At Metalwest, our goal is always to provide you with the processed metal you need for your products. Last month we talked about the many methods companies use to finish processed metal. This month we’re back to talk about more.

Plasma Cutting

Plasma cutting is the process of using an electrically-conductive channel of plasma to cut through molten metal. The plasma is created by firing a highly-concentrated stream of gas through a nozzle with a plasma cutter. As the stream is directed at the metal, an electric arc is formed between it and an electrode within the machine. This arc ionizes the gas, forming superheated plasma. 

Plasma cutting, which we perform at our Cd’A Metals and Norfolk Iron & Metal facilities, is one of the most highly efficient ways to finish processed metal. Plasma cutting can cut through thick metal plate and becomes more cost-effective every year. It creates clean cuts and can also be used to erase evidence of metal-melting fusions.

Polishing

Processed metal is not complete until it has been polished. Polishing sets any metal product’s appearance apart and improves its sanitation qualities. This is vital if your product is destined for the food processing or service industries. At Metalwest, we perform all of our polishing in-house and offer a wide range of finishes for our customers.

To finish processed metal by polishing involves buffing away irregularities on the metal’s surface. To do so, polishing lines use abrasives attached to a flexible backing to reach every surface of the metal product. The grit of these abrasives determines their role. 

Low-grit abrasives (those in the 60 or 80 ballpark) smooth out nicks or grooves in the surface, while high-grit abrasives (with values closer to 120 or 180) create a beautiful sheen. At Metalwest, we provide No. 3, No. 4, No. 4 Fine, No. 6, and No. 8 finishes in addition to other specialty finishes specific to your product.

Press Brake

A press brake is a piece of machinery designed to bend sheet metal. It is usually long and narrow to accommodate large pieces of metal. The material is pressed between a punch and a die, and the applied pressure is used, sometimes percussively, to shape the metal into specified configurations. 

The specifics of press brake machinery vary depending on the application. Press brakes can be mechanical, electric, pneumatic, or hydraulic. They have varying speed settings. Press brakes are rated by their tonnage—the amount of force they can apply. It is common for tonnage to sit between 100 and 300 tons, though some press brakes go up to 3000 tons, measuring 50 feet long.

Hydraulic press brakes are known for providing the most power. However, electronic press brakes minimize operating costs and reduce the risk of leaks. They also take up less space while working more quickly and accurately. When you want to finish processed metal with a press brake, the settings matter, and our team at Norfolk Iron & Metal is very familiar with the force and power required.

Sawing

Sawing describes the use of a saw blade to cut larger pieces of metal into smaller and more manageable pieces. It is a common method used to finish processed metals such as stainless steel, brass, bronze, aluminum, titanium, nickel alloys, and copper, and it is employed across a wide range of industries. All of our facilities—Metalwest, Cd’A Metals, and Norfolk Iron & Metal—have sawing capabilities. 

There are two main kinds of sawing. Band saw cutting uses a long straight blade with metal teeth to saw back and forth through metal pieces. Because the teeth are slightly bent, the cut created by a band saw is slightly wider than the blade without risk of the blades getting pinched or stuck. Band saws make highly accurate and straight cuts.

Circular saws are the other common tool used in manufacturing settings. The process uses a circular saw blade which spins as it cuts. circular saws are rigid and highly stable, making them ideal for reducing vibration levels. This results in impressive precision and speed. 

Sawing is beneficial for high-volume applications. It cuts down on material waste because the tolerance cutting is impressively close. Without sacrificing cut quality, sawing has quick turnaround times and impressive finishes. Usually the need for further finishing is minimal.

Shearing

Shearing is a form of cutting metal that utilizes sharp cutting blades coming together. The metal does not need to be heated before it can be sheared. Working at room temperature to finish processed metal is common, but shearing can even be performed when the metal is cold. The process is a way to ensure that the metal is not burned or melted while cutting and that no chips are formed. 

Shearing is generally conducted in one of two ways. Bench shears are good for smaller applications. They are small and lightweight and can be mounted on a workbench, easy for one person to use. Using a power shear (or guillotine machine) is another option. These are powered by electricity or a hydraulics system and are generally more complicated to operate, but they are also usually faster and more effective in large-scale applications.

In both cases, the metal roll or sheet being cut is placed by a squaring arm, and a higher blade is brought down quickly to meet a lower blade. This results in clean, straight cuts with minimal waste. While shearing is often used to finish processed metals like bronze, brass, and aluminum, it doesn’t work as well for harder metals, and performing the process incorrectly can lead to damage and deformation of the metal. We have shearing functionality at our Metalwest and Norfolk Iron & Metal locations.

Have you ever wondered just how raw metals are formed into the products you see on a daily basis? How does a sheet of metal become a highly-tuned medical instrument or the engine of a car? The metal fabrication process is as varied as the applications it serves, but understanding even the basics helps us appreciate rewards that much more.

What Is Metal Fabrication

To fabricate metal is to build finished products from raw metal materials. Metal fabricators work with things like plate metal, formed and expanded metal, castings, fittings, flat metal, sectional metal, and welding wire and employ processes like cutting, bending, welding, forming, machining, and assembling to create tools and equipment. Metal fabrication is used in every kind of production industry, commercial, industrial, and structural. 

What are the Main Steps for Metal Fabrication?

The metal fabrication process has countless applications, and the exact steps reflect them. However, there are some consistencies across the board. 

Designing

Unsurprisingly, the first step of the metal fabrication process is to design what you want to create. These drawings must reflect the manufacturer’s intended measurements and capabilities. Nowadays, it is most common to create such drawings with computer aided design (CAD) software. 

This kind of software allows engineers to finely plan each metric and angle, accounting for the necessary complexities of what the product must be able to do. The 3D models can actually be tested within the software, allowing changes to be made without wasting any metal. When the designs are complete, they often can feed directly into welding machines and other fabrication equipment.

Fabrication

Fabrication is the general term for the forming of raw metal. This usually refers to metal plate, two inches thick or more, and processes such as cutting, folding, assembling, and finishing.

Cutting

Cutting reduces raw metal to the components ready to be shaped. There are many ways to cut metal, including mechanical shearing, water jet cutting, laser cutting, and plasma cutting. These range in levels of precision and utilize different tools, things like lathes, shears, mills, and nibblers. 

On the less precise end of the spectrum, mechanical shearing is great for cutting through very thick sheet metal and force is prioritized. On the other hand, laser and plasma cutting are highly attuned processes and make very precise cuts. If a project has an especially low tolerance for error, these cutting methods are likely the right fit. 

Other Reductive Methods

Cutting is not the only way to reduce metal to smaller pieces. The best method depends on what kind of result the fabricator is hoping to achieve:

• Shearing—Metal shearing uses blades installed at various angles to produce diagonal cuts, especially in bronze, brass, aluminum, or stainless steel. The blades create straight cuts but can be used in succession to produce a variety of shapes. Shearing is most commonly used on flat sheet metal. 
• Notching—Notching, also called nibbling, is similar to shearing though it allows for greater precision and detail, achieving angles that aren’t possible with standard shearing processes. The notching process usually requires multiple rounds to achieve the desired shape.
• Punching—Punching is used to create holes in rolled or sheet metal. It uses a metal punch situated above the metal and a die placed underneath it, pressing through the metal to produce a metal slug.
• Blanking—Blanking is similar to punching and used to create larger pieces of metal that are more likely to undergo more work. Blanking works best on sheet or strip metal.

Forming

Once metal has been cut, it is then formed into the desired shape. Forming may be the heart of the metal fabrication process. When working with metal that is roughly already in the right shape, forming may mean employing many different techniques, including stamping, bending, folding, punching holes, and machining. 

On the other hand, sometimes molten metal is poured into a mold and allowed to harden in the right shape. This process is referred to as casting. There are several different types of casting, including die casting which uses a die instead of a mold. Once the metal solidifies, it can be further shaped with drills, punches, or lathes.

Assembling

The assembling component of the metal fabrication process requires all the necessary pieces to be brought together and joined into one final product. Each piece must be fitted together correctly, usually held in place with clamps, and then permanently joined using a method appropriate to the product (i.e. screwing, riveting, bonding, or welding). Each of these methods has further variations, and the blueprints will determine which is best.

Finishing

Once the product is formed and joined into a complete unit, the finishing touches are applied. These depend heavily on how the product will be used and the conditions it will face out in the world. It is common for products to be rust-proofed, colored, or glazed, usually with paint or powder coating. Other finishing processes include heat treatments, deburring, plating, polishing, brushing, and shining.

Once fabricators and engineers determine that the finished product meets specifications exactly, other finishing touches like manufacturer-specific decals, logos, and serial numbers can be applied.

Installing

Installation of a finished product is sometimes included in the metal fabrication process. This allows the team responsible for fabrication to be on-the-spot to make adjustments and corrections as needed. It can be helpful to have the team familiar with the product (with the correct expertise and equipment) on-hand as installation occurs to avoid any snags in the process. 

Maintaining 

While maintenance, including necessary repair and routine service, are commonly performed by site-specific technicians, some manufacturers may feel it necessary to offer such services as part of the metal fabrication process.

Looking to the Future of Metal Fabrication

Metal fabrication is an integral part of almost every industry on the planet. It produces the pieces for aircraft or ground vehicles, both commercial and military. It gives us equipment for agricultural work and construction applications. It shapes medical equipment and scientific instrumentation. It is responsible for equipment like fracking tanks and pumps in addition to the components of alternative energy structures. From home appliances to car seats, metal fabrication plays a part. 

As a career path, working in metal fabrication is a pretty safe bet. With nearly unlimited applications that show no sign of fizzling out, if you have any interest in shaping metal, you too can be a part of the metal fabrication process.

At Metalwest, we strive to provide our customers with the highest quality metal products and services. In order to do so, we must maintain a working environment that is safe, efficient, and enjoyable. Our maintenance technicians are responsible for much of this effect. If you have interest in working with your hands or tinkering with industrial equipment, this position may be right for you.

The Job: What Does a Maintenance Technician Do?

The maintenance technician is a critical part of any industrial team. Such technicians monitor the regular upkeep and repair of the equipment and machinery that is integral to the metalwork we do. This begins at installation and includes troubleshooting equipment issues throughout its lifetime, utilizing diagnostic testing equipment and experience to restore proper functionality with expediency. The work also includes installing new or required parts according to the specifications listed in the blueprints or manuals and even dismantling equipment and machines once their usefulness has been expended.

Thorough maintenance technicians have experience with everything from hydraulic systems to minor electrical work. They inspect, maintain, lubricate, repair, and operate every aspect of industry equipment. Small parts, including pulleys, gears, motors, shafts, and bearings fall within their notice, as do hand- and powered tools such as saws and chainsaws, torch tables, and welders. Larger machinery such as forklifts, cranes, and other gas and diesel equipment are also within a technician’s scope.

In addition to the equipment and machinery on the premises, technicians are also responsible for the building and grounds of the facility, monitoring them for safety, cleanliness, and order. They are part of the maintenance staff and behave accordingly, also using our maintenance management software system to assist with work order creation, parts look up, and preventative maintenance scheduling and execution.

In the management of both grounds and equipment, it is vital that technicians adhere to all protocols, manuals, blueprints, and schematic drawings. Doing so ensures adherence to quality guidelines as well as safety regulations. Every member of staff is responsible for both his or her safety as well as the safety of those around them. In addition to performing their jobs properly and safely, technicians should keep an eye out for unsafe working conditions and staff practices. These should be reported to the appropriate supervisor, and the technician should make onsite corrections as possible.

Technicians inspect equipment, buildings, and systems for any issues, scheduling and conducting necessary repairs for faulty equipment or damaged structures. This does much to maintain the safety of the working environment. Technicians should also protect themselves and set a good example by utilizing all correct protective equipment and by remaining alert and aware.

The currently available maintenance technician position is based out of Durant, Iowa. The schedule follows a 4-day, 10-hour pattern, comprising the third shift (8pm–6am) from Monday to Thursday each week. Some schedule flexibility in order to assist with projects may be required.

Benefits

At Metalwest, we make sure our team members are well taken care of. We offer a complete new hire benefits package, including medical, life, vision, and dental insurance. We also pay 100% of our employees’ medical health care premium. Looking for a 401k with a company match? We’ve got you covered. We make paid time off available right away and recognize eight annual paid holidays. The hourly rate we offer ($22/hr) is competitive, and our employees have no shortage of opportunities for supplemental compensation:

• Annual merit increases
• Cross-training increases
• Monthly production bonus
• Perfect attendance incentives
• Generous employee referral program

Joining Metalwest is a great place to start really forming a career. Our employees have many growth opportunities within the company, including the availability of a variety of locations across the country. The technician position specifically allows employees to stay active in an environment that is moderately-paced. We also value your safety, providing both prescription safety wear and an annual safety shoe allowance.

What We’re Looking For

At Metalwest, we are committed to creating a team environment that works hard to create high-quality results. Our top qualifications, therefore, have to do with the character of new hire candidates. We are looking for an individual who is motivated and friendly, ready to be a valuable member of our team. Ideally, this candidate works well as a member of a group while still being a self-starter, able to perform the work necessary without any external nudging.

We are looking for someone who is detail-oriented. The work of a maintenance technician is nuanced, and in order to identify minute issues and correct them, the technician must have an eye for detail. Devotion to a task and the dedication to see it through with integrity is a must. 

In addition to the aforementioned character traits, familiarity and experience with the kind of work required is key. A year or more of industrial maintenance experience is required, and related computer skills and experience as an industrial electrician or with industrial equipment are highly desirable. Additionally, we prefer that the candidate have an associate degree or better in relevant fields such as Mechanical or Electronics Technology.

It is important that our new hire be physically and cognitively capable of performing the work required. The job requires physical dexterity, particularly in the fingers and hands, and often requires standing for extended periods of time. Good problem-solving skills are an invaluable resource in a technician’s work, as is a working knowledge of tools, machinery, and equipment. A valid driver’s license is required, but a COVID-19 vaccination is not.

To apply for Metalwest’s maintenance technician position, visit the job posting.

About Metalwest

Metalwest is an industry standard in the realms of metal fabrication and processing. Having recently joined the Norfolk Iron & Metal conglomerate, Metalwest continues to evolve to better serve its national clientele. From our eight locations across the United States, we provide high-quality non-ferrous and carbon flat-rolled metal products. These include sheet and coil materials that are hot or cold rolled, galvanized, or stainless. 

We know that our customers’ metal needs are diverse and extensive, so we also provide painting, polishing, and coating material services in addition to treatments such as blanking, slitting, shearing, leveling, and polishing. The Metalwest vision continues to grow, innovating and evolving to meet growing metal processing demands. If you want to be a part of that vision, apply for our maintenance technician position today.