

Bubbles and/or Small Holes

Small holes on the surface of the weld indicate porosity which is when inert gas like hydrogen, nitrogen, and oxygen get trapped within the weld and form tiny air pockets. Aside from the trypophobia-inducing spongy look, porosity also makes the joint more prone to cracking and breaking altogether. There can be many causes of porosity, but it is often because of poor shielded gas handling or foreign material present in the workpiece before the weld. If having difficulty, it’s best to let the professionals that offers welding and fabrication services in Young, NSW handle it or you can ask for advice.

Cracks

 

Groves or Protrusions in the Weld Root

These small gaps are called undercuts and are caused by a myriad of reasons such as lack of penetration, improper weld technique, or mishandling of the workpiece. These grooves, much like other entries in this list, present a clear and dangerous area of vulnerability for the joint. Usually, a gap may form in a single side of the weld, but there are instances of both sides having roots, which indicate very poor penetration and fusion of the metals. On the opposite end of the spectrum, a small hill protruding from the other side of a weld is a sign of excessive penetration which is also bad because it may erode over time.

Splatter

This is far more common in Stick welding than in other techniques. Splatter from the weld pool can displace and scatter molten metal around the bead, making the joint weaker and less appealing.. It is mostly a danger to the welder, as these droplets of molten metal can burn their clothes or skin.

Conclusion

So ends this short list of the common signs of poor weld work. If you notice any of these in your own work, be sure to fix them immediately. Welding is not exactly the easiest type of work, but it’s nothing a little practice can’t help. If things just aren’t working out, you can always seek assistance from the best welding services in New South Wales. Good luck, and happy welding!

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How To Arc Weld for Beginners: Process, Types, Techniques, and a Lot More

Arc welding is essential to the process of metal fabrication. It is quite literally the glue that keeps your work from falling apart. That is why for many people looking to incorporate metal into the projects they are working on, it is a hurdle that they would need to overcome. Thankfully, the steps involved in welding are actually quite simpler than what people’s imaginations make them out to be. Arc welding can be enjoyable and useful beyond the current project. But where exactly do you start?

We have experience providing welding services in New South Wales and can help you get started with metal welding. We’ll cover the necessary equipment and methods in this tutorial. We won’t make you a master welder, but you will get an idea of how it all works.

What is Arc Welding?

Arc welding fuses metal pieces together with heat generated by an electrical arc. The world widely uses this welding method, which differs from other forms of welding. Let’s define what arc welding is and how it works before we dive into the process. There are many forms of arc welding as well which we will expound upon later on.Choose a different welding method if you don’t want to use electricity as the heat source. You’ll need a power supply, an electrode, and gas to protect the weld pool from contamination.

Different Types of Arc Welding

There also exist different variants of arc welding which vary in terms of the equipment used. Each of these variants has its advantages and disadvantages, and a welder can make use of more than one type of arc welding during metal fabrication. Your choice will be dependent on the materials you will be working with, how quickly you want to do the weld, and how precise you want your joints (where your two separate metal pieces meet) to be.

Stick Welding (Shielded Metal Arc Welding)

This variant of arc welding involves a short consumable rod that acts as both the electrode and the filler metal. Stick welding uses a coated rod that produces a chemical purifying agent to protect the weld pool as it dissolves, resulting in a stronger joint. It is an affordable and simple method, but its messiness makes it less suitable for precise and clean welds. Other than that, it has a lot of uses, one of which is stainless steel fabrication.

Metal Inert Gas (MIG) Welding

MIG welding discards the consumable rod and instead continuously feeds a spool of wire electrode and filler metal through the weld gun, while emitting protective gas through the same weld gun and supplying it with separate gas tanks instead of using flux. This setup allows for a steady and uninterrupted weld that is perfect for welding large metal surfaces. It is also quite beginner friendly, with most weld experts asserting that it is the fastest and easiest method of arc welding. It does come with a few disadvantages though. First of all, it has a higher cost of setting up. This is mostly because it requires so many components required to make it work. It can also be more expensive to maintain.

Tungsten Inert Gas (TIG) Welding

TIG welding completely departs from the idea of a consumable electrode by using one made from tungsten instead. The protective gas is still emitted by the weld pool, but the filler metals now need to be administered manually using the welder’s free hand. This grants the welder a greater sense of control over the quality of the weld, which is an ideal scenario for aluminum fabricators and other welders working with delicate materials. However, beginners should not use this welding method as it requires a lot of knowledge and experience from a welder to produce consistent results. When a welder does it correctly, TIG welding produces precise and clean welds that no other type of welding can match.

Flux-Cored Arc Welding

This variant of arc welding uses a hollow wire of filler metal with a flux core, combining Stick and MIG welding concepts. The wire is fed through a machine like MIG welding, while the flux produces gas as the electrode is consumed like Stick welding. It is best for outdoor welding as the protective gas will not be easily blown away by the wind. This welding method is fast and simple but produces a significant amount of smoke.

Safety Equipment When Welding

Prepare safety equipment before starting arc welding, such as welding helmets that protect the eyes and face from flying particles. It also helps reduce the amount of radiation that a welder is subjected to during long work hours. A pair of safety goggles can also be worn underneath the welding helmet for stronger protection. Welding gloves prevent burns due to the intense heat produced by the welding process while welding jackets protect the rest of the body. Finally, boots protect your shoes from getting damaged by the sparks. There are other protective equipments that you can wear while welding, so be sure to get as much to keep you comfortable, safe, and maneuverable. 

Conclusion

Welding is a very useful skill that anybody can make use of. It can be used for general repairs, modifications, construction, and even works of art. With enough practice and experience, anyone can become an expert welder. Our team of professional welders will sure to please and exceed your expectations.

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Topweld Achieves Masterful Metal Fabrication and Welding Services Using These Steps

Image of welding equipment and metal fabrication tools, representing Topweld's process for achieving masterful metal fabrication and welding services.

Metal fabrication is an important aspect of any construction or design project in the residential, industrial, or commercial trade. Metal creations are built to last for decades, serving as essential components in any construction or design project. However, their use requires meticulous planning and foresight, taking into account factors such as weight, corrosion, and aesthetic appeal. To ensure safe and quality metal fabrication and welding, it’s wise for homeowners and entrepreneurs to opt for professional engineering services. Topweld General Engineering in New South Wales provides affordable services by skilled workers and industry experts. The secret to this level of quality is our commitment to this time-tested series of methods.

The Design Phase

The design phase is a crucial step in metal fabrication where visions are turned into feasible plans incorporating design theory and scientific principles for optimal results. At Topweld, we carefully quantify costs and benefits of different fabrication methods and tools to achieve our clients’ objectives and goals. Our idea of “best” goes beyond aesthetics and functionality; we also prioritize resource efficiency and provisions for potential future problems or safety risks. This approach ensures that we deliver the best results for our clients and prepare for any potential issues that may arise.

Use of Industrial-Grade Equipment

We use modern and well-maintained equipment throughout the fabrication process, from cutting to polishing.Our belief is that subpar equipment not only produces suboptimal results, but also poses risks to our workers. Utilizing top-of-the-line tools enhances our efficiency, enables greater precision, and allows for a more intricate level of work. This emphasis on quality equipment is a key factor in our reputation as one of the top stainless steel and aluminum fabricators in Griffith, New South Wales. These metals are best welded with the best equipment available.

Proactive Quality Control

We have a goal-oriented approach when fabricating your project in Canberra, NSW. This means that our work isn’t simply about completion, but about producing results far beyond the expectations of our clients as well as fulfilling the objectives we set up at the design phase. To do this, we are constantly looking at every element of your project and looking for ways we can accomplish tasks given current and future circumstances. Note that based on the scale of the project being worked on, there could be unexpected problems along the way, so we make incremental changes to our work so that it could be completed on time and up to Topweld standards in Albury.

Mastery of Materials, Tools, and Methods

Of course, having good equipment won’t immediately make someone a good fabricator. In order to produce high-quality products, one needs to have mastery over the fundamental steps involved in the process. These include:

  • Designing – as mentioned before, this is the process of conceptualizing your project under realistic parameters. Costs, materials, and work required are all detailed here.
  • Cutting -The engineer cuts the metal according to the required measurements for the project. This step requires precision, and the engineer must choose the correct cutting method based on the part’s intended use.
    • Folding and Forming – After cutting the metals, workers will transform them into the required shape for the project. During this process, they will fold, bend, create grooves and holes where other parts will attach to, and use all other methods to give metal its form.
    • Assembling and Welding – Workers arrange and join metal parts together using heat during this phase. There are different methods of welding that produce slightly different results, and some might not work very well with certain materials. Trained welders will know which one to utilize for the material they are working with. 
    • Finishing – To put metal projects to use, they require some of the last few touches such as corrosion-resistant coating, insulation, and paint. Alongside looking much more aesthetically pleasing than just ugly naked metal parts welded together, they also add extra protection for the product and the people that will be using it.
    • Maintenance – Maintenance is optional for some metal products, but crucial for machine parts and automotive components to prevent dangerous issues caused by imperfections or damages over time.

    Topweld selectively hires highly skilled welders to ensure exceptional results on your projects. We also share our knowledge with peers to continuously improve our craft.

    Conclusion

    Choose Topweld as your fabricator for stainless steel and Aluminum, and you won’t regret it. Our successful means of materializing client requests have earned us praise from many satisfied customers, making us one of the best in the area. Contact us for a team prepared for the task and open to consultation and negotiation. Your project is in capable hands!