What Are the Most Common Metals Used in Fabrication

Metal fabrication is the process of creating metal structures out of raw metal resources. It involves a wide range of techniques like cutting, bending, shaping, and assembling to transform raw materials into final products, from complex machinery to simple handrails.

With a wide variety of metals and alloys available, choosing the right one depends on key properties such as tensile strength, formability, weight, and corrosion resistance. The most popular materials used in metal manufacturing will be covered in this guide, along with their raw forms.

Common Metals Utilized in Metal Fabrication Industries

1. Steel

Steel is a highly versatile alloy, composed primarily of iron and carbon. Manufacturers vary the amount of carbon and other components to produce different types of steel with specific properties. Due to its strength, durability, and affordability, this material is the most widely used in the metal fabrication sector.

• Carbon Steel: Known for its incredible strength and durability, carbon steel is the most versatile and widely used type of steel. Its properties make it perfect for heavy-duty structural applications like bridges and construction, plus it's highly malleable, making it simple to shape and work with.
• Stainless Steel: This alloy is created by adding a high percentage of chromium, which gives it excellent resistance to rust and corrosion.
• Alloy Steel: By incorporating elements like manganese, silicon, nickel, and tungsten, steel's properties can be customized for specific applications, such as improving its heat resistance, hardness, or strength.

2. Aluminum

With its lightweight nature, resistance to corrosion, and high malleability, aluminum is a valuable metal. It is well-known for its exceptional strength-to-weight ratio, which means it provides comprehensive durability at a much lighter weight than other metals like steel.

Aluminum is also an excellent thermal and electrical conductor and can be easily worked using a variety of fabrication techniques, including welding and stamping. Its ability to perform well in low-temperature applications also makes it suitable for products like refrigerated equipment and freezers.

3. Copper

Copper is a highly valued metal in fabrication due to its superior thermal and electrical conductivity. It is also naturally resistant to corrosion and microbes, which makes it ideal for use in plumbing and marine environments.

Applications: Due to its superior conductivity, copper is broadly utilized for electrical wiring and circuitry within the field of electrical engineering. Its malleability and unique color also make it popular for decorative elements, roofing, and heat exchangers.

4. Other Common Materials

Although copper, aluminum, and steel are the main metals, other metals and alloys are also important for manufacturing:

• Brass: An alloy of copper and zinc, brass is valued for its unique gold-like appearance and corrosion resistance. It is commonly used in fixtures, decorative elements, and musical instruments.
• Magnesium: Known for being incredibly lightweight, magnesium is used in specialized applications, particularly in the aerospace and automotive industries, to reduce overall vehicle weight.
• Titanium: This metal is incredibly lightweight, corrosion-resistant, and robust.  Despite being more costly, it is utilized in high-performance sports equipment, medical implants, and airplanes.

Common Raw Forms of Metal

The availability of metals in various standardized forms significantly simplifies fabrication.

Flat Metal

Flat metal is metal that's been pressed or rolled into thin, flat sheets.

• Foil/Leaf Metal: The thinnest form, typically used for decorative or flexible applications.
• Sheet Metal: Metal sheets less than 6 mm thick are used for panels, ductwork, and a variety of consumer products.
• Plate Metal: Any flat metal thicker than 0.25 inches. Used for heavy-duty structural components.

Sectional Metals

Standardized basic materials, such as sectional metals, are formed for structural support in engineering and building.

• I-Beam: A long beam with a cross-section resembling the letter "I." Provides excellent strength for supporting heavy loads.
• Hollow Structural Section (HSS): They are round, square, or rectangular hollow tubes.  When a sleek, modern look is desired, it is utilized for structural supports, frames, and architectural features.
• Bar: A bar is a long, flat piece of metal, often with a rectangular or square cross-section, commonly used for simple supports or frames.
• Rod: A long, round piece of metal, often used as rebar in concrete structures or for making hardware.

Welding Wire

These are thin, solid, or tubular rods of metal that are used as filler material to join two or more pieces of metal during the welding process.