Longsheng

• Gleichstrom-Positivverbindung (DCRP), Bogenspannung 10-15 V, Strom 50-150A.
• The argon flow rate is 15-25L/min and the tungsten electrode diameter is 2.4-4mm (adjusted for plate thickness).

Operational skills:

• High frequency or pulse arc ignition is used to reduce tungsten electrode pollution.
• Welding speed is controlled at 8-15m/min and crescent-shaped strip is used.

Laser welding is suitable for ultra-thin plates (0.1-3mm) or multilayer lap welding.

• Power 5-20kW, scanning speed 5-50mm/s, focal length workpiece surface 2-5mm.
• Protective gas: Ar gas (velocity 30-50L/min).
• Strengths: Length to width ratio (up to 10:1), suitable for welding complex shapes.

Spot Welding is suitable for lap joints.

• Welding current 2000-5000A, electrode pressure 50-200N, current time 0.1-1sec.
• Aluminum plates require copper plating (CrNi coating) to improve conductivity and prevent electrode adhesion.

3.Critical process control

Anti oxidation measures:

• Real-time air supply protection (tail length ≥1.5 fold weld length).
• Cover the welded area with an insulation blanket (such as ceramic fiber cloth) to reduce heat loss.

Thermal input management:

• Thick plates (greater than4mm) are welded in multiple layers with a 20% to 30 per cent reduction in current per layer.
• The thermal stress is dispersed by jump welding (spaced 30-50mm).

Deformation correction:

• After welding, use hydraulic press or vibration aging equipment to eliminate residual stress.
• Thin plates can be rigidly supported and partially cooled (such as copper pipes jets).

4.Post-welding treatment

Surface cleaning:

• Use a stainless steel brush to gently remove surface slag to avoid damaging the substrate.
• For more demanding occasions, acid pickling and polishing can be used.

Quality Inspection:

• Visual inspection of welds uniformity, non-crack and porosity.
• Radiographic testing (RT) or ultrasonic testing for internal defects.

5.Solutions to Frequently Asked Questions

How to balance strength and cost through a sheet metal gauge chart?

In sheet metal fabrication, the key to balance strength and cost through sheet metal gauge chart is scientific selection and process optimization:

1.Understand the relationship between sheet thickness and performance

The thickness of the sheet corresponds to the actual thickness (mm/inch) corresponding to the United States Standard No. (gauge), for example:

• 16 Gauge →≈ 1.588mm (high strength, suitable for load-bearing structures).
• 22 Gauge →≈ 0.711mm (lightweight, suitable for load bearing shells).
• JS company Technology: Thickness should be selected according to material type (e.g. stainless steel 304/316, aluminium 6061). For example, during bending, thin plates (<0.5mm) are prone to cracking and need to be compensated by prepressing or adjusting the bending radius.

2.Cost optimization strategy

• Accurate design of material thickness: The load distribution is calculated by finite element method to eliminate redundant thickness. z.B. JS company conducted a FEA simulation of the stainless steel drum of a washing machine for a household appliance enterprise. Reduction in thickness to 1.0mm and switch to cold-rolled steel cost reduction reducing costs by 25%.
• Alternative material applications: Aluminum alloy (e.g. 6063) is used instead of stainless steel for non-load-bearing components with 30% weight reduction, 20% cost reduction, and surface corrosion resistance improved by anodizing process.

3.Strength and cost balancing strategy

• Structural reinforcement design: Add local lifting structure to 1.0mm thin plate,increase bending stiffness by  more than 3 times and reduce material redundancy.
• Composite Structure Application: Lightweight composite structures is achieved by multi-plate welding/riveting to reduce total weight while maintaining strength.
• Optimization of bending parameters: Practical application shows that when the bending radius is greater than or equal to the thickness of the plate, the rebound and cracking risk of the plate can be reduced significantly. Taking 2mm aluminum plate as an example, using R2mm mould can guarantee edge quality of mould and reduce tool wear.

What factors should be considered when choosing suitable sheet metal fabricators?

1.Technical and process capabilities: Ensure mastery of required processing techniques (e.g. laser cutting, CNC bending, welding, surface treatment, etc.) and meet accuracy and complexity requirements.

2.Equipment and material quality: Check the sophistication of equipment (e.g. CNC bending machine, automated production line, etc.) and reliability of material sources (e.g. plate thickness tolerance, surface treatment standards, etc.).

3.Quality certification and standards: Confirmation of ISO, IATF certification and compliance with industry standards (e.g. special standards in the automotive and aviation fields).

4.Production size and delivery time: Assess production capacity to meet order quantity and ensure timely delivery, especially for emergency projects requiring flexible response capabilities.

5.Cost transparency: Compare offers to avoid hidden costs by including the full process costs (e.g. design, processing and reprocessing).

6.After-sales service and support: Understand technical support response speed, warranty policy and problem solving ability.

7.Environmental protection and safety compliance: Priority should be given to production enterprises that are waste recycling, comply with emission standards and comply with safe production standards.

8.Industry reputation and case studies: Reference past customer evaluations and success stories to verify actual delivery capabilities and technical stability.

When choosing a sheet metal fabricators, a comprehensive evaluation of its technical ability, quality control, industry experience and cost-effectiveness is required. As an industry-leading sheet metal processing service service provider advanced equipment, digital process optimization process optimization green manufacturing concept, JS Company provides high precision aluminum and galvanized sheet metal processing services to more than 2000 customers worldwide.

Summary

Sheet metal fabrication, as the core of modern industrial manufacturing, has always been an important force for product innovation and industrial upgrading. The company relies on the full chain service capabilities, from precision sheet metal bending processing to intelligent laser cutting system, from lightweight aluminum plates to steel plates, in the durability of continuous breakthroughs. We combine material characteristics with process optimization depth.

In sheet metal processing, not only the ultimate optimization of material properties, but also the perfect balance of cost control and large-scale production. With the penetration of intelligent manufacturing technologies, emerging technologies such as laser cutting, automatic bending, and 3D printing are reshaping the industry ecosystem, pushing sheet metal parts in a lighter, stronger, and smarter direction.

Disclaimer

The content of this page is for informational purposes only.JS SeriesNo representations or warranties of any kind, express or implied, are made as to the accuracy, completeness or validity of the information. It should not be inferred that the performance parameters, geometric tolerances, specific design features,material quality and type or workmanship that the third-party supplier or manufacturer will provide through the jusheng network. This is the responsibility of the buyerAsk for a quote for partsto determine the specific requirements for these parts.please Contact us Learn more information.

JS Team

JS is an industry-leading companyFocus on custom manufacturing solutions. With over 20 years of experience serving more than 5,000 customers,we focus on high precisionCNC machining,Sheet metal fabrication,3D printing,Injection molding,metal stamping,and other one-stop manufacturing services.
Our factory is equipped with more than 100 state-of-the-art 5-axis machining centers and is ISO 9001:2015 certified. We provide fast, efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world. Whether it's low-volume production or mass customization, we can meet your needs with the fastest delivery within 24 hours. chooseJS TechnologyIt means choosing efficiency, quality and professionalism.
To learn more, please visit our website:jsrpm.com

FAQs

1.Can sheet metal processing manufacture parts with complex structures?

Using laser cutting and CNC bending technology to manufacture complex structural parts, its high-precision cutting and multi-angle bending ability can be combined with welding technology to achieve complex geometry from small gap to large size.

2.Will thicker boards be stronger?

Increasing the thickness of the plate can improve the compressive and bending strength of the plate, but the plate is too thick (such as >10mm) and requires special processing (e.g. hot forming or hydraulic press) due to its stiffness, which makes it difficult to bend and prone to cracking.

3.Is aluminum alloy suitable for casting or sheet metal fabrication?

Both are acceptable. Casting is suitable for complex internal structure and mass production, with low cost and precision. Sheet metal processing is suitable for high precision curved surface or small batch customization, through laser cutting and bending to achieve lightweight and high strength.

4.How environmentally friendly is sheet metal processing?

Sheet metal processing can greatly reduce energy consumption and pollution through waste recycling (over 90% metal utilization), environmental protection processes (such as water-based spraying, powder metallurgy), and energy-efficient equipment 50% energy savings fromfiber laser cutting).

Resources

Metal fabrication

Sheet metal

Electric resistance welding