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Custom Metal and Glass – Design, Fabrication and Installation
 
“Casting is a process by which metal is poured into a mold
and therefore takes on the shape of the mold.”
Metalworking
Metalworking Process Components Get a Project Evaluation
Metalworking involves several different phases or processes. They include:
Marking Out
Casting
Forming
Cutting
Joining

Below, we’ll look at each of these processes in detail.

Marking Out
Marking out, which is sometimes also referred to as layout, is the process of taking an engineer’s design plan to the shop and preparing the project for manufacture.

Casting
Casting is a process by which metal is poured into a mold and therefore takes on the shape of the mold. There are several different types of casting used in different projects and processes. The various types of casting are:
Investment casting
Centrifugal casting
Die casting
Sand casting
Shell casting
Spin casting

Forming
Forming is a process by which the shape of a metal piece is changed without dissolving or taking away from the actual metal used in the piece. A combination of heat and mechanical forces are used to achieve results in forming.

There are different types of forming. They are:
Bulk forming
Sheet forming

Bulk forming requires heat, which softens the metal and makes it more receptive to mechanical force. Once the piece is heated up, mechanical processes are then used to re-form the piece.

Sheet forming does not use heat and rather uses mechanical force to re-shape the piece while it is at room temperature.

Cutting
Cutting is, to put it simply, the process by which the shape or size of metal is changed by making incisions in the metal and removing particular pieces from it. Cutting results in two pieces of metal - one that will be discarded or repurposed, and one that is part of the finished product.

There are different types of cutting processes, including:
Machining: a process that produces chips
Burning: a process through which an oxidized kerf is used to cut metal

Drilling a hole into a piece of metal would be considered machining, or a chip-producing process. Utilizing a torch in order to burn through material and separate it would be an example of burning.

Joining
Joining is the process by which metal is brought together. Welding is a particularly prevalent approach in joining. Welding uses heat to coalesce two metals together using heat. Sources of heat for welding range depending on the project. Some common heat sources for welding are:
Friction
Ultrasound
Electron beam
Laser
Electric Arc
Gas Flame

Brazing and soldering are also methods for joining. In brazing, a filler metal is heated up to melting point and is then drawn into a capillary i the metal piece. The filler metal solidifies in the capillary creating a joint. Soldering is a similar process, however it is completed at a lower temperature than brazing.

Finally, riveting is an ancient process for joining that is still used today. Riveting involves the use of a two-headed and unthreaded bolt, which joins two pieces of metal together. In order for this system to work, a hole must b drilled or punched into the metal prior to installation. Permanent links are created by forming dies or utilizing hammers.
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