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Welding Guide

February 26, 2021

The process of joining two or more metal parts together is called welding. Although most welding is done on metals and thermoplastics, sometimes it is done on wood too. The fusion of the components is done by applying pressure and heat. Many different types of welding processes include shield metal arc welding, gas tungsten arc welding, gas metal arc welding, and pulsed gas metal arc welding. This welding guide will cover everything there is to understand about welding and the different types.

What Is Welding and What Are the Types?

The first thing to understand in this welding guide, is the definition and process of welding. Welding is a type of fabrication of metals and thermoplastics where heat is used to meld two or more parts together permanently. These parts are completely fused when the components have been cooled down. During the welding process, the base metal is melted, and a pool of molten material is created with the help of a filler material. 

The metals joined together are called parent material or base metal, and the material used to form the joint is called a consumable or a filler. The filler chosen can be the same material or similar to the parent material. Many different energy sources are used, including gas flames, electric arc, laser, friction, electron beams, and even ultrasound. Welding parent material together can be done through various joint configurations. These are butt joint, T-joint, edge joint, corner joint, cruciform joint, and lap joint.

Welding is done through various processes, including arc, friction, laser, electron beam, and resistance. However, arc welding has become one of the most preferred methods in today’s times. We will discuss it in detail in this welding guide. Arc welding uses an electric arc to produce the heat that melts and joins the two-parent material. An AC or DC power supply is used to create heat that melts the metal. The different types of arc welding are:

  • Shield Metal Arc Welding: Shield metal arc welding or manual metal arc welding, or stick welding is one of the most used processes. In this process, an arc is fixed between the flux coated electrode and the base material. Both of the pieces melt with the heat, and a weld pool of metal is created. The flux coating on the electrode also softens and forms slag plus gas that acts as a protective barrier for the weld pool against the atmosphere. Using shield metal arc welding, one can fuse ferrous metals such as aluminum and steel as well as nonferrous ones. 
  • Gas Tungsten Arc Welding: The gas tungsten arc welding uses a non-consumable electrode that is used to create a weld between the two base materials. This technique uses a tungsten electrode to make the arc, and once the base material is fused, the inert shielding gas is produced to protect the molten pool from the atmosphere. 
  • Gas Metal Arc Welding: Gas metal arc welding uses a consumable metal inert gas wire electrode which is fixed onto the workpiece metal. The MIG wire heats the base metal and causes the weld pool. A shielding gas produced from the welding gun protects this weld pool from corrosion and other atmospheric contaminants.
  • Pulsed Gas Metal Arc Welding: Pulsed gas metal arc welding is a technique that uses lower heat to make very precise welds between the two parts. Both heat-sensitive aluminum and steel metals can be welded with the help of GMAW-P. This technique allows precision to control the arc, leading to faster filling and better weld durability. 

Finding The Right Welding Company

Welding fabrication can be used to shape and mold metals into a variety of shapes. However, the durability of these welded products depends on the work of the welding engineer. Welding technology has improved drastically throughout the years and is now available for a wide variety of metals. Finding good welding services can sometimes be a challenge. 

The welding engineer, as well as the team, should be experienced and skilled. Companies such as VeriForm have over 20 years of experience along with good customer feedback. Finding a company with experience, skill and appraisal always means that you will get quality work. Always research the reputation of a company before handing off your projects to them. For a welder to be qualified, they need CWB CSA W47.1 and W59 certificates just like every employee at VeriForm has. Experienced engineers can advise you on the different techniques that can be used for your product and create the most durable welds.

This welding guide has covered the basis of everything you should know about welding and how you can find a good welding company. VeriForm is one of the best companies that provide welding services for industrial as well as housing projects. You can visit VeriForm to find more about other services and rates. It is important to note that if you want to ensure the welding’s durability and quality, you should always employ experienced and trained professionals to do the job. If you have any other welding inquiries that you would like to discuss with a member of the team feel free to contact us.

Aluminum Metal Fabrication

February 9, 2021

Aluminum is one of the most durable metals, and its robustness makes it suitable for various uses. The aluminum metal fabrication process can mold this metal into any desired product such as solar panels, tools, or any other desired shape. Aluminum products are used in various industries, including housing, energy, electronic enclosures, medical, aerospace, defense, and many more. Projects including CAD/CAM and Solidworks, custom tooling designing, prototyping, Design/DMEA, and formed parts flattening can be done through the process of fabrication.  

Even though there are numerous benefits of using aluminum fabrication, the process in itself is complicated. Aluminum metal is softer than steel, and hence its handling needs to be done only by professional companies such as VeriForm. This article will cover a majority of everything there is to know about aluminum metal fabrication and the kind of projects that can be done through this process. 

What Is Aluminum Metal Fabrication?

Aluminum metal has a unique set of properties that make it one of the most popular materials for fabrication. It is lightweight, has an excellent strength to weight ratio, is soft and easy to shape, resistant to corrosion, and is nontoxic. The fabrication of aluminum can be done through various techniques. These techniques include extrusion, drawing, forming, casting, forging, welding, adhesive bonding, machining, drilling, CNC laser cutting, and CNC plasma cutting.

Types of Aluminum Metal Fabrication Services

Numerous services come under aluminum metal fabrication. These services aid in designing products and parts with the metal. The entire fabrication process includes designing the component and manufacturing it. Explained below are some of these fabrication services:

  • CAD/CAM and Solidworks: Computer-aided design and manufacturing are two very advanced yet useful aluminum fabrication services that any good company will provide. The CAD is used to design the parts with various software, and CAM used these designs to manufacture the parts for model generation. At VeriForm, the process is done with the help of Solidworks software. Solidworks is one of the best CAD and CAM software that offers 2D and 3D model designing features for the engineers. 
  • Custom Tooling Designing: Tooling is the procedure used to design and engineer specific tools required to manufacture individual components. VeriForm offers custom tooling designing, which means that the tools are customized depending on the product’s as well as the companies’ needs and manufacturing.
  • Design/FMEA and Prototyping: FMEA or Failure Mode and Effects Analysis is a method of analyzing any potential defects and failures in the product’s design. Another process that is a part of aluminum metal fabrication is prototyping. It means creating a small prototype of the aluminum part and checking its usability before manufacturing the entire product. 
  • Formed Parts Flattening: The process of taking something with a round shape or raised shape and pressing it down to form flattened parts is called flattening.  
  • CNC Plasma and Laser Cutting: Plasma cutting is a process in which an accelerated jet of hot plasma is used to cut aluminum, and laser cutting is the process that uses laser beams to make these cuts. The plasma cutting at VeriForm can be done on stainless steel and aluminum from 18ga to 1.5” thick x 18.0 ft. x 40 ft. table. The laser cutting can be done up to ¾” x 80” x 160” (4000W) +/- 0.005” Accuracy.
  • Shearing: The process of cutting straight lines on a flat metal is called shearing. At VeriForm, the CNC shearing process is used up to ½” x144” with a 48” CNC back gauge. 
  • CNC Punching: Computer numerically controlled punching is a process in which different sized holes are punched on an aluminum sheet pre-designed and controlled through computer software. The punching can be done on aluminum sheets of up to 1.5” diameter in 1” metal.
  • CNC Bending Forming: The process of reshaping the metal sheet from flat to bent through a press and computer numeric control is called bending forming. The press at VeriForm can do complex kinds of bending of metal to any shape. They have machines that are capable of bending 56-tonne x 48” parts to 900-tonne 7-Axis CNC X 240” to ¾” x 20 fee bending parts. 
  • Welding: Joining two or more sheets or aluminum parts together is called welding. VeriForm has CSA 47.1 Division 2 certified MIG/TIG/Spot welding facilities. Additionally, they also offer 10 welding stations, assembly services, and painting the parts for a quality finish. 

Finding the Right Professional

Aluminum, although very durable, is a metal that needs careful handling because of how malleable it can be. Welding of aluminum and laser cutting has to be done with precision because of aluminum’s high thermal conductivity. The high thermal conductivity of the metal makes fusion while welding tougher. Also, the property makes it challenging to cut thicker sheets of aluminum. Hence the laser cutting has to be done on thinner sheets. These are some points that inexperienced professionals tend to ignore. 

That is why only trained, and experienced professionals will provide you with the results you need. VeriForm has over 20 years of experience in this field. They have all the latest equipment and an experienced team that can handle aluminum parts with components of up to 20 ft. They also provide services such as oversize bending and rolling along with a two-day turnaround for tooling and prototypes. Quality engineering assistance along with the above-given services is what makes VeriForm one of the leaders in the metal fabrication industry. All the more, they have CWB CSA W47.1 and W59 certified welders and skilled engineers that overlook all the activities.

Aluminum metal fabrication is one of the most useful techniques within this industry. That is why it is imperative to find the right company such as VeriForm. It knows the challenges associated with handling aluminum and has a team of experienced professionals to ensure that you get quality products. Contact us today to learn more about aluminum fabrication and how it is done along with other services.

Custom Architectural Fabrication

January 26, 2021

Custom architectural fabrication is all about creating structures and parts from raw materials. To create the final product, the process entails:

  • Fabrication
  • Welding
  • Burning
  • Cutting
  • Machining
  • Forming
  • Assembly

You can use architectural fabrication for different needs and projects – for heavy equipment and machinery, or hand railings. Some people also use this for hand tools, cutlery, structural metals and architectural metals. And that’s why this fabrication works for canopies, statues, artwork, and others. Such metal decorative elements have risen in popularity, especially for luxury homes and commercial plazas. VeriForm helps engineering and design firms to transform ideas into reality through custom architectural fabrication.

Processes Used in Custom Architectural Fabrication

At VeriForm, there are different projects and processes to utilize custom architectural fabrication. Some of them include the following:

  • Attention to cosmetics and tight fit-up
  • Complex mathematical and natural forms
  • Passivation of stainless
  • Structural steels rolled to both concave and convex shapes
  • A large variety of industrial coatings – even Amercoat
  • Special insulation for silencing
  • Non-metals such as composites, wood, and plastics.
  • Custom shapes and contours
  • Exotic metals and finishes like bare Muntz metal, polished copper, and brass

The team at VeriForm is well able to carry out different architectural fabrications. Learn more about our capabilities to get a glimpse of what you can expect.

Benefits of Custom Architectural Fabrication

You are wrong for still falling under the group that believes using generic fabrication shops is cheaper than a professional architectural fabrication company. Using the latter ensures that you get customization and top-grade quality – something you are not likely to get elsewhere. So, here are some of the benefits you’re set to experience with a custom architectural fabrication:

Quality

We can’t emphasize this enough: working with a professional fabrication company will guarantee you immense quality in your project and products. The presence of state of the art equipment is one benefit you will definitely get with pros.

An expert company like VeriForm has tons of modern equipment that not only ensures quality, but also a faster turnaround time. Low budget shops, on the other hand, will charge less but at what cost? You’ll get low quality products that won’t be worthwhile ultimately. Working with professionals, you’re guaranteed customized cuts with great attention to details. It’s better to have accuracy and quality at a slightly higher margin.

Skilled Workers

With a professional custom architectural fabrication company, you get to work with skilled staff. This, in itself, is a specialized industry. Therefore, you can’t simply work with anyone. It has to be a highly-trained professional.

Our fabricators have years upon years of experience. We have been in operation for over 23 years (decades enough to show how experienced we are). So, if you need assistance with your project, be rest assured that you’re getting the full and more value for your money. These experts will deliver a high quality product on whatever project you’re working on. Get help when you want, and how you want it with VeriForm. We also offer consultation if you’re unsure of the type of metal you’ll need or the size.

Advanced Methods

With skilled professionals, It’s more likely they’ll use advanced methods for your product. With a ton of machinery and tools at our disposal, you will get the exact architectural fabrication you want. Conventional methods no longer work effectively for many, thus, the shift to more modern methods is unpreventable. We boast of high-precision tools that deliver cutting-edge results.

Gets You Exactly What You Want

Whether you want a sculpture, cutlery, statues, canopies, or even artwork, you can get it easily with a custom architectural fabrication. Going into an ordinary shop may not get you this level of versatility and convenience. Yes, you may get a metal, but it may not match your project entirely.

At VeriForm, you’ll get exactly what you want, as our experts will fabricate parts that are unique to your project. In addition, you can schedule a consultation with us to discuss your requirements. This will help us reach a consensus of what you expect, and how we’ll deliver.

How to Know If You Need Custom Architectural Fabrication

Choosing off-the-shelf items for your project can still work – no argument about that. However, this only becomes a point of concern when you need a specific design. Then, you’ll need professional architectural fabrication to get the exact design that works for your project.

A custom architectural fabrication is important when you want a specific metallic design for your project. If that is something you’re interested in, feel free to contact us for more details, or visit our website to get an instant quote. You can also call or send us an email, and we will respond as soon as possible.

Understanding CNC Machining and Capabilities

January 7, 2021

CNC machining is a method of fabricating metals through written codes in the manufacturing process. The codes determine everything including the RPMs, cutting head, and spindle speed, and much more. Many products that we use daily work by the CNC logic. Some of them include pens, paintball guns, ventilators, guitars, badges, and many more. CNC (Computer Numerical Control) enables economical and efficient production of repeatable parts of wood, metal, and plastics.

The kind of precision and speed you get from CNC machining is unmatched. That is why most industries use it, including healthcare, automobile, aerospace, and defense industries. It works for both basic and flexible or intricate with delicate parts. It’s crucial to work with trained CNC machining operators on your project to ensure a smooth and successful flow. They have profound knowledge and expertise in software and important programming languages. They can follow technical instructions and specifications of any kind, besides figuring out the ideal setup for the right product. Besides having a background in mathematics, CNC operators understand CAM/CAD technology. As you can see, you need to hire a pro to deliver a clinical result.

Types of CNC Machines

Getting the right machine that’ll suit the materials you want to work with is imperative. Here are some types of CNC machines to assess:

  •  Pick and Place – these CNC machines have different nozzles picking up electrical components for electronic equipment, then place them in the required location. These CNC machines are common in the manufacturing of tablets, phones and computers.
  • Laser – just like plasma cutters, laser cutters operate quickly. However, a laser cuts wood or metal, and sometimes plastic.
  • Plasma – used to cut 2D metal and wood using a plasma torch for penetration.
  • 3D Printer – these printers operate just like the CNC lasers, but deposit plastic in a slow constant motion until the project is complete.
  •  Router – CNC routers engrave wood, plastic, or metals.
  • Mills – milling machines help in metal engraving and woodworking. It can also work well for metallic sculptures or parts. Similar to all of the other CNC machines, they work through computer codes.
  • Lathes – lathes are common in glass working metal spinning, parts reclamation, woodturning, metal working, and thermal spraying. They are ideal for firearms manufacturing, aerospace, and automotive sectors.

CNC machining is prominent in sectors where high accuracy, precision, and attention to detail matters. Such sectors include the following:

  • Product design
  • Clothing
  • Automotive
  •  Industrial machinery
  •  Food and beverage
  • Mining
  • Defense
  • Electrical
  • Aerospace

Types of CNC Machining Projects

There are different types of CNC machining projects available. Here are some of the projects:

  •  Metal, structural, and rounds: plasma cutting using CNC creates 2D shapes from sheet metals using a high temperature and high velocity stream of ionized gas.       
  • Beveling: this is the process of preparing a metal for a welded seam. CNC does this from the length of the bevel to the degree of the angle. Aside from just having the right tools, this process needs a skilled hand.
  • Tapping: with tapping, you can produce internal threads in the product.
  • Slotting: some of the common shapes here include a straight slot, locking slot that’s curved on the end, and a keyway.
  • Countersinking: this procedure allows screw heads to sink into the metal rather than protrude from the surface.
  • Boring: this produces circular internal profiles on a hole made by drilling.
  • Drilling: this is one of the most common uses of CNC machining. It produces holes in a metal piece of up to 1.5” diameter.
  • Milling: using a rotating cutter, this process removes small chips.

These are just some of the projects you can manage through CNC machining. Take time to learn more about increasing productivity using CNC. Since 1996, VeriForm has displayed a professional and customer-driven approach to machining through innovation and creativity. With decades (Over 23 years) of machining experience, VeriForm has mastered the art of welded fabrications.

The new 20 foot long CNC machining center guarantees high uptime through multiple workstations. It also ensures that productivity is second to none. Machining parts from VeriForm end up in most of the main equipment such as naval vessels, nuclear reactors, MRI medical equipment, and even the flagship VeriForm product – VeriCUT Crossflow Downdraft Table. CNC machining is an innovative technology that most industries benefit from. Are you interested in it, contact us for more details, or visit our website to get an instant quote. You can also send us an Email message, and we will respond as soon as possible.

Metal Fabrication Basics

December 15, 2020

Metal is one of the most widely used materials around the globe. It is a versatile material that can be used in the manufacturing process within various industries, as well as large scale projects. For metal to be processed into a functional structure, a fabrication process is first required. Working on any project, it’s important to understand metal fabrication basics. These form the basis of metal production – once a manufacturer or project manager understands the basics, it becomes easier to proceed with the project processes. 

What Is Metal Fabrication?

Metal fabrication is a term used to refer to the processing of metal materials. The process starts with raw metal materials. There are different types of fabrication processes that can be used. Apart from types, there are also a variety of techniques used in metal fabrication. 

Metal fabrication basics essentially involve understanding how the raw metal is processed into usable parts. These parts can be anything from frameworks used in construction to smaller and complex structures. 

The main techniques used in metal fabrication include:

Sheet metal fabrication is currently considered the primary option for companies looking to manufacture items with raw metal materials. 

There are also experienced companies that are able to deal with metal fabrication basics, providing the manufacturer with pre-processed metal parts. VeriForm, for example, has been offering such services for more than 20 years already – with a focus on community, sustainability, and education. 

Stages of Metal Fabrication

Metal fabrication can be a complex process and generally involves a range of stages. Each stage needs to be completed to ensure the raw materials are processed efficiently and to produce a more functional metal part in the end. 

Below is an overview of the stages that generally form part of metal fabrication:

Design: The process of metal fabrication starts with a design. There are different approaches to the design process of metal fabrication. A designer will be required for this process. The designer needs to be experienced in using CAD programs, as this forms the basis for the designing of metal parts. Careful planning of the design is essential – precision also plays a major part in this stage. If the design lacks precision, the parts will not be able to fit together as they should once the fabrication process is complete. 

Programming: After an approval process for the design, the next stage is programming. The design is used to develop a custom program for the metal fabrication process. Metal sheets are used during this process. A 2D pattern that represents the part is drawn on the sheets. Multiple sheets are then layered on each other. 

Cutting: The next stage involves cutting. During this process, the drawings are used as a guideline. A laser is then utilized in order to cut at the drawings that were made during the programming stage. A specialized program is used, providing an automated process that enhances the overall accuracy. 

Punching: When there are countersinks, ribs, or louvers in the parts, a punching stage will be required. A CNC punching machine will be used at this stage. It will hit the sheets in order to create specific shapes that are required. 

Bending: Another important stage is bending. During this stage, the sheets are bent to complete the shapes that the manufacturer needs. There are different techniques that can be used during this stage. A clamp is often used to assist with the bending process. 

Welding: In most cases, a welding stage is needed too. The specific type of welding depends on the requirements of the project. This may include projection welding, TIG welding, MIG welding, robotic welding, and spot welding. The experts working with the metal fabrication project will decide what type of welding is most ideal for the parts that are being produced

Assembly: Once the primary stages are done, the metal parts are assembled. The assembly process can be simple or complex, depending on the shapes and parts that have been produced. 

Powder Coating: An electrostatic powder coating is usually applied to the final product. 

Finding the Right Metal Fabrication Provider

There are numerous providers that can assist in the metal fabrication process. It is important to do research prior to selecting a provider. 

VeriForm has been in business for more than two decades and focuses on providing superior metal fabrication services. Experts at VeriForm are able to provide on-time delivery to clients. All systems utilized by VeriForm follow ISO 9000-2015 quality standards. This ensures the client can expect only the highest quality fabrication services. 

VeriForm is experienced in different types of welding procedures. We also offer precision plasma cutting, among many other services. In recent news, VeriForm has also been named the greenest fabrication company in the Northern region of America.   

Visit our website or contact our experts for more information on how metal fabrication experts can help with your manufacturing project. 

Metal fabrication is a process that requires specialized expertise. The first step for manufacturers would be to thoroughly understand the essential metal fabrication basics. Manufacturing facilities not equipped with appropriate hardware to process raw metal can also consider using the services of metal processing plants, such as VeriForm.