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Metal Manufacturing – Which Repetition Welding Method is Best?

In the metal manufacturing industry, repetition welding methods are an important consideration which affects the cosmetics and economics as well as the functionality of the welded componentry.

In partnering with Swift Metal Services to improve design on metal componentry, the client often asks; “what is the best way to weld these parts?”. The answer is varied because it may differ according to the type of material, the aesthetic requirements or the economic restraints of the project.

In today’s metal manufacturing arena, there are 3 main types of weld methods.

GMAW (Mig Welding) is the most cost effective method of welding medium to heavy plate for production of repetition fabricated components. Hence, this is increasingly important in companies producing large volumes of metal manufacturing, requiring efficient production lines. Typically, where components do not require a high quality finish, MIG welding is the best option. This is because the heat affects a larger zone, and the weld itself is larger than that of TIG welding.

Key Benefits of MIG welding are:
  1. Productivity: Welders in the metal manufacturing industry use MIG welding for high quantity production runs of metal components because they can weld faster and more efficiently.
  2. Versatile: The MIG Welding process can be used to join almost any steel and in most thicknesses. Including; Mild Steels, all grades of Stainless Steel, Aluminium, Nickel Alloys, Copper, & Titanium.
  3. Quality: MIG Welding provides a clean weld and there is also very little slag to clean.

This is the most common method for welded componentry. Useful for all material from around 2mm up to heavy plate. As a result, is used across the whole spectrum of fabrication, and is the most efficient method of repetition welding.

View the Benefits of Repetition Fabrication here:

GTAW (Tig Welding)

If a high aesthetic appeal, food grade welds or minimal space for a weld are critical considerations in the design, then TIG welding will be a good option. TIG welding is most often used for precision welding of thinner materials or when the weld quality and appearance is important.

Key Benefits of TIG welding are:
  1. Highly aesthetic. A good operator lays down a very small, smooth weld that can be highly polished. This is important in the food industry, where cleanliness is paramount, as well as in the architectural industry, where clean lines & seamless finish is so important.
  2. Welds are small. The TIG welding process can be for materials as thin as 0.9mm. This, then is the ideal option for small, light gauge components which require accuracy or a high-end finish.
  3. The application of heat in the TIG process is much more targeted & controllable than MIG welding. The smaller HAZ (Heat affected zone), leads to less thermal distortion and a better looking part.
  4. TIG welding is most commonly used to weld thin sections of carbon steels & stainless steels and non-ferrous metals such as aluminium, magnesium, and copper alloys, however it is also possible to weld some dissimilar metals.

 

RSW (Spot Welding) is for thin sheet metal component welding (up to 3mm) in a sandwich configuration. Electrodes clamp the sheets together while the operator applies an electrical current. Creating the fusion of the material in a small area.

Key Benefits of Spot welding are:
  1. Welders can perform quickly and without the need for any clean up. As well as being able to operate in quick succession.
  2. Minimal heat distortion.
  3. Can weld up to 4 thickness of material in one operation.
  4. Designed for assembly of metal components and the joining of flat faces.

Here at Swift Metal Services we supply high quantities of welded componentry and steel assemblies. The teams in our repetition welding and component assembly areas receive high levels of training and certifications. Therefore they are available to discuss the particular details of your componentry requirements. Furthermore, Swift have invested in the latest welding equipment and automated welding methods. We utilise MIG welding, TIG welding and Spot welding, or a combination of these for welded componentry.

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5 Things You Should Discuss With Your Metal Parts Manufacturer

When you are ordering metal parts from an external manufacturer it is important to remember that the reputation and principals of your own company is dependent on the contract manufacturing companies ability to meet deadlines and produce quality components. There are a number of points you should discuss with your metal parts manufacturer.

It is vital to your company standing that you have an understanding with the external manufacturing company. Ensuring they are capable to produce your metal parts according to your specifications and quality standards. You also need to know that they are willing, and have the production space to produce the components in the agreed time-frame.

Swift Metal Services is a turnkey manufacturing company. Because of our experience in dealing with customers and meeting their needs, we have come up with the following 5 points to assist you:

  1. Tolerances: Assess whether your tolerances are important. Can the Metal Parts Manufacturer meet your tolerances? When producing large volumes of components, each part may need to fit within a specific tolerance range. Failure to meet this could result in badly fitting components, reducing the quality of the final product.
  2. Material: The material choice is one of the largest factors in the manufacture of custom parts. The material chosen should be able to withstand the conditions in which the final product will be.
  3. Finishing & Coating: Does the metal parts manufacturer also offer services in part finishing or coating? As well as the material chosen, the finish or coating of a component directly affects the life-span of the complete product.
  4. Production Method: How are the parts manufactured? Manufacturing techniques are constantly developing and changing. Many tasks that were once done by hand are now done by automated machinery. Discuss with your custom parts manufacturer, what method are they using? Will the parts be of high quality, a consistent standard and in an effective time frame? View Automated Metal Pressing Video here:
  5. Lead-time: How fast can the manufacturer produce your order? Using a contract manufacturer is an effective way of reducing your own production time-frames, but can the external company meet your lead-times? Find out the benefits of using a turnkey manufacturing company here.

Understanding your external metal component manufacturing company, and trusting them to produce your components cost effectively and to a high standard, is the most important way of ensuring you are meeting your own company obligations.

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