Sheet Metal Components

Introducing the Utility of Sheet Metal Components

Sheet Metal Components
 

Components designed from thin and flat sheets to satisfy particular functional and designed specifications are known as sheet metal components. These components show strength, durability, and adaptability in various industrial applications. Some common applications are aerospace fuselages, automotive body panels, electronic enclosures, industrial machinery parts, and building components. 
 

Types of Sheet Metal
 

• Steel

Steel sheets are available in three types: carbon steel which is strong and cost-effective, widely used in construction, automotive, and machinery. Stainless steel is widely used in kitchen equipment, medical devices, and the food processing industry which is resistant to corrosion and staining. Galvanized steel for outdoor applications and construction and it is coated with a zinc layer. 

• Aluminum

Aluminum sheet metal components are lightweight and corrosion-resistant as compared to steel components. It is commonly used in aerospace, automotive, and packaging industries. It is used in combining forms in alloys for strength, ductility, and corrosion resistance. 

• Copper

Copper is used in many electrical components, roofing, and plumbing due to its best thermal and electrical conductivity. Compared to aluminum, it has higher electrical and thermal conductivity and is more expensive. 

• Brass

Brass is an alloy of copper and zinc which is durable, strong, long-lasting, and corrosion resistant. According to the requirements of different applications, a change in the ratio of copper and zinc alters the mechanical, corrosion, and thermal properties. It’s used in musical instruments, decorative items, and plumbing fittings. 

• Galvanized Steel

Galvanized steel is produced by coating steel with zinc through hot dipping to make it more corrosion-resistant. Galvanized steel is used to produce automobile bodies, water pipes, and construction elements like fences, roofs, and staircases.  

• Titanium

Titanium is used in aviation parts, medical equipment, and construction elements. It offers a high strength-to-weight ratio and corrosion resistance. It offers high recyclability, durability, and biocompatibility. 

• Nickel

Nickel sheet metal components are used in chemical processing, marine applications, and battery components. It can be used in harsh environments and corrosion resistant properties to handle harsh conditions. 
 

Manufacturing Processes
 

Cutting Methods
 

• Shearing force is used to cut straight lines on flat sheet metal. 

• Laser cutting works with complex designs to cut the street precisely. 
• Plasma cutting uses ionized gas to cut thick sheets. 
• High-pressure water jet cutting with abrasives to cut through thick materials without distorting the heat. 
• It uses the punching method and dies to create holes.
   

Forming Processes

• Bending uses two techniques: press braking and roll bending for deforming sheet metal in a straight axis. 
• Pressing a die to form or cut shapes with the stamping process for coining, flanging, embossing, and blanking.
• Deep drawing techniques create deep hollow shapes by drawing sheet metal into a die. 
• Spinning for symmetrical pieces to revolve and force sheet metal up against a mold. 
• Roll forming is the process of continuously bending a strip of sheet metal through rolls to create long, uniform pieces. 

Joining 

• Welding is of different types spot, TIG, and MIG for melting and fusing components. 
• Riveting is used in construction and aircraft to join pieces with distorted rivets. 
• Adhesive bonding is used to provide a clean look if welding is not possible. 

Finishing Process

• Applying a protective or ornamental layer which includes powder coating and electroplating known as painting and coating.  
• The process of removing burrs and sharp edges is known as deburring to improve look and safety. 
• Surfaces can be made more appealing by polishing. 

Special Processes

• The hydroforming process forms the metal into complicated shapes using a high-pressure hydraulic fluid. 
• For exact components, electroforming uses electroplating to deposit metal onto a mold. 

Applications of sheet metal components
 

• Automotive Industry

Body Panels, Chassis, Exhaust Systems, Fuel Tanks, and Engine Components.

• Aerospace 

Fuselage, Wings and Empennage, Interior Components, Engine Cowling, Fuel, and Hydraulic Tanks

• Construction Industry

Roofing and Siding, HVAC Systems, Architectural Elements, Structural Components, Gutters and Downspouts.

• Electronics and Electrical Industry

Enclosures, Chassis, Heat Sinks, Electrical Cabinets, Connectors and Terminals.

• Consumer Goods

Appliances, Furniture, Lighting Fixtures, Kitchenware, Toys, and Sporting Goods.

• Medical 

Surgical Instruments, Medical Equipment, Implants, Sterilization Trays, Hospital Furniture.

• Industrial Machinery

Machine Frames, Conveyor Systems, Pumps and Valves, Tooling, and Protective Guards.

• Agriculture

Tractors and Implements, Storage Silos, Irrigation Systems, Livestock Equipment.

• Transportation

Railway Cars, Shipping Containers, Bicycles, Boats and Ships.

Advantages 
 

• Malleable

Sheets are easy to mold and form as desired requirements. Sheet metal components are very popular for use in various applications due to their malleability nature. 

• Durable

Sheet metal components are more durable for holding high-pressure levels. It can resist corrosion and degradation from sun, water, and moisture in all types of environments. 

• Lightweight

Sheet metal components are low-weight. It allows one to reduce weight as it allows to improve fuel efficiency and overall performance in the aerospace and automotive industry. 

• Versatility 

Sheet metal shows a versatile nature as it is easily cut, bent, and shaped into complex forms. It allows design and creation according to customized preferences. 

• Cost-Effective

Sheet metals are generally less expensive than solid blocks. It reduces labor costs and increases the production rates. It’s a cost-effective solution for many industrial applications.

Quality Control and Testing
 

1. Do the material Inspection with visual inspection, chemical analysis, and mechanical property testing. 
2. Dimensional Inspection with calipers and micrometers, coordinate measuring machines, and gauge inspection to check tolerance and fit. 
3. Surface Finish Inspection with roughness testers and coating thickness gauges to ensure it meets the required finish.
4. Inspection of welding by visual and non-destructive testing techniques to detect internal defects without any damage to components. 
5. Flatness and Form Inspection with flatness gauges and form gauges for free from wrapping, accuracy of bending, and curves.