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Steel Fabrication and its general application

Steel Fabrication and its general application

Steel fabrication is a process that is used to develop various components and products that we use in our  day-to-day life. It’s a process of transforming raw steel into a product or an item that can be used in construction projects. This process involves taking raw materials and shaping them to the  required form.

In this method, the raw materials are melted down and processed into finished steel product before being created into shapes. The steel fabrication process requires highly-skilled workers with experience in transforming raw components into marketable items.

The use of steel fabrication depends on the end-use of the product being fabricated. However, steel fabrication falls into three main categories-

  1. Commercial Fabrication: This fabrication process develops commercial products that are used by consumers. Appliances and cars, steel parts are the best examples of commercial fabrication.
  2. Industrial Fabrication: Industrial fabrication designs pieces that are used in developing other equipment. Bandsaws and ironworking machines are the best examples of industrial fabrication.
  3. Structural Fabrication: Structural fabrication refers to metalworking which is used as a part of the building process. Usually, structural fabricated steels are used in shops, manufacturers, buildings and skyscrapers.

PROCESS OF STEEL FABRICATION

Corrosion resistance, strength and durability are some of the principal characteristics of steel. The primary methods of fabricating steel include cutting, folding, welding, machining, shearing, punching, stamping and casting. Here is a brief overview of how each of these processes work:

  • Cutting- It is the most commonly used steel fabrication process that involves splitting the metal sheet into halves, thirds or smaller sections. Mostly, the sheets or bars are being cut and recreated into other desired shapes. They are cut using lasers and plasma torches that make the end product a more elaborate and high-tech piece.
  • Folding- Folding is one of the most complicated processes that involve the manipulation of steel into shapes of a certain angle. In this process, the metal surfaces are being folded at a 90-degree angle or other degrees to make the product more or less blunt.
  • Welding- This process involves the joining of two separate metal parts. The parts used in this process include sheet, panels, bars or any other shaped steel. They are joined together through numerous methods and machines that result in finished usable products.
  • Machining- Machining is a process of removing portions from a piece of metal. The process is usually performed on a lathe, which rotates the metal against tools that trim the corners and edges to cut the piece to the desired shape.
  • Punching- Punching is the process of forming a hole in a metal piece, where metal is placed under a die and punched through by a drill. In most cases, the holes are drilled into a panel of metal to fasten the latches or other foreign parts. In other applications — also known as blanking — the area with the hole is precisely extracted from the larger panel to form a bit smaller part.
  • Shearing- Shearing is a steel fabricating process that is used to cut straight lines on the flat steel sheet. During this process, a top blade and a bottom blade are driven past each other with the little space between them. Usually, one of the blades remains fixed. Steel shearing can be performed on a sheet, strip, bar, plate, and even angle metal stock.
  • Stamping- It is a fabrication process used to transform flat steel sheets into particular shapes. It is a complicated process that can incorporate several metal forming techniques like blanking, punching, bending and piercing.

    Stamping is similar to carving. A primary example of metal stamping is seen on coins, where words, currency, amounts etc. are stamped on each side of it.
  • Casting- Casting is a process in which hot liquid metal is poured into a mould that holds a hollow cut out of the desired shape. The liquid metal is then left to solidify, which is removed from the mould, revealing the end product, or the “Casting Form.” As one of the most flexible methods of metal fabrication, casting is ideal for a wide range of complex shape-making. The most common examples are jewellery, sculptures, weapons etc.

From paperclips to plane parts, steel is used to create a wide variety of products. It comes in several distinct grades and holds unique chemical compositions. At Sunflag Steel, we provide you with the best quality steel that is durable and sturdy in the long run.

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Concrete Rebar Reinforcement – When is it necessary

Concrete Rebar Reinforcement – When is it necessary

By adding rebar reinforcement to the concrete surface, you can easily make the surface much more robust and resistant to cracks. Concrete surfaces that often carry heavy trucks or machinery do not need concrete rebar reinforcement; however, they are required to withstand tension forces.

With the help of rebar reinforcement, the tensile strength of concrete can be increased. Since the concrete is fragile in tension but strong in compression, this process can increase the tensile strength while helping it resist cracking and breaking. With greater tensile strength, concrete becomes resistant to breakage even after putting pressure on it. Rebar helps prevent cracks from growing wider primarily by preventing cracked slabs from moving apart.

Concrete is a solid and durable material that performs exceptionally well during compressive forces, such as heavy vehicle concrete drive-through or road. But even if it is self-sufficient when it comes to strength, with the rebarring process, it becomes even more robust and weight-resistant. Concrete also sometimes needs support against expansion and contraction forces that occur naturally with changes in temperature. Underneath a beautiful-looking concrete surface, you’ll always find a well-engineered rebar structure that gives the concrete slab, wall, or even curb a beautiful structure and much-needed strength and stability.

WHAT IS REBAR?

Rebar is also known as Reinforcing bar, Reinforcing Steel, etc. In this process, a group of steel bars or a mesh of steel wires is formed to create tension in reinforced concrete and masonry structures. Through this process, the rebar helps build strength and compression by holding the material in a compressed state.

The bars are made of multiple hot-rolled steel materials. Most are made of new steel billets, but the materials are often derived from steel debris or sometimes old railroad tracks. You can find the engraved symbols that indicate where it was produced. You can also find the yield strength on the surface, with can be around 60-75, or metric 420 or 520.

DO YOU NEED CONCRETE REBAR REINFORCEMENT?

Not all construction projects require concrete rebar reinforcement; however, if you use the rebar reinforcement, it will immensely change the strength of the area. There will be comparatively fewer cracks that appear on the concrete over time. As mentioned earlier, the concrete surface requires to uphold large vehicles, non-stop traffics, which is why they need rebar reinforcement. On the other hand, if your driveway is only expected to uphold the family minivan or a few cars, you might not need rebar reinforcement.

You can also try other options for your household facility, like welded wire mesh made into galvanized panels. They are a perfect solution for residential driveways that are not used daily or driven on by heavy trucks.

We’ll be more than happy to assist you in finding the best material for your usage. Connect with us anytime if you have questions regarding concrete rebar reinforcement or anything else.

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Superalloys – Facts you must know

Supperalloy

To match the demands of the vast growing industries, high-performance materials are needed for the highest efficiency. Ordinary steels and alloys are incapable of that higher performance. That’s where the complex and high-performance alloys come into the scenario. They have a high tolerance to oxidizing environments and high temperatures. Those are named superalloys

These superalloys are mainly classified according to their predominant matrix elements which are nickel, cobalt, or iron. They also contain multiple alloying elements including the refractory metals (Nb, Mo, W, Ta), Chromium, and Titanium. Especially at high temperatures, they exhibit high mechanical strength, creep resistance, and corrosion resistance. For these properties, they become more challenging to produce and costlier than other alloys. But they are very critical for components in the aerospace industries

SOME PROPERTIES OF SUPERALLOYS –

As superalloys are used for high-temperature applications,they need to maintain their shapes at elevated temperatures close to their melting points (above 650ᵒC or 1200ᵒF). At extreme temperatures, being alloyed with certain elements, superalloys can maintain high strength, stability, and corrosion and oxidation resistance.

EXAMPLES OF SUPERALLOYS –

By alloying the matrix element (Ni, Co, or Fe) with various other elements such as Chromium (Cr), Titanium (Ti), Aluminum (Al), and Boron (B), the high-temperature properties of superalloys are produced. In some cases, some refractory metals are also added, such as Molybdenum (Mo), Cobalt (Co), Niobium (Nb), and Zirconium (Zr) amongst others

PROCESSING OF SUPERALLOYS –

Generally, Superalloys are processed by two separate methods which are Casting and Powder Metallurgy.

Investment Casting

Wax models or replicas are used to create a casing for the molten metals and are mainly
used for complex shapes. To improve upon the formerly prevalent cold-rolling
techniques, it was the first method.

Vacuum Induction Melting (VIM)

Using electric currents, raw metallic materials are melted within a vacuum. As the
control over chemical composition is greater in this method, this is also called an
improvement upon investment casting.

Secondary Melting

After the VIM process, an additional melting process is applied to increase the
homogeneity. It reduces problems associated with the initial process.

Conversion

To make the superalloy ingots produced by secondary melting suitable for mechanical
applications, this process is involved. It consists of several stages of thermal deformation.

Direct Solidification

By the presence of a thermal gradient, the alloy is allowed to nucleate on a lowtemperature surface. Greater creep resistance along the grain direction is produced.

Single Crystal Growth

A monocrystalline superalloy component is slowly grown from a seed crystal.

Powder Metallurgy (P/M)

For producing alloys used in critical fatigue applications a group of processes is
completed. Superalloys are formed from a mixture of metal powders. Chemical pressures
are applied to bond these metal powders into parts.

Powder Metallurgy (P/M)

For producing alloys used in critical fatigue applications a group of processes is
completed. Superalloys are formed from a mixture of metal powders. Chemical pressures
are applied to bond these metal powders into parts.

Applications of Superalloys

Superalloy applications mainly consist of aircraft components, petrochemical equipments,
automobile equipments, chemical plant, and power plant equipments.

Future Trends of Superalloys

The future scopes in this field include decreasing the high cost of producing unique and complex
parts, and the synthesis of nanoparticles.

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Wire Mesh vs Rebar

Wire Mesh vs Rebar

Often projects involve the usage of concrete to create long-lasting construction results. Whether you are building walls, roads or other structures like bridges, pathways etc., you can consider using Rebar or Wire Mesh under your concrete structure. Using any of these supporters provides significant reinforcement and has a long-lasting effect. But before using that, it is quite necessary to understand the difference between Wire Mesh and Rebar. So let’s take a look at how these methods are a robust option to make your concrete projects durable.

WHAT IS WIRE MESH?

Wire Mesh, also known as wire cloth or wire fabric, is a highly versatile product that can be used in countless applications. Depending upon the manufacturing capabilities, wire mesh can be made with an endless combination of opening sizes and diameter wires, which is either woven or welded as per the requirements. They are woven metal fabric created in varying degrees of coarseness, weight, and aperture.

When using Wire Mesh for concrete, it gives a significant advantage that allows a certain amount of shaping of concrete which is not possible with Rebar. Wire mesh comes in various materials such as plain steel, galvanized, or stainless steel products that are resistant to corrosion, which is why it is convenient to use.

WHAT IS REBAR?

Rebar is a structured steel bar that is primarily used in concrete construction. With the help of these reinforcing steel bars, the reinforced concrete surface is prepared. They are often used on floor slabs, walls or posts. It helps keep cracks that protect the surface from falling apart. It also provides structural strength to the structure. When opting for Rebar, various grades and sizes of steel for whatever strength level are required.

HOW IS WIRE MESH AND REBAR MADE?

To make Wire Mesh, metal wires are woven on industrial weaving looms. They are made as per a precise specification, leaving either square or rectangular gaps between the wires. The wire mesh is created by weaving metal on automatic rapier-style looms that give precise control over the number of wires used to make the finished mesh. This closely regulates the approach that is required to maintain consistency in both aperture size and mesh thickness.

To make Rebar, steel (carbon or alloy) is melted down to liquid form. Once melted, the liquid steel is pulled through small round openings to create a rebar structure. While unfinished steel is the cheapest form of Rebar; however, sometimes epoxy-coated or stainless steel is also used. Epoxy-coated rebars are expensive as compared to other material rebar. After the steel has been properly shaped, it is twisted and grooved on the metal to ensure the stability of the structure. Their ends are protected with plastic caps to prevent accidental harm to workers. During construction, the rebars are bent through hydraulic benders and cutter on the basis of the requirements and sizes.

WHERE ARE WIRE MESH AND REBAR USED?

Wire mesh and Rebar are commonly used for a myriad of industrial uses. Wire mesh is widely used in industrial filtration, sieving, shielding, sorting, sifting, screening and separation procedures. Woven mesh is a highly flexible and malleable material. It can be shaped to suit precise requirements and edged to fit any structure. Wire Mesh is often used in industrial applications when separation and filtration is required. It is used in commercial applications like insect screening or animal fencing. They also provide various type of security, like in window machines, stairwell panel guards, fireplace screens, ventilation, RFI shielding, etc.

On the other hand, Rebar is used to provide resistance to support design loads. They are used for durability and aesthetic purposes, as well. They are commonly used in floor slabs, stairs, and roof construction. A heavier fabrication of welded wire fabric can be used in walls and structural floor slabs. This is commonly used in road pavement, box culverts, drainage structures, and small concrete canals.

Sunflag Steel offers a wide range of wire mesh and rebar products designed to cater to standard industrial processes and regular work. We can develop custom solutions to meet your unique requirements, as well. Please connect to us anytime for the perfect products for your needs.

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Received the prestigious NEI Supplier Award at the NEI Supplier Conference in Jaipur

Sunflag Steel has been honored with the ‘Best in Class for Raw Material Quality & Delivery’ award at the NEI Supplier Conference. This esteemed event, held in Jaipur on March 22, 2024, brought together leading industry suppliers to celebrate outstanding achievements and innovation.

Receiving this accolade is a testament to our unwavering commitment to excellence in raw material quality and timely delivery. It highlights our dedication to maintaining the highest standards and consistently delivering superior products to our valued clients.

This achievement would not have been possible without the hard work and dedication of our incredible team. Their relentless pursuit of quality and efficiency has been instrumental in earning this recognition. We extend our heartfelt thanks to each member of the Sunflag Steel family for their invaluable contributions.

As we celebrate this milestone, we remain committed to upholding our standards of excellence and continuing to drive innovation in the steel industry. Thank you to NEI for this honor, and to our clients and partners for their ongoing support.