Different projects require different metals in a variety of shapes, which is when a metal service center comes into play. They have the tools necessary to break down metals and cut them into the exact shape specified by a blueprint.
The process of cutting metal can be broken down into two broad categories known as thermal cutting processes and mechanical cutting processes. Before deciding what kind of metal to use, it’s important to understand the attributes of each metal-cutting process and how they will affect the result.
Thermal Cutting Processes
This process uses an energy source to heat and liquify specific portions of metal for thermal cutting. The cut is made by precisely blowing away the molten metal from the solid metal.
The three most common thermal cutting processes are:
Depending on the application, thermal cutting is often the preferred method because it’s much faster than other processes.
Mechanical Cutting Processes
Unlike the heat applications involved in thermal processes, mechanical cutting processes involve a physical cut to the metal. The quality of the cut can vary greatly depending on the specific type of automated cutting process being used. There are a few methods considered to be highly auspicious, so they are used much more often.
Saw
Saw cutting for metal uses a vertical or horizontal band-saw cut and a coolant, which is generally applied to offset the frictional heat between the saw and metal. Saw cutting is an effective way to produce metals in an array of shapes, types, and sizes. On the other hand, it is slower than other production methods.
Miter
Miter saws use a circular metal saw blade, usually composed of carbides. As the blade spins, it is lowered at precise angles to make exact cuts.
Shearing
Using considerable force, shearing compresses the metal into a sharp edge to deform and eventually make the cut to the metal. This tactic most commonly applies to sheet metal cutting. While it is a high-quality cut, the process can leave visually un-appealing edges.
Hole Punch
This method is mostly utilized to cut metal into shapes like tubes or cylinders. It works similar to shearing. A metal tool of a specific configuration is pressed into the newly forming metal until a shape is punched out.
Notching
Notching employs the same tactic as shearing, except the sides are slowly worn away to create a specific shape, making this the preferred method for three-dimensional objects. Notching is mostly used for sheet metal or thin bar stock.
Drilling
A drill bit is pushed into the metal to cut cylinder-shaped holes. A countersink bit can also be used to make sharp cuts.
Water Jet
High-pressure water is forced through a nozzle to cut softer metals. An abrasive material is often added as an erosive.
If you’re still not sure which tactic is best to cut the metal you need, seek the advice of professionals at your local metal service center. Avion Alloys has extensive experience creating an assortment of metals for different projects and can explain exactly which method to use depending on the end-goal. For more information, contact us today.
]]>Tubing is formed by running slit coils of metal through a tube mill to create a round, rectangular, or square tubular shape. The edges are then welded together using a process such as electric resistance welding or high-frequency welding. The method used depends on the type and thickness of the metal, as well as the preferences of the manufacturers. The tube is then refined with an annealing process to create the final product.
Hollow bar is not welded together. Instead, hollow bar is created using one of two processes. The first, called drilling, involves sending a drill through a solid bar stock. The second, called centrifugal casting, is when molten metal is poured into a cast as it undergoes high-speed rotation. The high-speed rotation forces the metal to the outside of the frame, where it hardens as it cools to create a dense, uniform final product. Hollow bar typically only come in bronze and stainless steel.
The difference in manufacturing makes for a big difference in quality. Hollow bar can be created to be flexible and fit into tight dimensions in a way that tube can’t. Tubing can also result in a lower quality product when the manufacturer is unskilled.
Avoid a reduction in quality by removing the excess weld metal and heat-treating, or annealing, the tube after welding. Otherwise, crystalline structures may affect the strength and structure of the metal that develop.
Most materials can be formed into tube using the welding process. This process is appropriate for any material that conducts electricity. While hollow bars can also be made out of most materials, it can be challenging to extrude strong and hard materials.
The choice between hollow bar or tube is ultimately up to you. Take into consideration what type of project you’re doing, your desired material, budget, and your project’s final application.
Regardless of what you choose, be sure that your materials and compounds are of the highest quality by choosing Avion Alloys. We procure prime metals exclusively from United States Mills, and we are a NASA approved vendor. For a free quote, contact us at (866) 610-1660.
]]>When unintentional, however, abrasion can cause machine and building components to fail. In these instances, it’s essential to use abrasion-resistant steel, which is strong enough to prevent this type of erosion.
This material is an alloy of carbon, iron ore, and other elements such as manganese and chromium. The iron is melted in a blast furnace to remove impurities, and alloying materials (including carbon) are added during that process. The additional elements help the steel resist wear even with prolonged rubbing. Other substances are added to prevent oxidation. The molten steel is then shaped, heat treated and cut.
The resulting chemical composition has several components that help it resist abrasions. Carbon adds strength and hardness. Chromium and manganese limit the steel’s reaction to wearing. Heat treatment helps the steel form robust microstructures that increase hardness.
Abrasion-resistant steel comes in a variety of grades, each with a specific hardness value on the Brinell scale. The Brinell hardness test uses an indenting machine to test the force that a material can withstand and the size of the indent created by the tool. This contrasts with other types of steel, which are graded by toughness and tensile strength. Hardness is critical to limit the effects of abrasion.
AR400 is a standard grade of abrasion-resistant steel, with 400 representing the Brinell hardness value of the material. AR450 and AR500 have values of 450 and 500 respectively, meaning they are harder than AR400. However, AR400 is more flexible and is easier to form. All three types are appropriate for creating cement forming and pouring equipment, conveyor systems, and mining and excavation equipment. Check out these steel uses for military.
Some brands produce proprietary abrasion-resistant steel varieties, such as MAS500 AR and Hardox 400. Grades with the designation CR have been cold rolled. Proprietary types of steel are used for the same applications described above. If you need to manufacture heavy equipment, abrasion-resistant steel plate can ensure its durability.
As a NASA approved vendor, Avion Alloys is a leading global distributor of high-performance compounds. Manufacturing industrial metal products for many different practices, we welcome all requests and inquiries. For a free quote, contact us today.
]]>HSLA steel is produced by mixing coal and iron ore in a furnace hot enough to melt these elements. Adding the alloying materials to the molten mixture in varying amounts will result in different grades of HSLA steel. The steel is purified and then solidifies in a rectangular shape.
HSLA has several benefits compared to traditional carbon steel. The atoms in the alloying elements increase the hardness and strength of the steel by blocking movement in its microstructure.
These elements can include:
Other elements are effective in increasing the steel’s resistance to corrosion. Chromium, copper, and nickel help prevent the formation of rust as well.
HSLA steel can be manufactured in many grades and used for diverse applications because of the range of alloying elements that can be added in different amounts. One common type is ASTM A36, which is general purpose HSLA steel primarily used for erecting structures. It’s popular because it is machinable, weldable, and affordable, with versatile mechanical uses.
Weathering steel is most often used in applications such as bridge construction where it will not be painted or coated. ASTM A242 and ASTM A588 are two frequently used types of weathering steel.
Oil and gas transmission pipelines often use HSLA steel. Many modern pipelines rely on API 5L Grade X70, with the number 70 referring to the minimum yield strength of 70,000 pounds per square inch. ASTM A573 is popular for petroleum storage tank construction.
Many other grades of HSLA are available for a range of engineering purposes, including steel that is easily weldable, resists abrasion, or is hardened by precipitation. The engineering project manager is charged with choosing the right type of steel for the specific job.
High-strength low-alloy steel is used in a variety of different fields for various items. If you’re in need of HSLA steel, look no further than Avion Alloys. As a NASA-approved vendor, we produce high quality materials for multiple industries. Contact us today for a free quote.
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