Shearing-type cutting methods
Cutting processes can be categorized into two main buckets in the way they extract the geometry: shearing-type cutting (e.g. punching), in which the entire geometry can be cut out of the sheet at once with mechanical force, and profile cutting techniques, where a cutting source draws the geometry like a pen (e.g. waterjet, plasma, lasers, etc.)

Punching vs. laser cutting
Punch cutting can be really fast, because in many cases the entire geometry can be carved out with a with a single hit. However, it requires large upfront tooling costs and therefore the production batch should be large enough to justify the cost. The mechanical forces used in punching can be limited by some geometrical features, such as thin webs. Some job shops working in an agile environment may be discouraged from punch cutting because of geometrical limitations (e.g. post-process burr removal.) 
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Profile cutting processes use soft tooling to adapt to the changing designs at no fixed cost. Therefore, they unlock opportunities for manufacturers to prototype, run short-term and medium-term production, and maintain the low-volume customers that have the potential of mass production in the horizon. Fiber lasers have paved the path to high power industrial lasers becoming more affordable. More cost-effective technology as well as advances in automation are rapidly changing the equations for cross-over point of mass producing sheet metal parts, when one compares laser to punch. Many manufacturers have used laser cutting as a complementary process to punch mass production or replacing old punch machines with laser cutting machines. 

Shearing-type cutting methods
This section discusses the major strong and weak performance points of profile cutting methods with a focus on sheet metal cutting rather than plate cutting, as the highest demand for cutting in the market is for sheet metals. Please note that thicknesses up to 12 mm are referred to as sheet metal whereas thicknesses more than 12 mm are named plates.

In many cases, engineers and designers often overlook the benefits of stainless steel, mainly due to its higher cost. However, the benefits associated with stainless steel will often justify the initial investment, as the material can offer the greatest value over the life of a fabrication project.
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What Exactly is Stainless Steel?
According to the British Stainless Steel Association, stainless steel is an alloy of iron with a minimum of 10.5% chromium.” Chromium produces a thin layer of oxide on the surface of the steel, which is known as the “passive layer.” The chromium present in the steel is what allows the steel to be corrosion-resistant, creating a durable and invisible surface.

What are the Benefits of Stainless Steel for Fabrication Projects?
Stainless steel is not free from disadvantages: there’s a high initial cost, the metal must be handled with high-quality equipment, and it’s easy to run into difficulties with welding; however, the benefits far outweighs the disadvantages when you’re working with this dependable metal. Depending on your industry, there can be many unique benefits of stainless steel for metal fabrication projects, including (but not limited to):​

Easy to Work With
Using stainless steel in a fabrication project is only a challenge if your selected fabricator is working with outdated machinery. Extol Engineering utilizes top-of-the-line, modern equipment, which makes it easy to cut, weld, and everything in-between.

Corrosion Resistance
One of the primary selling points of stainless steel is its inherent ability fight rust. If you are interested in selling rust-free products, stainless steel may be a natural choice. Stainless steel is resistant to corrosion, which inevitably impacts the overall value and long-term investment. Chromium allows the steel to remain resistant to corrosion while different levels of alloy impact corrosion in different settings. For use in wet applications, lower grades of alloy typically work best. However, for use around acid and alkaline solutions, a higher alloy grade is a better option.

Great for Use in Hygienic Products
As we’ve alluded to, stainless steel is very easy to keep clean, which makes it a great choice for applications with high standards for sanitary conditions, such as commercial kitchens, pharmaceutical research or food and beverage processing.

Maintenance Free
The long-term value of working with stainless steel should not be overlooked, as it outweighs the initial investment that often turns the uninformed away. The life cycle cost should always be a part of the decision making  process. Choosing a maintenance free product like stainless steel allows you to focus on a great process and product.

Temperature Resistance
Stainless steel is well-known for its ability to withstand heat, which makes it well suited for use in applications that may be subjected to more extreme temperatures like boilers, valves, feed water heaters and other heat exchangers.

Sustainability
Stainless steel is recyclable. If your company, like many in the modern world, are concerned about the environmental impact of your manufacturing efforts and products, using stainless steel is a great way to mitigate some of the impact.

Extol Engineering Ltd
It's crucial to do your research when choosing a metal fabrication, as not all companies are capable of completing the same quality of work. Extol Engineering has years of experience, honing our skills across the board to deliver a quality product and measurable bottom line value to our customers. We excel in all types of metal fabrication services and would be honored to use stainless steel in your products if that is in line with your request. As a full-service metal fabricator, we can work with your designed stainless-steel project from start to finish and do it without the need to outsource any of the work, saving you time and money with fewer headaches. 

Click HERE to Discuss your next Production with the Experienced Extol Team. 

In the world of manufacturing, the term “lead time” is used to define the period between when an order is placed and when that order is complete (i.e. ready for pick up or delivery.)

Lead time in manufacturing is important for all parties involved, as it ensures that orders are placed and fulfilled according to a predictable timetable established at the outset. Depending on what is being produced and the processes which it requires, lead times can be fairly standard throughout the industry, but there are always circumstances that could extend or shorten production lead times. Knowing what goes into determining lead time can be extremely beneficial when quoting jobs or placing orders, and there helpful steps to consider when expediting lead time is a priority.

What Affects Production Lead Times In Manufacturing
There are quite a few factors that could affect production lead time. 

One of the main considerations when determining production lead times is material/part availability. While many manufacturers will keep a certain amount of stock on hand, in many instances they must source-specific material or part components from their suppliers. This is subject to its own lead time from the vendor, which can vary widely based on availability. 

Once material and components have arrived, machine/operator capacity is another factor to take into account. Production queues are generally determined days or weeks in advance, so lead times must leave enough wiggle room to ensure that all jobs can get through a given machine without creating too much of a bottleneck. Some manufacturers will offer an expedite option to move a specific job to the front of the line, but this generally comes at an added cost and can be to the detriment of other customers if not managed properly.

After production, products may go out for secondary processing (heat treatment, surface finishing, etc.) These too will have lead times associated and must be accounted for when projecting the total duration of a project. 

How To Reduce Lead Times
Now that we know some of the elements that go into determining lead time, what can we do to minimize this period and get products produced faster?  Though it’s not possible in every instance, there are a few ways that manufacturers can speed up production, and some steps that customers can take when designing/ordering products to streamline the process and ensure that lead times remain as minimal as possible. 

The One-Stop Shop
Relying on multiple vendors for individual aspects of manufacturing can pose a challenge when you want to get things done in a hurry. Instead, a proven method to minimize lead time is to have one shop oversee all facets of production. This could entail material sourcing, machining/fabrication, secondary processes, and assembly/packaging. By limiting the number of parties involved, you can help mitigate unexpected delays and significantly streamline the manufacturing process. While not everyone offers this service, it can be a game-changer when it comes to limiting production time, and it is definitely worth a discussion with your machine shop to determine their capabilities and contacts to see if they can shoulder more of the burden when it comes to coordinating and managing additional operations. 

 Production Capacity
 Have a conversation with your manufacturer about capacity. Do they have open machine time? How far out is their production queue? Are they expecting any large orders that would tie up equipment for a prolonged period? Production capacity is a huge factor when it comes to determining the lead time. If machines are open and operators are free, it can be easy to quickly push a job through without delay. On the other hand, it there is a backlog of orders to get through a machine, it can take weeks before new orders make it to the front of the line. 

Most machine shops will be upfront about their capacity and will communicate realistic lead times to allow enough wiggle room so that they can have products ready by a given date. That said, a quoted lead time is always subject to change. If a customer inquires about a product and then waits a few weeks or months to order, production capacity (not to mention material availability) could change dramatically in that time. It’s best to order products as close to the date of the quote as possible. 

Order Frequency / Forecasting
It can be more cost-effective to order products in large quantities, but if time is of the essence, it may be worth considering lowering your numbers to get items through production quicker. By decreasing the quantity, and increasing the frequency at which orders are being placed, you can help ensure that you can meet customer demand without prolonged lead times. 

It can also be helpful to share order forecasts with your manufacturer so they can plan ahead. Many shops will produce extra products if they are expecting upcoming orders, and some will even agree to stock a specified amount  of product that they can release when customers are in a pinch. 

Standardize Everything
Custom features add time and money to a project, so it is always advised to stick to industry standards whenever possible. 

This applies to material, which comes in standard sizes/thicknesses and types. Many machine shops will keep stock on hand, but when specialty material is required, it will need to be ordered from outside vendors and that could add days or weeks to lead time.  

This also can apply to product design. Relying on standard sizes for machined features (holes, taps, radii, etc.) helps ensure that shops will have tooling available to machine parts as soon as an order is placed. Custom features require custom tooling, which will need to be acquired prior to production, and will come at a cost (both in time and money.) It can be worth discussing substitutions with your manufacturer, as certain materials/tooling may be more readily available than what was originally specified. By substituting for something on-hand, it can significantly reduce production lead times.

Click HERE to Discuss your next Production with the Experienced Extol Team. 

There are many methods and machines capable of cutting parts, but one of the most effective, efficient and affordable approaches is known as water jet cutting. Water jet cutting is the preferred operation for many manufacturers looking to cut high-quality parts without adverse material effects that can come into play when relying on other cutting methods.

A water jet uses a concentrated mixture of water and garnet (fine sand) that is sprayed through a small orifice at extremely high pressure (50,000-60,000 psi.) The result is an extremely fine cutting stream, capable of passing through nearly any type of material with little hardness/thickness restrictions. As with other CNC style machines, a water jet uses CAD data to follow designated tool paths as well as varying cut types/qualities to adjust for speed, depth of cut, etc.

The water jet is an incredibly effective piece of machinery, and it is gaining popularity across the industry as more manufacturers and engineers are learning of its unique capabilities and benefits. Below, we will dive deeper into several of the advantages of water jet cutting, as well as how the water jet stacks up against more conventional cutting options.

It Can Cut Thicker parts
One of the biggest advantages of cutting on a water jet is that you are not limited by material thickness. The water jet can fly through thin material with ease, and operators will often create layered stacks of thin stock so the water jet can cut through several sheets at once. This method can help reduce production time and increase material yield without sacrificing cut quality.

The real advantage of the water jet comes into play on thicker materials. While other cutting methods may start to lose performance/quality anywhere from 12mm to 50mm in limited materials, the water jet is able to reliably cut up to a mind-blowing 300mm thick stainless steel. This truly separates the water jet from its competition. Think of the time that can be saved on secondary machining operations by water jet cutting high-quality profiles in thick material, or by using a water jet to modify existing parts that would otherwise be too thick for other machines to handle.

No heat created in cutting
Another unique advantage that the water jet provides is the ability to cut parts without creating any heat. This has a number of benefits when it comes to material selection and secondary operations.

In many instances, heat can spell trouble in machining. When cutting softer materials, too much heat will result in melting, warping, discoloration and other negative side effects that will adversely affect a finished part. On harder materials, added heat will actually change the physical make up of plate/stock making it far more difficult to machine during secondary operations.

When a customer wants to feel confident that their material will be cut without losing any structural integrity due to effects from heat, they choose the water jet every time.

Can cut almost any material
We’ve already established that thickness and heat are not limiting factors when it comes to water jet cutting. So, does that mean that a water jet can cut virtually any material? The answer is….pretty much, yeah. The ability to cut a wide range of material is yet another benefit of water jet cutting that makes it one of the most versatile machines in any shop.

The water jet can cut a seemingly endless list of organic and inorganic material. Ferrous and non-ferrous metals of all types are some of the most commonly cut materials on a water jet, including brass, copper, aluminum, titanium and a wide variety of steels. The water jet is equally effective at cutting more abstract materials such as plastic, rubber, wood, tile, stone, glass, and more.

Very little fixturing
Some CNC machines require lengthy setups with complex fixturing that can take hours to install and calibrate before a single chip is cut. The water jet, on the other hand, requires very little in terms of fixturing and can be set up and running in minutes instead of hours.

Whether a job calls for a large sheet of material, or you just need to cut a small part from an existing remnant, the water jet generally only requires a handful of clamps, weights for brackets to secure material in place. After that, it’s just a matter of establishing zeroes and loading a program. A skilled operator can have the process completed in no time, making set up costs next to nothing.
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The quick set up and limited fixturing on a water jet can be a real benefit to the customer. Depending on the size of the job, Extol can offer significantly shorter lead times on water jet work which can be a huge difference-maker when it comes to reducing costs and expediting production.

Waterjet Cutting Vs The Alternatives
Waterjet Cutting vs Plasma
Plasma is another commonly used method for cutting certain materials, but it is far more limited than the water jet. It uses a series of gas/consumables to create a plasma arc that corrodes material along a path. Plasma can quickly cut through certain ferrous/non-ferrous metals, but it can not cut non-conductive materials like plastic. Plasma also introduces a great deal of heat which limits it’s cutting capabilities to select materials/thicknesses before melting and work hardening occurs. Plasma cutters will omit gaseous fumes when cutting so precautions must be taken for proper ventilation.

Waterjet Cutting vs Laser
Laser cutting is a highly efficient cutting method that rivals the water jet in many areas. It is able to cut with more speed and precision, but it is limited as to what it can cut. The laser also introduces heat into its parts which can lead to melted material and work hardening. Laser may be a more effective method for cutting certain thin metals, but the benefits and advantages of the water jet remain outmatched due to its broad versatility across applications.

Click HERE to Discuss your next Cutting Project with the Experienced Extol Team. 

When searching for a company to handle your metal fabrication project, cost is a major factor. You might be tempted to choose the lowest quote you find in order to save money. However, cheaper isn’t always better with these quotes. Unfortunately, you’ll often find that the lowest quote, especially a quote significantly lower than all other quotes, will cost you more in the long run. Here are some of the reasons you shouldn’t always choose the cheapest metal fabrication quote.

Not All Fabrication Companies Are Equal
One of the biggest mistakes you can make when choosing a metal fabrication company is assuming that all companies are equal. If this were the case, the cheapest quote would be the best quote. However, companies have different levels of experience and different qualifications. Different companies will also have different scales of operations, which can often affect the speed at which your project is finished. It’s important to choose a company with enough experience to get your job done right.

Reasons for a Low Bid
A low bid is often attractive, as we all like to save money. However, it’s important to find out why the bid is so low. In some cases, the bid might be lower because certain scope items could have been missed. A less experienced company might also underestimate the complexities of the job. Additionally, one of the most concerning reasons a bid might be low is that the company undervalues craftsmanship and its employees, paying them lower wages than they deserve.

Hidden Costs of a Low Bid
In addition to the questionable reasons a company might have a low bid, you will probably encounter hidden costs. One of the biggest costs of a low priced fabrication project is sloppy workmanship that leads to a poor appearance of your project. In some cases, you might end up with a project that does not work, often failing just past the warranty period. Another hidden cost of a low big could be wasted time, whether it’s the result of poor time management or time wasted getting inexperienced workers up to speed. At the end of the day, a low bid could cost you more.

Don’t Settle
Although you might be tempted by a low quote on your metal fabrication project, you really shouldn’t settle. If you’re looking for quality work, you need a quality company. Of course, cost should be a factor and you should never overpay for services. However, you should not settle for a subpar metal fabrication company simply because of a low bid. For the best possible outcome on your project, don’t settle for the cheapest quote.

Extol Engineering & Fabrication 
It's crucial to do your research when choosing a metal fabrication, as not all companies are capable of completing the same quality of work. Extol Engineering has years of experience, honing our skills across the board to deliver a quality product and measurable bottom line value to our customers.

Click HERE to get your next job quote prepared by Extol. 

Designing, fabricating, assembling, finishing, and cleaning equipment for food-grade applications, regardless of the alloy used, has a myriad of requirements that must be met every step of the way. The term food grade and its many variants refers to surfaces that have a sanitary finish—a finish that is safe for processing food products and can easily and reliably be cleaned and sanitized.

The grinding, sanding, and finishing of food-grade stainless steel must result in surfaces devoid of areas that encourage bacteria growth. The surfaces must be free of lines, grooves, pits, or divots. Additionally, the surfaces must withstand corrosion from the food being handled and the chemicals used to sanitize the equipment. Also note that stainless steel isn’t a single material; many stainless alloys are used in food-oriented applications.

Judge a Book by Its Cover, and the Story Inside
In the majority of applications, a finish at the high end of No. 4 is considered food grade. This finish is achieved using a high-grit abrasive in the range of 150-220 and is identified by short, parallel lines that run the length of the material. The success of the finish can ultimately be determined by a surface roughness average (Ra), measured by height in millionths of an inch (µin.), or microinches. A profilometer determines Ra values by moving a diamond stylus across the workpiece’s surface for a specified distance and using a specified contact force. It measures small surface variations and calculates their average to determine the roughness. In most food-grade applications, 60-36 Ra is achieved with 150-220 grit. Because milk products spoil more quickly and carry more bacteria than other food and beverage items, dairy applications should have a finer finish, No. 4A, which is 40-24 Ra and achieved with a 220-grit abrasive or finer.

Keep in mind that the abrasive’s grit value isn’t the only determinant of the surface finish; other factors are the condition of the abrasive, the particular tool, its speed, and the operator’s technique.

Areas that do not come in direct contact with food don’t need to adhere to the sanitary finish specifications. However, they do need to be cleaned and sanitized frequently, so the surface should be able to accommodate such harsh treatment. In these instances, it is most often easier — and more aesthetically pleasing — to use a consistent finish for all the surfaces. Bear in mind that cleaning and sanitizing are more effective if the system is designed to discourage the bacteria buildup.

Finishing the inside of a pipe or tube can be a challenge. After welding slag is flushed out, the best finishing tools usually are long arms and elbow grease. For small diameters, mounting a flap wheel to a flexible shaft is a possibility. Long stretches of pipe require a little more creativity. The tool might be as simple as an abrasive mounted to a long dowel or a broomstick.
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Choosing Abrasives and Tools
The abrasive and the tool shouldn’t be chosen in isolation; they should be evaluated together to arrive at the best combination for the job.

The Right Abrasive for the Job. 
Each project requires several products with various grits to achieve the final finish. Conventional abrasives are composed mainly of aluminum oxide or zirconium. These materials perform well, but ceramic materials are making inroads. Nonwoven abrasives such as fleece provide an even, consistent finish without shadows. Their softness reduces chattering on the surface and resists glazing from soft materials. Another new class, unitized abrasives, also are finding their way into the mainstream. As with other products, the decision to switch to ceramics or unitized abrasives requires careful evaluation of their costs and benefits.

The Right Tool for the Job. 
Because most fabricated pieces are unique in design, few if any tools enable mass production of a finish. Therefore, most finishing is done by hand or with a hand tool. Some tools are “unitaskers,” whereas others are “multitaskers.” If you find good old hand abrasives and elbow grease aren’t right for the job, these guidelines can help you select a tool.

• Among the tools that essentially do one job, also known as unitaskers, are finger belt sanders and wraparound pipe sanders. Finger belt sanders are ideal for getting into angles and tight spaces. Their narrow abrasives fit into small areas where traditional belt sanders are too large. Wraparound pipe sanders finish the circumference of both open and closed pipe constructions.
• Tools that can perform many functions, also known as multitaskers, include combination finishers/wrap-around pipe belt sanders and linear finishing machines. The combination finisher/wraparound pipe belt sander performs several processes on round and flat surfaces. It removes weld seams in straight lines without edges or wavy finishes and longitudinally grinds flat surfaces to remove spot welds and deep scratches. Its sanding belt also follows the individual contours of pipes and handrails to grind, sand, and polish the surface to a smooth, blemish-free finish.
• A linear finishing system is well-suited to finish long, flat surfaces without shadows, streaks, or transitions. This tool is also adept at finishing in corners. Linear finishers are ideal for graining, polishing, brushing, blending, and deburring. Flap wheels, belt sleeves, and brushes can all be used on this machine.

Need a Little Direction?
Choosing the right tool and abrasive are not enough to get the job done; the geometry of every component requires careful consideration. Round pipe is best-suited for circumferential, not lengthwise, finishing. Square pieces are best finished lengthwise, in the same direction, on all four sides. Trying to go around all four sides in one pass will result in an uneven finish with poor grain quality. Flat expanses of material are best taken a section at a time, always working in the same direction. Pay close attention to the areas where the sections join; blend them until the transitions are nonexistent.

Polish the Approach and the End Is in Sight
Now armed with all of this technical information about food-grade finishing, the next question is, What can go wrong?

• The customer’s expectations are crucial. Finishes that are simple, such as a grain that runs the length of a rail, have a lower time-cost factor than a difficult finish, such as a grain that goes around the circumference of a square tube or pipe.
• Before assembly, ensure that all pregrained pieces have a consistent pattern. When welding two or more pieces together, make sure the grain patterns are aligned as closely as possible. A mistake early in the process is almost impossible to correct later on.
• Always choose the correct application-specific tool for the project. This will increase productivity and decrease total costs.
• Use the finished spot as a starting point, and work toward unfinished areas. Going the other direction leads to mismatches.
• Haste makes waste. The best finish is achieved with time and patience. Hurrying can lead to using a material that is too aggressive to start, applying too much pressure, or using tools at a speed that is too high for the application. The result often is a surface that has deep scratches, requiring rework.

Note that designing, assembling, and finishing a food-grade project require substantial technical knowledge, but ultimately the project’s success hinges on compliance with the standards established by the governing authority.

Tips for Designing, Assembling a Sanitary Piping System
Finishing a stainless steel surface shouldn’t begin after the project is assembled; it should be a consideration in the project’s design phase. The initial engineering drawings should be clear about the design and sanitary specifications for the project.

• Right-angle joints (T joints) and elbows provide a place for food and bacteria to accumulate and are difficult to clean thoroughly. The project’s design should exclude 90-degree angles.
• Any bend less than 135 degrees should be rounded gently, preferably with a radius of more than 8 mm. Some projects, because of their design or role in the food surface application, can have smaller radii. Regardless of the radius, smooth, gently rounded welds on the exterior are ideal.
• Because the finishing process typically is the most time- and labor-intensive aspect of the project, it can be beneficial to consider all assembly options. If the forming and fabricating steps comprise more than half the project, it might be more cost-effective to purchase prefinished material, assemble the project, then grind and finish the welds to match the prefinished pieces.
• All joints should have a continuous, butt-type connection and should be finished to No. 4 or finer. If a butt joint isn’t possible, press- and shrink-fit joints are viable options.
• When two pipes need to be welded together, specify a bevel angle of 30 or 45 degrees to create a V-groove.

Stainless Steel Finishes
The finishing industry uses numbers and letters to define 13 stainless steel surface finishes. The first five, numbered 0 to 2, are mill finishes; 2B is among the most common for fabricators to start with. The other eight finishes, numbered 3 to 10, are applied by steel producers, toll processors, or fabricators.
No. 0: Hot-rolled and annealed
No. 1: Hot-rolled, annealed, and passivated
No. 2D: Cold-rolled, annealed, pickled, and passivated
No. 2B: Cold-rolled, annealed, pickled, and passivated, with an additional pass through highly polished rollers
No. 2BA: Bright annealed, which is similar to 2B but has an additional step in which the steel is annealed in an oxygen-free atmosphere
No. 3: Coarse
No. 4: Brushed
No. 5: Satin
No. 6: Matte
No. 7: Reflective
No. 8: Mirror
No. 9: Bead blast
No. 10: Any of several electropolished or heat-colored surfaces

Click HERE to find out more about all of our Food Grade fabrication services. 

Metal fabrication is a very involved process. From cutting to welding to polishing, there are many different operations involved in the metal fabrication process. Although there are different companies that can handle different parts of the job, for the best product it’s better to deal with a single, all-encompassing metal fabrication company. Here are some reasons why you should use one metal fabrication company to handle your entire project.

Cost
When one metal fabrication company handles your entire project, you’ll never have surprise costs. From the very beginning, you’ll receive a quote for the entire process. You won’t have to worry about comparing prices for different services. Combining all of your services into one bundle will save money on the cost of the project and help you avoid surprise costs.

Efficiency
When you use a single metal fabrication company, you’ll save the hassle of seeking out different companies for individual services. You can also cut out the wait time between each service while the product is shipped out to different companies and shelved. If you want the most efficient option for metal fabrication, using a single company is your best bet.

Quality
When you choose a single metal fabrication company, you can be certain that every service is completed with the same quality in mind. When you use different companies for different parts of the process, you could end up with a product that was cut perfectly, but poorly welded. If one piece of the process is not completed with the same quality as the rest, the quality of the whole product will suffer. If you want your product to be of the highest quality, it’s best to use a single metal fabrication company.

Expertise
Metal fabrication can be an involved, lengthy process. For this reason, if one company is involved throughout the entire process, it is likely that a partnership between you and the company will emerge. With this partnership, the company is more likely to understand what you want out of the product and will be able to make more efficient decisions. It will cut down on the overall time to complete the project and provide you with the best finished product.

Options
While you might think that utilizing different companies for metal fabrication will give you more production options, the opposite is actually true. When you deal with a single company, certain options will be available to you that otherwise would not. The company can make suggestions that involve specific techniques at different steps of the process. When you use a single metal fabrication company, you will have more options for techniques and the overall outcome of your product.

EXTOL Engineering | Mastercraft Metal Fabrication
It's crucial to do your research when choosing a metal fabrication, as not all companies are capable of completing the same quality of work. EXTOL has years of experience, honing our skills across the board to deliver a quality product and measurable bottom line value to our customers.

Click HERE to find out more about all of our fabrication services. 

Welding stainless steel has its challenges and differences. Though not as difficult to weld as some metals, stainless steel has specific properties that vary from other more common steels that should be addressed before welding.

Stainless steel is a nonferrous metal alloy of iron, carbon, and a minimum of 10.5% chromium. It’s known for its strength and corrosion resistance. The many different grades of stainless steel are determined by the degree and combination of other elements mixed with the iron, carbon, and chromium such as nickel, niobium, molybdenum, and titanium. The addition of chromium to the alloy–which is resistant to rust and tarnishing—also gives the metal its familiar shine.

Stainless steel has a wide variety of industrial applications. Primary uses are for architectural paneling, food processing and other kitchen equipment, aerospace, automotive, and marine equipment. Because of its wide use, it’s a popular metal in many welding applications for industrial equipment.

To achieve an aesthetic result when welding stainless steel, regardless of your method, heating and cooling of the metal must be controlled. The metal is known to retain heat, which can lead to problems like warping, rust, or embrittlement. Too much heat, as few as five amps, can mean the difference between a burned seam and perfection. Secondly, make sure the filler metals match the material being welded. Finally, ensure a clean working space and keep debris off the welding table, as stainless steel can scratch very easily.

Most importantly, welding stainless steel requires ventilation. Because of the chromium, the fumes can be toxic. Exhaust fans, special smoke suction tips attached to the welding torch, and a breathing apparatus are all highly advised to keep the fumes and harmful smoke away from the welder.
The three most common methods for welding stainless steel are TIG Welding, MIG Welding, and Resistance Welding. Each has their own benefits and unique characteristics.

TIG Welding
TIG stands for Tungsten Inert Gas, which is short for Gas Tungsten Arc Welding (GTAW). It’s named for the tungsten electrode, and the inert gas sheathing surrounding it. The non-consumable tungsten electrode delivers the current to a welding arc. Argon gas is used because it protects and cools the tungsten, creates much less smoke than other gases, and prevents oxidization.

TIG welding is ideal for critical joints and is widely used in the industry for fine, precise welds, and it is the most common method for welding thin stainless steel sections on thinner metals. Benefits for using TIG Welding on stainless steel include, low electrode wear, pore-free, sound welds, concentrated heat source, which in turn leads to a narrow fusion zone, precise control, a very stable arc, welding with or without filler, and oxidation residue is eliminated, resulting in a simplified final cleaning process.

MIG Welding
Metal Inert Gas, MIG welding, also known as, Gas Metal Arc Welding (GMAW), is the welding process that uses electricity to melt and join pieces of metal together. In the world of welding, it’s often referred to as the “hot glue gun” and was developed in the 1940s for welding non-ferrous metals. MIG welding requires a wire to be connected to a source of direct current that acts as an electrode to join two pieces of metal while it continuously passes through a welding gun. The shielding gas mix for MIG welding stainless steel is 90% helium, 7.5% argon, 2.5% carbon dioxide.

The primary advantage of MIG welding is that it allows the metal to be welded much more quickly than traditional “stick welding” techniques. MIG welding method produces long, continuous welds much faster and can be used on thicker stainless steel in applications where long weld lines are needed. Because the shielding gas protects the welding arc, this type of welding produces a clean weld with very little splatter.

Resistance Welding
Resistance welding is the welding process for spot and seam welding. When electrical current sent through an electrode comes into contact with the metal, both resistance heat and a nugget are produced. The end result is a metal joint. Though it requires substantial amounts of current from its power source, it uses low voltage to operate.

In manufacturing, compared to other methods of welding, resistance welding can be much more efficient as it only requires pressing a button to perform the process. Particularly with regard to stainless steel, heating time and heat concentration are less, and thus affects less of an area being worked on. For manufacturers, the process can be mechanized and automated and does not require long hours of pre-service training for welders. The result is not only aesthetically pleasing but high productivity and low cost, creating fewer fumes and a healthier working environment, which overall is more cost-effective for manufacturers.

Unsure of which method would suit your specific needs? Feel free to contact us today, our knowledgeable and friendly staff are here to help!