Glossary of sheet metal fabrication techniques

A
Assembling
A process done by welding, binding with adhesives and bending in the form of a crimped seam.

B
Bending
A process done by hammering or via press brakes.

Blanking
A process in which a part is cut out of the sheet metal and the material around the part is discarded.

Brazing
A process in which two or more metals are joined together by melting and flowing a filler metal (an alloy) into the joint with the filler metal having a lower melting point than the adjoining metal; used to join dissimilar metals like aluminium, copper, gold, nickel, and silver.

C
Cutting
A process done by sawing, shearing, or chiselling with manual and power tools, or torching with hand-held plasma torches using computer numerical computer (CNC) cutters like lasers.

D
Deburring
A process used to remove potential liabilities, like burrs or sharp square edges, from blanking systems.

Die cutting
A process that cuts metal pieces without the formation of chips or the use of burning or melting; also known as shearing.

F
Fastening
A process using self-clinching tools like nuts, studs, spacers, access hardware, or cable tie mounts and hooks to provide torque resistance in applications where the sheet metal is too thin to be secured by other methods.

Finishing
A process in which a completed metal project’s surface is altered to achieve a certain property, which can include improved appearance, adhesion or wettability, solderability, corrosion resistance, tarnish chemical resistance, wear resistance, hardness, electrical conductivity, surface friction control, and blemish removal.

G
Galvanizing
A process of applying a protective zinc coating to steel or iron to prevent rusting.

Glazing
A process where two metals are slid against each other to create a shiny, wear-protective layer of oxide.

H
Hydroforming
A forming and fabricating process that uses a specialized type of die moulding which utilizes highly pressurized fluid to shape metals like steel, stainless steel, copper, aluminium, and brass.

M
Metal punching
A process in which metal fabrication equipment punches hole, louvres, or a predetermined shape out of sheet metal.

Metal inert gas welding (MIG)
An arc welding process in which a continuous solid wire electrode is fed through a welding gun and into the weld pool, joining the two base materials; also known as wire welding or gas metal arc welding (GMAW).

Milling
A process of using rotary cutters to remove material from a metal piece advancing in a direction at an angle with the axis of a tool.

Oxyacetylene welding
A process in which a tank of oxygen and acetylene are combined with an adjustable torch to result in a precise, controlled flame used to heat metal.

P
Plasma cutting
A process that cuts through electrically conductive materials, like aluminium, brass, copper, and steel, by means of an accelerated jet of hot plasma.

R
Roll forming
A constant bending process in which sheet metal, coil, bar, or strips of metal pass through rolls that form the metal.

S
Soldering
A process in which two or more metals are joined by melting and flowing a lead-free filler metal (solders) into the joint with the filler metal having a lower melting point than the adjoining metal at below 840 degrees Fahrenheit; used to join electrical components.

Stamping
A high production process in which single or multiple punches, bends and embossing are performed simultaneously or in a progressive die.

T
Tungsten inert gas welding (TIG)
A two-handed arc welding process that uses a non-consumable tungsten electrode to produce the weld.