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((Short description|Creation of metal structures))
((For multi|shaping metal|metalworking|other uses|fabricator (disambiguation)))
((More citations needed|date=May 2014))

[[Image:FANUC 6-axis welding robots.jpg|thumb|A set of six-axis [[robot welding|welding robots]]]]

'''Metal fabrication''' is the creation of [[metal]] structures by cutting, bending and assembling processes. It is a value-added<ref>((Cite web|url=https://service.asu.edu/blog/value-added-and-non-value-added-process-steps|title=Value-Added And Non-Value Added Process Steps &#124; Service at ASU|date=March 27, 2019|archive-url=https://web.archive.org/web/20190327090040/https://service.asu.edu/blog/value-added-and-non-value-added-process-steps |archive-date=2019-03-27 ))</ref> process involving the creation of machines, parts, and structures from various raw materials. 

Typically, a fabrication shop bids on a job, usually based on [[engineering drawing]]s, and if awarded the contract, builds the product. Large fab shops employ a multitude of value-added processes, including welding, cutting, forming and machining. 

As with other manufacturing processes, both human labor and [[automation]] are commonly used. A fabricated product may be called a ''fabrication'', and shops specializing in this type of work are called ''fab shops''. The end products of other common types of metalworking, such as [[machining]], [[metal stamping]], [[forging]], and [[casting]], may be similar in shape and function, but those processes are not classified as fabrication.

==Processes==
*''Cutting'' is done by [[saw]]ing,<ref>((cite web|url=https://www.rathboneprofiles.com/precision-cutoff.html|title=Precision Cutoff Services by Rathbone, Palmer, Massachusetts|website=www.rathboneprofiles.com|language=en|access-date=2018-08-28))</ref> [[shear (sheet metal)|shearing]], or [[Chisel|chiselling]] (all with [[hand tool|manual]] and [[power tool|powered]] variants); torching with handheld torches (such as [[oxy-fuel welding and cutting|oxy-fuel torches]] or [[plasma torch]]es); and via [[numerical control]] (CNC) cutters (using a [[laser]], [[Milling cutter|mill bits]], torch, or [[water jet cutter|water jet]]).<ref>((cite web| url=https://cnc3ds.com|title= Plasma cutting machines )) Sunday, 17 March 2019 </ref>
*''Bending'' is done by [[hammer]]ing (manual or powered) or via [[press brake]]s, [[tube bending|tube benders]] and similar tools.  Modern metal fabricators use press brakes to [[Coining (metalworking)|coin]] or air-bend metal sheet into form. CNC-controlled backgauges use hard stops to position cut parts to place bend lines in specific positions.
* ''Assembling'' (joining of pieces) is done by [[welding]], binding with [[adhesive]]s, [[rivet]]ing, [[screw|threaded fasteners]], or further bending in the form of crimped seams. [[Structural steel]] and [[sheet metal]] are the usual materials for fabrication; welding wire, flux and/or fasteners are used to join the cut pieces. 

Fabrication comprises or overlaps with various metalworking specialties:

* Fabrication shops and machine shops have overlapping capabilities, but fabrication shops generally concentrate on metal preparation and assembly (as described above). Machine shops cut metal, but focus primarily on the machining of parts on [[machine tool]]s. Some firms do both fab work and machining.
* [[Blacksmith]]ing has always involved fabrication, although that term has not always been used.
*[[Welder]]-produced products, often referred to as ''weldments'', are examples of fabrication.
* [[Boilermaker]]s originally specialized in fabricating [[boiler]]s, but the term is now used more broadly.
*[[Millwright]]s originally specialized in setting up grain mills and saw mills, but now perform a wide range of fabrication.
* [[Ironworker]]s, also known as [[steel erector]]s, also engage in fabrication. They often work with prefabricated segments, produced in fab shops, that are delivered to the site.

== Raw materials ==
Standard metal fabrication materials are:
*Plate metal
*Formed and [[expanded metal]]
**Tube stock
*Welding wire/welding rod
*[[Casting (metalworking)|Casting]]

==((anchor|Cutting)) <!-- [[Steel cutting]] redirects here-->Cutting and burning ==
A variety of tools are used to cut raw material. The most common cutting method is [[Shearing (metalworking)|shearing]].

Special [[band saw]]s for cutting metal have hardened blades and feed mechanisms for even cutting. Abrasive cut-off saws, also known as chop saws, are similar to [[Miter saw|miter saws]] but have a steel-cutting abrasive disks. [[Cutting torch]]es can cut large sections of steel with little effort.

Burn tables are CNC (computer-operated) cutting torches, usually powered by natural gas. Plasma and [[laser cutting]] tables, and [[water jet cutter]]s, are also common. Plate steel is loaded on the table and the parts are cut out as programmed. The support table consists of a grid of bars that can be replaced when worn. Higher-end burn tables may include CNC punch capability using a carousel of punches and taps. In [[fabrication of structural steel by plasma and laser cutting]], robots move the cutting head in three dimensions around the cut material.

== Forming ==
[[Forming (metalworking)|Forming]] converts flat sheet metal into 3-D parts<ref>((cite web|url=http://www.thefabricator.com/glossary/forming|title=Metal Fabricating Glossary-Forming|website=thefabricator.com|type=Definition|access-date=20 July 2017))</ref> by applying force without adding or removing material.<ref>((Cite book|title=Handbook of metal forming|last=Lange, Kurt|publisher=Society of Manufacturing Engineers|year=1995|isbn=0872634574|edition= 1st|location=Dearborn, Mich.|pages= 2.1|oclc=802867641))</ref> The force must be great enough to change the metal's initial shape. Forming can be controlled with tools such as punches and dies. Machinery can regulate force magnitude and direction. Machine-based forming can combine forming and welding to produce lengths of fabricated sheeting (e.g. linear grating for water drainage).<ref>((cite web|url=http://www.paigestainless.com.au/linear-surface-water-drainage/|title=Linear Surface Water Drainage|website=paigestainless.com.au|type=Photo Gallery|access-date=20 February 2016))</ref> Most metallic materials, being at least somewhat ductile and capable of considerable permanent deformation without cracking or breaking, lend themselves particularly well to these techniques.<ref>((Cite web |title=What is fabrication? Explain forming operations. |url=https://www.mechanicalsite.com/2022/07/fabrication-forming.html |access-date=2022-07-31 |website=www.mechanicalsite.com))</ref>

Proper design and use of tools with machinery creates a repeatable form that can be used to create products for many industries, including jewelry, aerospace, automotive, construction, civil and architectural.

== Machining == 
((main|Machining))

Machining is a specialized trade of removing material from a block of metal to make it a desired shape. Fab shops generally have some machining capability, using metal [[Lathe (metal)|lathes]], [[milling machine|mills]], [[drill]]s, and other portable machining tools. Most solid components, such as gears, bolts, screws and nuts, are machined.

== Welding ==
((main|Welding))
[[File:Workers Welding.png|thumb|Workers welding in parking garage]]
Welding is the main focus of steel fabrication.<ref>((Cite web |title=What is Steel Fabrication? |url=https://staraluminiumscaffolds.com.au/engineering-solutions/custom-solution/steel-fabrication/ |access-date=2021-11-12 |website=staraluminiumscaffolds.com.au))</ref> Formed and machined parts are assembled and tack-welded in place, then rechecked for accuracy. If multiple weldments have been ordered, a [[Fixture (tool)|fixture]] may be used to locate parts for welding. A welder then finishes the work according to engineering drawings (for detailed welding) or by their own experience and judgement (if no details are provided).

Special measures may be needed to prevent or correct [[wikt:warping|warping]] of weldments due to heat. These may include redesigning the piece to require less welding, employing staggered welding, using a stout fixture, covering the weldment in sand as it cools, and post-weld straightening.

Straightening of warped steel weldments is done with an [[Oxy-fuel welding and cutting|oxyacetylene torch]]. In this highly specialized work, heat is selectively applied to the steel in a slow, linear sweep, causing the steel to contract in the direction of the sweep as it cools. A highly skilled welder can remove significant warpage this way.

Steel weldments are occasionally [[Annealing (metallurgy)|annealed]] in a low-temperature oven to relieve [[residual stress]]es. Such weldments, particularly those for engine blocks, may be line-bored after heat treatment.

After the weldment has cooled, seams are usually ground clean, and the assembly can be [[sand blasting|sandblasted]], primed and painted. Any additional manufacturing is then performed, and the finished product is [[Quality (business)|inspected]] and shipped.

== Specialties ==

Many fabrication shops offer specialty processes, including :

*[[Casting]]
*[[Powder coating]]
*[[Powder metallurgy]]
*[[Welding]]
*[[Machining]]

== See also ==
*[[Contract manufacturer|Contract manufacturing]]
*[[Electrical discharge machining]]
*[[Form, fit and function]]
*[[Interchangeable parts]]
*[[Manufacturing engineering]]

==References==
((Reflist))

[[Category:Fabrication (metal)| ]]

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