Are you curious about what metals don’t rust? Whether you’re a DIY enthusiast, engineer, or architect, rust resistance is a hot topic in the world of metalwork. Especially in Britain’s famously unpredictable weather! Knowing which metals can stand up to rain, salt, and the test of time is key to building long-lasting, low-maintenance structures, gadgets, and artworks.

We’ve been working in the world of sheet metal fabricators for over 50 years now, so we know a thing or two about metal! From gleaming stainless steel to lightweight aluminium, the world offers a host of metals that shrug off rust and corrosion, each with unique advantages. In this guide, we’ll explain the difference between rust and corrosion, explore why certain metals hold up better than others, and showcase the top 10 rust-proof metals.

What causes metal to rust?

Rust is a specific form of corrosion and is a form of iron oxide. It is the enemy of iron and its alloys, like steel. The science is simple – when iron meets oxygen and moisture, a chemical reaction forms iron oxide, better known as rust. This familiar orange, brown layer is more than unsightly, it also expands as it forms. This puts stress on metal structures, making them brittle and exposing them to the risk of failure.

What makes rust especially challenging in the UK is our climate. We have plenty of rain, high humidity, and coastal salt, all of which accelerate rust formation. And if sulphur dioxide or carbon dioxide are present (in city air or industrial settings) the process is even quicker.

Rust is also permeable. That means even once the surface has rusted, water and air can keep seeping in, allowing the corrosion to fester deeper into the metal. For engineers, homeowners, and fabricators, preventing rust is all about careful material choice and protection.

The difference between rust and corrosion 

Although the terms are sometimes used interchangeably, there’s a crucial distinction between rust and corrosion. Corrosion is the broad term for the gradual destruction of metals due to chemical reactions. Any metal can corrode, though some do so much more readily than others.

Rust, on the other hand, is specific to iron and iron-based alloys. This can weaken anything iron from old garden gates to the Cliff Bridge. Other metals, like aluminium or copper, may tarnish or form their own oxides, but these layers are usually much more stable and protective, rather than destructive.

Top 10 metals that don’t rust

So, what metals don’t rust? Below, we reveal the top ten, detailing why they resist rust, where they’re used, and their key properties.

What makes these metals resistant to rust?

The main secret behind what metals don’t rust comes down to chemistry. Metals like stainless steel, aluminium, and titanium form a thin, invisible oxide layer that acts as a barrier. This protects the rest of the metal beneath from air and moisture.

For others, like copper and bronze, a natural patina forms on the surface. This is a green or brown coating that’s not only attractive, but also keeps out further corrosion. Meanwhile, metals like gold and platinum simply don’t react with air or water, making them impervious to rust.

Galvanised steel takes another route. By coating steel in zinc, it gets a protective shield. Even if scratched, the zinc corrodes first, sacrificing itself to protect the steel underneath. This process is known as ‘cathodic protection.’

When to choose rust resistant metals

The choice of what metals don’t rust should be guided by your project’s needs.

• Outdoor structures: Opt for stainless steel, aluminium, or bronze for railings, sculptures, or signage.
• Marine applications: Bronze and titanium excel in saltwater environments, while galvanised steel offers cost-effective protection for short-term uses.
• Medical and food use: Stainless steel and titanium are biocompatible and easy to sterilise.
• Aesthetic projects: Copper, brass, and bronze provide rich, lasting colours and patinas.
• Electronics: Gold and nickel are invaluable for reliable, rust-free connections.

5 metals that are prone to rust or corrosion

Now we’ve highlighted our top 10 list for what metals don’t rust, let’s take a quick look at some that are on the opposite side of the scale.

1. Iron: Pure iron rusts very quickly when exposed to air and water, forming iron oxide (rust). This is commonly found in structural beams, old pipes, and cast iron items.
2. Carbon steel: An alloy of iron and carbon with little or no protective alloying elements. This is widely used in construction and manufacturing, but will rust rapidly if not coated or protected.
3. Cast iron: Another iron and carbon alloy, even more brittle than steel, and highly susceptible to rusting if left unprotected. Used for manhole covers, old cookware, and some pipes.
4. Low alloy steel: This steel has only minor additions of other elements like manganese or nickel. This offers little corrosion resistance compared to stainless steel. This can be found in bridges, frames, and machinery parts.
5. Wrought iron: Malleable iron with a very low carbon content, historically used for gates and fences. Although it has some natural corrosion resistance compared to pure iron, it still rusts easily if exposed to the elements.

How to prevent rust

• Pick rust resistant metals: Opt for stainless steel, aluminium, titanium, and other metals from our top 10 list, especially for outdoor or marine applications.
• Apply protective coatings: Paint, powder coating, oil, or specialised sealants can prevent moisture from reaching metal surfaces.
• Use galvanised or plated finishes: Galvanising coats steel in zinc, while other metals can be nickel or chrome plated for extra protection.
• Keep metals clean and dry: Regular cleaning removes corrosive salts, acids, and pollutants.
• Consider cathodic protection: Especially in marine or underground settings, sacrificial anodes made from zinc or magnesium help protect key metalwork.
• Environmental control: For valuable metalwork (like classic cars or art), use dehumidifiers, climate control, or silica gel packs to minimise moisture exposure.

How to prevent corrosion 

• Choose corrosion free metals: Aluminium and stainless steel are both versatile and eco-friendly choices for a range of environments.
• Laser treatment: Advanced laser technology can create a non-crystalline surface, increasing resistance to corrosion.
• Non-metallic coatings: Grease, carbon fibre, plastics, paint, and oil create effective moisture barriers.
• Specialist anti-corrosion coatings: Modern products provide strong, UV-resistant layers that don’t chalk, fade, or require multiple coats.
• Use drying agents: Keep equipment and storage areas free from dampness and check regularly for leaks.
• Regular maintenance: Inspect and maintain all metal items, addressing any damage to coatings immediately.

Contact Salamander Fabrications for your metal protection needs today!

If you would like any more information on how to ensure your metal projects are protected from the elements, please give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

We’re also happy to talk you through any of our services, including our:

• Welding services
• Metal folding services
• Sheet metal fabrication services
• CAD design services
• Electro mechanical assembly services

If you liked reading this blog then you may like to check out our other post – How to Cut Metal: 10 Techniques to Know.

By Embryo

What is a pure metal in comparison to an alloy metal? Also, ever wondered what the full list of pure metals actually is? You’ve come to the right place for the answer! We like to think of ourselves as more than just a sheet metal company, with over 50 years of industry experience, we believe we know everything there is to know about metal!

So we’ve brought you this handy guide to discuss what a pure metal is, the difference between pure and alloy metals, and a table of pure metals with their associated features and properties. Keep reading for more information.

What is a pure metal and where does it come from?

So, what is a pure metal in everyday terms? In short, a pure metal is an element that can’t be broken down into anything simpler by chemical means. It consists of only one type of atom. They are also known as single-phase metals. Gold, silver, copper, and iron are all examples of pure metals in their natural, unalloyed state. These metals form the backbone of modern civilisation and are found in almost everything, from electronics to cutlery, cars, and coins.

In contrast, alloys like steel, brass, and bronze are born from mixing pure metals together. A dash of non-metallic elements, like carbon, is also often introduced to boost performance in specific applications. But it’s the pure metals themselves that offer the original, distinctive set of characteristics. This includes electrical conductivity, corrosion resistance, and ductility.

The origins of pure metals

Most pure metals aren’t just lying around waiting to be picked up. They are typically locked away inside rocks as ores. Through mining, crushing, and various extraction processes (like smelting or electrolysis), these ores are transformed into the metallic materials we use today.

Major mining operations around the globe dig for metals like iron, copper, aluminium, and nickel to supply the raw materials that keep the modern world turning. Some, like gold and platinum, are far rarer, which makes them precious and often pricey. Estimations of the gold content of the Earth’s crust are in the range of 0.001 to 0.006 parts per million.

What is a pure metal vs an alloy metal?

While pure metals are made up of one element, alloys are blends of two or more elements. These are often designed to make the metal harder, stronger, or more resistant to corrosion and wear. For example, copper and tin create bronze; iron and carbon make steel; and gold and silver produce the luxurious white gold.

Most metal items around us these days are actually alloys. Yet, the unique qualities of pure metals remain in high demand for critical applications.

If you have liked reading this blog so far you should take a look at this one next – What is the Strongest Metal?

Full list of pure metals

To answer the question, what is the full list of pure metals? – Here’s a comprehensive table featuring the most significant pure metals, their properties, real world uses, and where they are primarily found around the world.

For more information like this you can check out our other blog – The Different Types of Metals; Their Properties, And Their Applications.

Unique features and properties of pure metals

So now we’ve discussed what is a pure metal and highlighted the full list of pure metals, let’s take a look at some of their collective unique qualities. Pure metals display a fascinating array of properties that set them apart from their alloyed counterparts. 

Here are a few highlights:

• Conductivity: Silver and copper are world beating conductors, making them essential for most electrical applications.
• Corrosion resistance: Gold, platinum, and titanium hardly ever tarnish or rust. This makes them ideal for jewellery, dentistry, and chemical equipment.
• Strength to weight ratio: Aluminium and titanium are both very strong and incredibly light, revolutionising both the transport and aerospace industries.
• Rarity and value: Gold, platinum and their associated group of metals are highly prized, not just for beauty and rarity, but their use in cutting edge technology.

Key Applications

• Electronics: Copper, silver, and gold wires power circuits and connections.
• Transport: Aluminium and titanium make trains, planes, and cars lighter and stronger.
• Construction: Iron and steel (mainly alloyed, but pure iron is the starting point) are used for beams and girders.
• Jewellery: Gold, platinum, silver, and palladium create stunning keepsakes.
• Healthcare: Titanium, platinum, and silver are used in implants, medical instruments, and antimicrobial coatings.
• Batteries: Lithium, cobalt, and nickel power everything from electric vehicles to mobile phones.

Contact Salamander Fabrications today for your sheet metal fabrication needs! 

What is a pure metal without metal fabrication services? A blank canvas for the team here at Salamander Fabrications to work their magic on! In truth and despite their unique qualities, pure metals are rarely used alone for most practical purposes these days. They are either too soft or brittle, too expensive, or outperformed by alloyed alternatives. Most of the metals we work on are from the alloy family of metals.

Whether you’re searching for more info on what is a pure metal, exploring the full list of pure metals, or considering a custom fabrication project, Salamander Fabrications can help. With over 50 years’ experience in the industry, we offer a full suite of services, including:

• Laser cutting services
• Welding services
• Metal folding services
• Sheet metal fabrication services
• Powder coating services

For any queries or bespoke requirements, get in touch via our contact page, call us on 01484 843599, or email sales@salamanderfabs.com. Our expert team are always happy to share their knowledge and help you select the right metal for your project.

By Embryo

Welcome to our definitive guide on how to cut aluminium, brought to you by the team here at Salamander Fabrications. We’re here to help with your project in any way that we can, whether you need a sheet metal contractor to help facilitate your project, or just some tips and advice on how to cut aluminium sheet. 

Aluminium’s lightweight strength, corrosion resistance, and versatility make it an extremely popular material. It is used in everything from garden furniture to commercial vehicles and architectural features. But its unique combination of properties also means that knowing how to cut aluminium accurately and efficiently is essential, whether you’re a DIY hobbyist, tradesperson, or working on an industrial scale. 

In this comprehensive guide, we’ll discuss the best ways to cut aluminium sheet, the specialist tools and techniques available, and the fabrication processes that ensure your finished product looks and performs as it should.

Techniques for how to cut aluminium sheets

Aluminium sheets are available in a huge range of thicknesses, from ultra-thin foil to sturdy multi-millimetre plates. When it comes to the methods of how to cut aluminium sheet, the one you choose will depend on several factors. This includes the thickness and type of aluminium, the level of accuracy needed, and the tools you have at your disposal.

Picking the right technique not only ensures a neat, clean cut but also minimises material waste and reduces the risk of unwanted damage. This is especially crucial for parts that need to look sharp or fit together precisely.

Below, we’ll break down the most effective methods for cutting aluminium sheet, along with expert tips to help you achieve the best possible finish every time.

Laser cutting

Laser cutting services have revolutionised the metal fabrication industry, offering incredible precision and control that simply cannot be matched by manual tools. This method uses a focused laser beam to heat and melt through aluminium sheets along a pre-programmed path.

Advantages:

• Exceptional accuracy for intricate shapes
• Minimal material distortion and clean, burr-free edges
• Suitable for large scale or repetitive projects

Considerations:

• Requires specialist machinery and proper ventilation
• Best suited to lightweight metals and thin to moderately thick aluminium sheets

Ideal for:

• Architectural features
• Bespoke signage
• Detailed brackets
• Any project where tight tolerances or a smooth finish are required

Plasma cutting

Plasma cutting is another powerhouse of metal fabrication, ideal for tackling thicker sections of aluminium or making complex shapes where brute force and flexibility are needed. It works by blasting ionised gas (plasma) at extreme temperatures through a small nozzle, effectively slicing through metal.

Advantages:

• Powerful enough for thick aluminium plates
• Fast, with impressive edge quality for most uses
• Great for irregular or freeform shapes

Considerations:

• Leaves a slightly wider cut width compared to laser cutting
• May require additional edge finishing

Ideal for:

• Industrial fabrication
• Automotive repairs
• Structural frameworks
• Any job involving substantial aluminium profiles

Waterjet cutting

Waterjet cutting harnesses the raw force of high pressure water mixed with abrasive particles to slice through aluminium. This technique is prized for its ability to handle both very thin foils and extremely thick plates, all while keeping the metal cool.

Advantages:

• No heat distortion or structural weakening
• Ultra-precision makes it suitable for intricate designs or small batch work
• Cuts a wide range of thicknesses and alloys

Considerations:

• Can be more expensive due to equipment and abrasive costs
• Requires a skilled operator for the best results

Ideal for:

• Aerospace components
• Decorative screens
• Complex assemblies where material integrity is critical

Hand tools

For smaller projects, prototypes, or onsite adjustments, hand tools remain an important part of learning how to cut aluminium sheet. They require minimal setup and can be surprisingly effective when used correctly.

• Hacksaw: Best for straight cuts in thin aluminium sheets or bars
• Tin snips: Best for cutting curves or intricate shapes in thin aluminium
• Utility knife: Best for scoring and snapping very thin aluminium, especially for ductwork or foil

Power tools

When you need more muscle, power tools are the answer for efficient, repeatable cuts (especially in medium to thick aluminium sheets). You should always wear goggles, gloves, and a dust mask when cutting aluminium.

• Circular Saw: Best for long, straight cuts in thicker aluminium sheet or plate
• Jigsaw: Best for curved or intricate cuts in aluminium
• Band Saw: Best for both straight and curved cuts, especially in thicker stock

Alternative sheet metal fabrication services

Here at Salamander Fabrications, we understand that there’s more to working with aluminium than just cutting. Sometimes, a project needs bending, welding, or other fabrication processes to bring your vision to life. Here’s a quick overview of other essential metalworking techniques.

Welding

Welding services are at the heart of most metal fabrication projects, especially for joining aluminium parts together. Whether you’re building frames, enclosures, or bespoke pieces, welding creates robust, long lasting joints.

Different types of welding:

• MIG Welding: Great for thicker aluminium, providing fast, strong welds
• Robotic MIG Welding: Delivers consistent quality and is ideal for high volume or repetitive work
• TIG Welding: Perfect for thin sheet aluminium or work that demands a clean, attractive finish
• Spot Welding: Used to join thin sheets without filler, common in automotive and appliance manufacturing

Want to know more? Read our detailed blog post on the subject – What Are The Different Types of Welding?

Sheet metal folding

Sheet metal folding is vital for producing parts with bends or angles, and CNC-controlled folding machines ensure every bend is precise and repeatable.

Stand-out features:

• Precision: Allows for exact bends and identical pieces that meet strict quality standards
• Cost-effective: Lowers costs by reducing the need for welding or additional assembly

Coating and finishing

Aluminium’s natural oxide layer makes it resistant to corrosion, but the right finishing or powder coating process can enhance durability and appearance even further.

Popular finishing techniques:

• Powder coating: Creates a tough, colourful finish that resists scratching and UV fading.
• Electroplating: Adds a decorative or protective metal layer which is ideal for high wear or visible components.
• Polishing and brushing: Delivers a high shine or a modern, textured look for decorative aluminium.

Choosing the best method for how to cut aluminium

Selecting the best method for how to cut aluminium depends on your tools, the thickness and alloy of the sheet, and the demands of your project. Hand tools are great for light work, while power tools and advanced machinery offer the accuracy and speed required for larger or more complex jobs.

Don’t forget to clean, deburr, and finish all cut edges for safety and appearance. If in doubt, consult a professional sheet metal contractor. Working with aluminium is as much about experience as it is about equipment.

Contact Salamander Fabrications for more information on our laser cutter – our method for how to cut aluminium

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us any time. The team here at Salamander Fabrications are more than happy to talk through the services we have to offer and share our expertise.

Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Wondering how to engrave metal? Want to know if there is a single technique that works for everything, or do different methods suit different projects? If you’re looking for guidance on the full range of options and want to understand the strengths and uses of each, you’ve landed in the perfect spot. Here at Salamander Fabrications, the home of expert metal fabrication services, we specialise in all things sheet metal – a common material used for engraving.

In this guide, we’ll break down the five main ways of how to engrave metal, covering both timeless hand skills and the latest machinery. We’ll explore what makes each method unique, the tools you’ll need, best practices, and what types of jobs each approach is suitable for.

1. Engraving metal by hand

Let’s start with the old faithful and the most traditional method of how to engrave metal. The classic image of an artisan at a workbench springs to mind. Hand engraving has centuries of tradition behind it and is still favoured for intricate jewellery, ceremonial objects, and one off pieces where artistry is prized over speed.

This method is best for softer metals like silver, gold, copper, and brass. It is a time consuming process that demands patience and practice. For batch production or very hard metals, other methods may be preferable. The tools you’ll need include gravers (burins), a ball vice, and sharpening stones.

Hand to engrave metal by hand

1. Sketch or print your design, then transfer it onto the metal surface (using paper, acetone, or a vinyl sticker).
2. Secure the metal piece in a ball vice to hold it steady.
3. Select the right graver for your design and sharpen if necessary.
4. Hold the graver at a roughly 45-degree angle to the metal.
5. Push or glide the graver along the design, using consistent, controlled pressure to etch lines.
6. Rotate the metal as needed for curves and intricate patterns.
7. Brush away any debris and clean the surface after engraving.
8. Apply a protective coating or lacquer if desired, especially for metals that tarnish.

Why choose hand engraving?

• Personal touch: Every mark is unique, resulting in truly individual pieces.
• Perfect for: Bespoke jewellery, commemorative items, fine art, and restoration work.

2. Laser engraving

Laser engraving is now one of the most popular ways to engrave metal in the UK and worldwide. Fast, precise, and repeatable – much like our laser cutting services – it’s the go to choice for modern industrial applications.

For this, you will of course need a laser engraving machine (fibre or diode lasers are common for metal). This method is suitable for most metals, including stainless steel, aluminium, copper, and more. The initial setup cost of running your own laser machine can be high, but running costs are generally quite low. It’s a lot more cost-effective to use a professional service that can handle your project from design through to the final product.

Laser engraving can also be utilised alongside CAD design services to help make designs better and more effective. It allows you to accurately set out what you wish to design and then implement it with high precision and speed. For more information on this, you can check out our other blog – What Are The Advantages of CAD?

How to engrave metal with lasers

1. Prepare and set up your laser engraving machine according to manufacturer’s guidelines.
2. Choose your metal blank and position it securely in the engraver.
3. Load your digital design into the engraving software.
4. Adjust laser power, speed, and other settings to suit your metal type.
5. Begin engraving, following all safety precautions (eye protection, ventilation, safety screens).
6. Allow the machine to complete the engraving, then remove and inspect your piece.

Why choose laser engraving?

• Speed and repeatability: Excellent for mass production and high detail work.
• Perfect for: Promotional items, signage, industrial labelling, machine parts, and complex patterns.

3. Rotary engraving with a power tool

For DIY enthusiasts or workshops that need versatility, rotary engraving with an electric tool (like a Dremel) is a practical option. This method combines the control of hand engraving with the efficiency of power tools. This method works well on most common metals, but harder metals may require specialist tool bits.

For this method, you will need your rotary tool, a range of engraving bits, clamps or a vice. Be mindful, though, the rotary tool technique is less precise than laser or CNC engraving for very fine work. You should also always wear eye protection and secure your workpiece to prevent accidents. Fine metal dust can also be produced, so consider respiratory protection or a dust extraction system too.

How to engrave metal with a rotary power tool

1. Clean your metal item thoroughly with alcohol.
2. Mark out your design using a vinyl sticker, transferred print, or permanent marker.
3. Clamp the metal securely in place.
4. Insert the appropriate engraving bit into your rotary tool (diamond bits are ideal for metal).
5. Set the tool to a lower speed, increasing as needed for your metal type.
6. Carefully follow your design, engraving lines with steady pressure
7. Repeat for deeper marks if desired.
8. Switch off the tool and brush away any metal filings or dust.
9. Polish or clean the area to finish.

Why choose rotary engraving?

• Versatility: Suitable for a wide range of projects and can be done at home.
• Perfect for: Custom tools, trophies, signs, hobbyist crafts, and repairs.

4. CNC engraving

Computer Numerical Control (CNC) engraving brings automation to the process, using computer-guided tools to cut complex or repetitive designs with minimal manual effort. It uses the same CNC technology we use for our Press Brakes and Metal Folding Services.

This technique is ideal for metals such as aluminium, brass, copper, stainless steel, and many others. The tools you will need include a CNC engraving machine, various cutting bits, and the required computer software. You may also use a nylon flap or soft brush to remove burrs and sharp edges and achieve a smooth, professional finish.

This method requires investment in equipment and software, as well as programming knowledge, unless you have a professional team handle your project for you.

How to engrave metal with a CNC machine

1. Securely fasten your metal workpiece onto the CNC machine bed.
2. Choose the appropriate bit (diamond cutter, twist drill, or v-bit).
3. Import your design into the CNC software and set your engraving parameters (depth, speed, etc.).
4. Start the engraving operation and monitor progress.
5. Once finished, use a nylon flap or brush to clean off any burrs or debris.
6. Apply a polish or lacquer for extra shine and protection, if needed.

Why choose CNC engraving?

• Automation: Excellent for high volume production or detailed, repeatable designs.
• Perfect for: Industrial parts, machine plates, serial numbers, and complex artwork.

5. Chemical etching

The last one on our list is not technically engraving but the process is very similar and used to achieve the same results. Chemical etching is a powerful and flexible technique widely used in industry for precise, intricate designs that might be too delicate or complex for mechanical engraving. It’s used for items like circuit boards, nameplates, and fine art.

For this technique, you will need metal blanks, photoresist or acid resistant mask, etching solution (usually acid or ferric chloride), a design stencil, and protective equipment. This requires careful handling of chemicals, proper ventilation, and safety precautions. You must also always dispose of used chemicals responsibly according to local environmental regulations.

The chemical etching process

First, a design is applied to the metal using a photoresist film or acid-resistant mask—this can be as simple as hand-drawn patterns or as sophisticated as photographic transfers. The metal is then immersed in an etching solution, which eats away the exposed areas while the masked sections remain untouched. The duration of etching determines the depth of the design. Once etched, the mask is removed, and the piece is thoroughly cleaned and neutralised.

Why choose chemical etching?

• Intricate detail: Can achieve extremely fine and crisp designs, even on thin metals.
• Perfect for: Electronic components, decorative panels, labels, jewellery, and architectural features.

Discover how to engrave metal and much more with Salamander Fabrications.

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us at any time. 

Our other metal fabrication techniques include:

• Welding services
• Sheet metal fabrication services
• Powder coating services

If you’re considering a metal engraving project, looking for advice on how to engrave metal, or need expert help with laser cutting and fabrication, Salamander Fabrications has decades of experience and the right tools for the job.

Our advanced facilities, skilled workforce, and commitment to quality mean every project gets the attention to detail it deserves. We’re always happy to discuss your ideas and recommend the best approach for your idea, no matter how big or small.

Give us a call if you think we can help you on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Metals are known for their ability to conduct heat and electricity. They’re also extremely ductile, versatile, and machinable. For these reasons and many more, metal is part of our everyday lives and is pretty much everywhere. You’re probably within inches of something metal reading this blog right now. But, have you ever wondered, exactly where does metal come from? 

Here at Salamander Fabrications, we are specialists in sheet metal fabrication services, so it’s safe to say we know a thing or two about the material. If you’d like to know more about what metal is made of and how metal is made, continue reading…

So…where does metal come from?

Every single metal that exists on Earth today originated billions of years ago, way before we did. The first humans to discover metal stumbled upon copper, tin, and gold by hammering into rocks. Over time we have learned how to mix metals with other metals, and other substances, to create new metals that we now refer to as alloys. This is primarily done to improve strength amongst other characteristics.

For example, if you combine copper with tin, then you create bronze. Or if you mix iron and a little bit of carbon, you get steel, and so on and so forth. Most natural metals come from the earth’s crust, found in ores. An ore is a solid material that minerals can be extracted from. To extract the metal ores from the ground, huge mining operations are used across the world.

Our planet approximately consists of:

• 30% iron
• 14% magnesium
• 1.5% nickel
• 1.4% aluminium

This makes up almost half of the Earth – meaning we are almost 50% metal! Precious metals like gold, silver, or platinum exist in very, very small amounts. Estimations of the gold content of the earth’s crust are in the range of 0.001 to 0.006 parts per million. Extremely low in comparison to iron and magnesium. 

Where are metals found?

As mentioned in the previous section, the vast majority of metals on Earth are mined from the Earth’s core and crust. This means the metals you see all around you may have come from all different corners of the world. Australia and Brazil are some of the highest exporters and miners of metal, but there are many other countries that contribute to global production too.

This table provides a detailed look at where major metals are mined, their contributions to global supply, and their key applications.

What is metal made of?

Natural metals are mined and extracted, refined, and then smelted – so in essence they already exist and are not ‘made of’ anything. They are pure metals. In relation to metal alloys – these are a combination of two or more metals or other materials.

Almost all metal elements can be alloyed into different types. Different types of metal alloys are made of different things. Each one offers its own unique physical beneficial features and characteristics. 

This table shows a variety of metal alloys, their compositions, key applications, and important properties.

Check out our other blog – Examples of Ferrous and Non-Ferrous Metals to find out more about the difference between the two. This includes a deep dive into ferrous and non-ferrous metals, including their features and properties in comparison to each other.

How is metal made?

To answer this question, let’s take a look at the process of metal manufacturing at a basic level. The steps include:

1. Extract the raw ore from the Earth’s crust
2. Remove any non-metal material, such as rock and debris
3. Crush the ore into a fine powder
4. Heat the resulting powder to a high temperature
5. Rinse with cold water or a chemical bath
6. Filter the sludge
7. Separate the solid from the liquid
8. Apply an electrical current to break chemical bonds

Let’s take a look at the finer details of how some common metals are made.

Aluminium: The most common ore used for aluminium production is bauxite. This is crushed and then electrolysis is used to split it into aluminium and oxygen. The pure metal is cast into blocks known as ingots. To find out more about aluminium, check out our guide on the top ten uses of aluminium. 

Zinc: Zinc extraction commonly involves a method called froth flotation, which is also used for refining copper and lead. The zinc ore is ground into a fine powder and mixed with water, pine oil, and flotation agents. This mixture is stirred, causing the zinc particles to rise to the surface, where they are collected and further refined.

Lead: Lead ore is typically found deep underground and contains a significant amount of sulphur. The ore is first crushed and mixed with water, where it undergoes flotation to separate it from unwanted materials. However, additional refining is required – heating the lead further helps remove excess sulphur and other impurities.

Copper: Copper ores generally contain only a small percentage of copper, often around 4%. The refining process gradually increases its purity. The ore is first broken down into tiny fragments and combined with water before being placed in large tanks, where air and chemical agents help separate copper particles from other minerals. The resulting material is then heated in a large furnace called a smelter. This process burns off additional impurities, leaving behind copper matte, a substance that is at least 50% pure copper.

Brass: Unlike natural metals, brass is an engineered alloy made primarily from copper and zinc. Since it is not extracted from an ore, it is produced by melting these two metals together in a furnace. The molten brass is then shaped into pipes, tubes, or sheets, depending on its intended use. Brass is classified as a type of copper alloy due to its high copper content.

Steel: Steel production begins with iron extraction, primarily from hematite and magnetite ores. These iron-rich minerals are found in rock formations and deposits, with hematite easily identified by its distinctive reddish colour. The method of extraction varies based on the depth and location of the iron ore, but once it is mined, the refining process begins. The first stage involves processing the ore in a blast furnace, where it is heated and purified to prepare it for steelmaking. For more information on steel you can check out our other blog – Mild Steel Vs Stainless Steel: What’s The Difference?

Where are metals found and expertly fabricated? Right here at Salamander Fabrications! 

Where does metal come from before it enters our workshops? Well, we don’t always know the origin (in terms of the country) where the key elements were originally extracted. But what we do know is the quality of the metals that leave our workshop before they go on to fulfil their applications. 

Whether you require laser cutting services, expert welding services or metal folding services, our expert team will use their decades of experience to ensure your exact needs are met. The team here at Salamander Fabrications is more than happy to share their expertise and talk to you more about some of the services we have to offer. 

Visit our contact page or just give us a ring on 01484 843599. Or you can email us at sales@salamanderfabs.com.

By Embryo

Out of the 118 elements on the periodic table, around 75 to 80 are considered to be metal. So the competition for what is the strongest metal is pretty fierce. Here at Salamander Fabrications we have cut, bent, rolled, welded, and coated quite a few different types of metal in our time – including some of the strongest metals in the world.

Our metal fabrication services have provided us with opportunities to work with a variety of different metals, across a number of different projects. So we know a thing or two about metal strength and some of the strongest metals in the world. Carry on reading to find out what is the strongest metal…

Different types of metal strength

When thinking about the strongest metals in the world, there are several factors to consider, as there are several different types of strength.

Tensile strength

Tensile strength is all about tension. This refers to the amount of force needed to stretch or pull a metal apart. The higher the tensile strength, the more force required to pull it apart. 

Compressive strength

How far can a metal withstand being compressed or squeezed together? This is compressive strength. To test this, pressure is placed on the metal between the plates of a compression testing machine. A load is gradually applied until the metal breaks, reduces in size, or reaches a predetermined load value. Compressive strength is often measured using the Mohs Hardness Test. 

Yield strength

This refers to a metal’s capability to withstand bending. It tests the elastic limit of a piece of metal. This often involves gripping either side of it and applying stress to bend it. This will tell you how much stress is required until the metal will not return to its original shape when the stress is removed. 

Impact strength

Impact strength refers to a metal’s ability to withstand a blow without shattering or fracturing. 

Alloys vs natural metals

Now that we’ve discussed the different types of metal strength, there’s something else we need to highlight before we get into the strongest metal. That means discussing what is actually a ‘metal.’ There are metals and then there are metal alloys.

As we mentioned at the start, out of the 118 elements on the periodic table, around 75 to 80 are considered metal. Natural metals, also known as native metals, exist in pure, elemental form in nature. This means they are not chemically combined with any other elements. Gold, copper, silver, tin, lead, and iron are all examples of naturally occurring metals.

Metal alloys are combinations of two or more metals. The main reason for making metal alloys is to create a stronger material. Examples include steel (iron and carbon), brass (copper and zinc), and bronze (copper and tin).

Our list of the strongest metals in the world contains both metals and metal alloys. But for argument’s sake, we will just consider them all to be simply metal – as does most of the rest of the world.

Comparing the strongest metals in the world

So without further ado, and in no particular order at all, here is our list to answer the question – what is the strongest metal in the world? We thought it would be quite boring to list just the one, and in truth, it’s a close call at the top, so we’ve included a few for you to check out.

Stainless steel

Let’s start our list of the strongest metals in the world with one of the most common and perhaps unexpected – stainless steel. This is often referred to as the strongest alloy in the world and is highly resistant to rusting and corrosion. It is made from iron and carbon and is a highly versatile alloy.

You may be surprised by this, as stainless steel is almost everywhere. Bending one of your stainless steel spoons might make you think we’re talking nonsense. But this is just a very thin piece of metal that is also often coated with stainless steel, rather than being constructed entirely from it. The strength of each alloy can differ significantly too. Some grades of stainless steel offer incredible tensile strength, making it an incredibly popular choice across countless industries.

So stainless steel is very much a type of metal with great tensile strength qualities. It’s also widely used in metal fabrication services due to its popularity, durability, and availability.

Common applications include:

• Construction materials
• Medical equipment
• Automotive parts
• Kitchenware and appliances
• Aerospace components

We have even more information on stainless steel in our other blog – Stainless Steel Properties, Grades, and Applications.

Chromium

Chromium sounds expensive just from the name, but in truth, it is a relatively inexpensive metal that is abundant in the Earth’s crust. It is often referred to as the hardest metal in the world. chromium scores very high on the Moh’s Hardness Test, meaning it has incredible compressive strength. There are only two metals above chromium in this respect, and they are boron and diamond. Despite its incredible compressive strength, however, it does fail to offer a lot of tensile strength.

So whereas it cannot be easily squished or crushed, it can be torn apart a lot easier in comparison. You don’t often find a lot of things made of chromium alone either, as it is often combined with other materials to provide added strength. 

Common applications include:

• Coatings and plating for corrosion resistance
• Stainless steel production
• Automotive trim and parts
• Aerospace applications
• Industrial tools and cutting equipment

Inconel

This is one of the lesser-known metals on the list of what is the strongest metal. Inconel is a group of nickel-based superalloys. Its superpower is tensile strength and the ability to withstand extremely high temperatures. It also has high corrosion and oxidation resistance and excellent mechanical properties.

Common applications include:

• Jet engines and aerospace engineering
• Marine applications
• Chemical processing plants
• High-temperature industrial applications
• Gas turbines

Titanium

Now we’re into the big players in the league of extraordinary metals! Almost everyone has heard of titanium and is pretty much aware of how strong it is. Titanium has an extremely high melting point and incredibly high strength to weight ratio. If you need maximum strength but minimum weight, this is a common choice.

Common applications include:

• Aerospace and aviation components
• Medical implants and prosthetics
• High-performance automotive parts
• Military and defense applications
• Sporting goods and high-performance equipment

Tungsten 

The last on our list of the strongest metals in the world. It’s a fight for the top spot alongside titanium. Tungsten is often referred to as the strongest natural metal in the world (different from the strongest alloy). Despite its incredible strength, with the highest tensile strength of any metal, tungsten is brittle and prone to shattering. So impact strength is not up there with its tensile qualities. This metal is often combined with steel and other metals. It also has the highest melting point of any natural metal.

• Cutting tools and industrial machinery
• Military armour and ammunition
• Electrical contacts and electrodes
• Aerospace components
• High temperature applications

Tungsten vs Titanium

Since these are the strongest metals in our discovery, it’s only fair we give them their own section and stand-off.

Tungsten

• Highest tensile strength of any natural metal, making it incredibly resistant to being pulled apart.
• Highest melting point of any metal (3,422°C), making it ideal for high temperature applications.
• Extremely dense, almost twice as heavy as lead.
• Less practical for applications requiring lightweight materials.
• Brittle in its pure form, meaning it can shatter under high impact.
• Often used in alloys with steel to improve strength and durability while reducing brittleness.

Titanium

• Excellent strength to weight ratio.
• Highly resistant to corrosion, even in extreme environments like seawater and acidic conditions.
• High melting point (1,668°C), making it useful for aerospace and high-performance applications.
• More flexible and less brittle than tungsten, meaning it can absorb impact without breaking.
• Biocompatible with the human body.

Which is the strongest?

The choice between tungsten and titanium depends on the application. 

If you need maximum tensile strength and heat resistance, tungsten is the winner. However, if you need a strong, lightweight, and impact resistant metal, titanium is the better choice. Tungsten is ideal for industrial applications like cutting tools and military uses, whereas titanium excels in aerospace, medical, and sporting applications. 

If this has been an interesting read then you may be interested in our other blog – Melting Point of Metals. This includes a chart showing the melting point of various metals and a guide on how to measure the melting point.

Find out more about working with Salamander Fabrications on your next sheet metal project…

Here at Salamander Fabrications, we use a variety of techniques to shape, design, and transform some of the strongest metals in the world. This includes laser cutting services, expert welding services, and metal folding services.

If you would like some more information or advice on what we have to offer, please feel free to contact us. You can call us on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Welcome to our definitive guide on how to cut metal, with 10 techniques to know how and what cuts through metal. 

Here at Salamander Fabrications, we know a thing or two about metal fabrication services, and how to cut through metal pieces to create a desired shape or form. So keep reading for more information and perhaps discover a tool for cutting metal that suits your exact requirements…

1. Laser cutting tool for cutting metal

We’ll start off with our favoured method of how to cut through metal – with a laser cutter. Laser cutting services provide a precise and efficient method of cutting metal using a high powered laser. This heats and vaporises the material to create a clean cut. The process is usually controlled by CAD design software, which allows for highly detailed and intricate designs.

Laser cutting is widely used in industries like manufacturing, engineering, and design. And right here at Salamander Fabrications! We have two laser cutters with 24/7 running capability – one 3kw and one 6kw. The bed size for our laser cutters is 300cm x 150cm, which allows us to take on a multitude of different projects.

Other benefits of laser cutting include:

• Precision and accuracy: The laser can cut complex shapes with high precision, often to within fractions of a millimetre.
• Clean edges: Post processing is minimal as cuts are smooth with minimal burrs or rough edges.
• Versatile: You can cut metal, wood, acrylic, fabric, leather, and more with a laser.
• Efficiency and speed: It’s a lot faster than traditional cutting methods, especially for intricate designs.
• Reduced wear and tear: The laser doesn’t physically touch the metal so there is less wear and tear on parts.
• Automation: It’s a great method for mass production, as designs can be replicated with consistent quality.

2. Chop saws

Now that we’ve satisfied our bias and covered our favoured method of what cuts through metal, we can crack on with the rest of the list. A chop saw is another example of a tool for cutting metal that is widely used in industries like manufacturing, engineering, and the construction sector. In particular, they are often used to cut steel and other heavy duty metals like a knife through butter – but with a lot more sparks.

Stand out features:

• Very quick method for how to cut metal
• Ability to handle larger and thicker metals.
• Ideal for clean, straight cross cuts.

3. Mitre saw

The mighty mitre saw is very similar to the chop saw, they might as well be cousins. The key difference is that a mitre saw is designed for making angled cuts at precise angles, rather than straight cross cuts. 

Stand out features:

• Mounted design doesn’t require manual support.
• Makes accurate angled cuts.
• Cuts metals quickly and effectively.

4. Holesaws

The clue is in the name of this one. Holesaws are typically attached to the end of power drills for cutting holes into metal and other materials. They are cylindrical in shape – obviously – to create clean circular holes. Holesaws are often used in plumbing and electrical work, and joinery and woodworking.

Stand out features:

• Creates smooth holes without much finishing work needed afterwards.
• You can almost cut a hole as big as you like.
• Used on a variety of different materials including wood, metal, plastic, and tile.

5. Mag drills

You may think a drill isn’t a tool for cutting metal, but in this case, it can be. A mag drill uses a rotating cutter, like an annular cutter or twist drill bit, to remove metal material.

Stand out features:

• The term ‘mag’ comes from the magnetic base that keeps the setup stable and offers accurate cuts.
• Ideal for places that are hard to reach.
• Compatible with cutting tools like twist drills and annular cutters.

6. Annular cutters

Speaking of annular cutters, let’s cover them next on our list of how to cut metal. These tools create clean holes in metal for a variety of applications. An annular cutter cuts around the perimeter of the hole. This reduces the amount of material to be removed, as well as the effort to do so.

Stand out features:

• Can withstand hardy materials like cast iron.
• Quicker compared to other drilling methods.
• Creates smooth and accurate holes.

7. Angle grinder

Next up on what cuts through metal – the famous angle grinder. This handheld power tool can cut, grind, and polish metal – making it an all-in-one champion. The rotating abrasive disc is capable of cutting through various metal materials…

Stand out features:

• Lightweight and easy to transport.
• Ability to cut, grind, and polish metal with interchangeable discs.
• A go-to DIY tool for both beginners and professionals.

8. Tin snips

Number eight on our list of how to cut metal – the humble tin snips. These little scissor-like tools glide through sheet metal with ease. They are the unsung heroes of sheet metal fabrication. Sharp jaws mean they can cut with precision but only bit-by-bit, in small amounts at a time.

Stand out features:

• Precise cuts without a lot of effort.
• You can buy left handed or right handed tin snips to suit your dexterity. 
• Perhaps the cheapest option on the list of how to cut metal so far.

9. Mini hacksaw

We’re almost at the end of our guide on how to cut through metal. Mini hacksaws are similar to tin snips in that they are suited to small-scale projects or pieces of metal. They are small (obviously) and have a thin blade compared to any other type of saw, ideal for working in narrow spaces.

Stand out features:

• Affordable tool for cutting metal.
• Ideal for working in tight spaces where precise cuts are required.
• Lightweight and easy to transport.

10. Plasma cutters

Plasma cutters are specifically designed for cutting metal at a precise level, so a nice way to round off our list of what cuts through metal. Plasma cutters utilise a stream of ionized gas (also known as plasma) at high velocity. This melts the metal away and creates a clean cut in rapid time. The cutter’s amperage and gas flow are set according to the thickness of the metal being cut.

Stand out features:

• Suitable for a wide range of metals such as aluminium and stainless steel.
• Precise, clean cuts every time.
• Requires little to no surface preparation or preheating, saving time and resources. 

Contact Salamander Fabrications for more information

If you would like some more information on our laser cutting capabilities, or any of our other sheet metal fabrication services, please feel free to contact us any time. The team here at Salamander Fabrications is more than happy to talk through the services we have to offer and share their expertise.

Our advanced equipment, skilled workforce, and commitment to excellence ensure every one of our projects is completed with precision and efficiency. Every project is unique, and we work closely with clients to develop tailored solutions that meet their specific requirements.

Give us a call if you think we can help you on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Metal extrusion is a manufacturing process where a solid metal billet (a tubular or rectangular block) is forced through a die to create a desired shape. This creates objects with a fixed cross-sectional profile. It refers to the shape of a metal piece when viewed as if it were cut straight across its length. 

It’s very similar to squeezing toothpaste out of a tube or pushing playdough through a stencil – but on a much larger scale. The metal extrusion process is commonplace in pipe and steel rod manufacturing. The most common materials extruded are aluminium and plastic.

The metal extrusion process is not considered a form of sheet metal fabrication, as it involves a solid metal billet and not a flat sheet of metal. Here at Salamander Fabrications, we offer a range of sheet metal fabrication services that we’re more than happy to elaborate on further. Or continue reading for more information on the extrusion process, the different types, its applications, advantages, and disadvantages.

Basic metal extrusion process

Generally speaking, here is a rundown of how the metal extrusion process works:

1. The billet is produced and prepared.
2. The billet is heated in hot extrusion or remains at room temperature (more on that later) and placed into an extrusion press. It’s pushed by a piston into a cylinder, where a die is fitted at the other end.
3. Compressive force is applied by the piston (also known as a plunger) as it pushes the billet towards the die.
4. This force makes the metal flow through the die as it is converted into the desired shape.
5. The extruded part is removed from the press. It may also be heat treated for improved mechanical properties.

Types of metals used in the metal extrusion process

Each metal presents different challenges and advantages in the metal extrusion process. Manufacturers must always think about these when choosing the correct metal for a given application. Below are just a few examples of the types of metals used in metal extrusion.

Aluminium and aluminium alloys

These are the most commonly extruded metals due to their lightweight nature, corrosion resistance, and excellent machinability. Common applications include window frames, automotive components, and aerospace structures.

Copper and copper alloys

Copper and copper alloys are known for high electrical and thermal conductivity, making them ideal for electrical applications. They are often used in electrical conductors, plumbing pipes, and heat exchangers. The drawback is that copper is expensive and has lower mechanical strength when compared to other extruded metals.

Steel and stainless steel

Used when strength and durability are the primary concerns. They also provide excellent corrosion resistance, making them suitable for the marine, medical, and food processing industries. Steel often needs higher extrusion pressures and often hot extrusion due to its toughness.

Titanium and titanium alloys

Titanium is famous for its strength-to-weight ratio and corrosion resistance. For this reason, it is often used in the aerospace, medical, and automotive industries. It is very expensive when compared to aluminium and steel and more challenging to extrude.

Magnesium alloys

This is one of the lightest structural metals; it’s even lighter than using aluminium, but still offers good strength qualities. It is sometimes used in automotive, aerospace, and electronics to reduce weight. However, it is more prone to corrosion than aluminium.

Nickel alloys

Nickel alloys are resistant to high temperatures and harsh environments. They are commonly used in chemical processing, aerospace, and marine applications.

Types of metal extrusion (direction of flow)

Direct extrusion: The metal is forced to flow in the same direction of the piston feed. The piston pushes the metal through a cylinder towards and out the other end of the die.

Indirect extrusion: The die is fitted to a hollow piston that pushes the metal into a closed container. The metal flows in the opposite direction during extrusion, out through the hollowed-out piston.

Hydrostatic extrusion: This metal extrusion process uses fluid to apply pressure on the billet. The billet is not in contact with the cylinder wall or the piston, which causes less friction. Vegetable oils are often used as the fluid.

Types of metal extrusion (temperature)

Hot extrusion: This is where the metal extrusion process takes place above the recrystallisation temperature (around 50 to 60% of its melting temperature). This requires low force when compared to cold extrusion and is easier to work with. However, it causes increased wear on the die, and higher maintenance is required.

Cold extrusion: This is where the metal extrusion process takes place below crystallisation temperature or at room temperature. It offers high mechanical properties and a smooth surface finish with no chance of oxidation. However, high force is required. 

Advanced metal extrusion techniques

Hydrostatic extrusion: Instead of a mechanical piston, pressurised fluid is used to force the billet through the die. This reduces friction, allowing for higher extrusion ratios. It can be used for brittle materials like tungsten.

Impact extrusion: A piston forces the material into a die with a single, powerful impact rather than a ‘slow push’. This high speed process produces thin-walled, seamless components.

Friction extrusion: This is a relatively new process that combines extrusion with heat, which is generated by friction. This is meant to reduce energy consumption.

Co-extrusion: This involves extruding two or more different metals together, as the name suggests. It allows manufacturers to combine the strength of one metal with the corrosion resistance of another.

Micro extrusion: This specialised form of extrusion is used to create very small, precise parts – again, as the name suggests! It enables the production of components in medical devices, microelectronics, and aerospace, amongst many others.

Benefits of metal extrusion

• Easily create complex cross sections
• Can be applied to brittle and ductile materials
• High mechanical properties can achieved

Drawbacks of metal extrusion

• High initial setup cost
• A high compressive force is required, which requires a lot of energy
• Not environmentally friendly

Common applications of metal extrusion

• Automotive Industry: Used for making parts like engine components, chassis sections, and crash management systems.
• Construction: Aluminium extrusions are widely used for window frames, doors, and structural components.
• Aerospace: Lightweight and strong extrusions are used for fuselage frames, seat tracks, and structural supports.
• Electrical Industry: Copper and aluminium extrusions are used for busbars, heat sinks, and cable trays.
• Consumer Goods: Used in ladders, furniture, and sporting goods like bicycle frames.
  

As mentioned in this blog numerous times, aluminium is perhaps one of the most commonly extruded metals. For more information on this particular metal, you can read our other blog, ‘11 Advantages of Aluminium’. 

Quality control in the metal extrusion process

Manufacturers must use several quality control and testing methods to ensure that extruded metal products meet high standards. Even with precise manufacturing processes, defects can still occur.

These can include:

• surface cracks and scratches caused by excessive friction or overheating
• air pockets
• incomplete or inconsistent material flow
• warping or distortion due to uneven cooling or residual stresses
• dimensional variations due to the die being worn

Inspection and testing methods

Dimensional checks: Callipers, micrometres, and laser scanners are used to measure extruded components to ensure they match specifications.

Ultrasonic testing: High-frequency sound waves detect internal flaws or inconsistencies.

X-ray inspection: Helps identify internal voids (like air pockets) that might weaken the structure.

Hardness and strength testing: Measures how much force a material can withstand before breaking.

Corrosion and fatigue testing: Simulates real world conditions to ensure extruded metals can withstand environmental exposure, stress, and loading.

Surface finish inspection: Profilometers or a simple visual inspection will ensure that no defects affect the material’s performance. Smooth surfaces are critical for aesthetic and functional purposes.

Future trends and innovations in metal extrusion

As technology advances, the metal extrusion industry is evolving to become more efficient, sustainable, and precise. Several innovations and emerging trends are shaping the future of metal extrusion, improving material properties, production efficiency, and environmental impact.

Advanced materials and alloy development

High performance alloys will improve strength, corrosion resistance, thermal stability, and weight reduction. This includes the development of new heat-resistant aluminium alloys for applications in electric vehicles and aerospace components. Lighter and stronger metal alloys (such as Titanium and Magnesium) are being refined for structural applications where weight reduction is critical.

Automation and machine learning

This seems to be the hot topic for almost every industry in the world these days! The rise of AI and smart manufacturing is transforming the metal extrusion process through automation and real-time monitoring. Predictive algorithms can optimise extrusion parameters, reduce defects, and improve material efficiency. Robotic handling and automated quality control also help to ensure the highest quality finished products. 

Sustainable and green technology

More and more industries are pushing for eco-friendly solutions to manufacturing and general operations. Metal extrusion, too, is moving towards sustainable materials and energy-efficient processes. More manufacturers may start using recycled materials to lower carbon footprints while maintaining material strength.

Hydraulic electric hybrid presses also help to reduce energy consumption compared to traditional hydraulic presses.

Other metal forming techniques

Welding

Welding services provide professional metal joining solutions for industries like construction, automotive, and manufacturing. We use several different types of welding techniques here at Salamander Fabrications, such as MIG (metal inert gas), robotic MIG welding, TIG (tungsten inert gas), and spot welding.

Cutting and shaping

Metals can be cut into shape using techniques such as shearing, laser cutting, and plasma cutting. We have 24/7 running capability on both of our laser cutting machines and the ability to hold up to 200 different metal materials.

Sheet metal folding

CNC press brakes or folding machines are used to bend sheets of metal into a desired shape. Sheet metal folding allows for accurate bends and angles, which is essential for manufacturing parts with tight tolerances.

Forming and fabrication

Sheet metal fabrication may involve bending, rolling, or stamping metals into various forms. This produces sheets, strips, or bars as opposed to complex cross-sections, as with metal extrusion. Before you begin this stage, you may use 2D and 3D CAD design services to wireframe and design your vision first.

Coating and finishing

Powder coating services improve the aesthetic appearance and corrosion resistance of the finished product. It is often important for outdoor-use metals.

Casting

This technique is used to create complex shapes from molten metals like cast iron. The molten metal is poured into a mould and allowed to solidify into a desired shape. Common applications include the automotive industry, aerospace components, construction and infrastructure, and artistic and decorative items. This produces more material waste in comparison to metal extrusion due to excess molten metal and the required finishing.

Heat treatment

Heat treatment can include annealing, quenching, and tempering. These processes are used to alter the physical and mechanical properties of metals by heating and cooling them in a specific way. This improves hardness, strength, ductility, and wear resistance. This process can often be employed after the metal extrusion process takes place.

Here for all of your sheet metal fabrication service needs

We have a wealth of information available on our main news page on a range of different topics related to sheet metal fabrication.

The team here at Salamander Fabrications is more than happy to share their expertise and talk to you some more about some of the services we have to offer. If you would like some more information or advice, please feel free to contact us. Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

What is soldering? In basic terms, the soldering process involves joining two or more pieces of metal together using a filler metal (the solder). In this process, the base metals are not melted, only the filler. Instead of fusing the metals together, the solder melts and flows into the joint, which creates a strong bond once cooled.

Soldering is similar to welding in a lot of respects but with some key differences. Welding is just one of the many sheet metal fabrication services we offer here at Salamander Fabrications, so we have plenty of knowledge and expertise around the subject.

So we’ve come up with this complete guide on what soldering is and the soldering process. Continue reading for more!

How the soldering process works

Generally speaking, and in the most basic terms, here is a rundown of how the soldering process works. There are a number of different techniques, applications, and variables that may affect or add to this baseline process, as we will cover later on in this article. 

1. Prepare the surface: To ensure proper adhesion, clean the base metals to remove oxidation, dirt, and grease.
2. Apply the flux: A chemical cleaning agent (flux) prevents oxidation when you apply heat and improves the solder flow.
3. Apply heat: A number of tools or techniques can be used to apply heat to the joint, including a soldering iron, torch, or hot air gun.
4. Melt the solder: Apply the filler metal (solder). Capillary action will draw it into the joint.
5. Cool and solidify: A strong mechanical bond is formed once the solder cools.

What is soldering used for?

Soldering has a wide range of uses and applications, but some of the most common are listed here.

• Electronics: To connect wires, circuit boards, and electrical components. Provides good electrical conductivity and secure connections.
• Plumbing: To seal copper pipes and more. Requires an acid-based flux to remove oxidation.
• Jewellery making: Attaching delicate metal pieces and creating strong bonds.
• Automotive and aerospace: To manufacture or repair electrical systems and metal components.
• Musical instruments: Brass instruments use silver soldering for precise assembly.
• HVAC: Used for gas pipelines, refrigeration coils, and heat exchangers.

Benefits of soldering

• Low heat required (compared to welding)
• Can be used to join dissimilar metals (for example, copper to aluminium)
• Provides good electrical conductivity
• Simple and cost-effective process
• Works well with precious metals (for example, gold, silver, and platinum)
• It can be resistant to heat and corrosion

Types of soldering

Soft soldering (low-temperature soldering process)

Soft soldering is the most common soldering process method. It involves using a solder with a low melting point. This creates a weaker bond compared to hard soldering or brazing, which we detail next. It also cannot withstand high temperatures, which limits its use in high heat applications.

• Temperature range: Below 450°C
• Solder material: Tin-based alloys (for example, tin-lead or lead-free alternatives)
• Flux used: Rosin-based or acid-based flux
• Common tools: Soldering iron, soldering gun, hot air gun

Hard soldering (silver soldering process)

Hard soldering uses a solder with a higher melting point, often containing silver, to create a stronger joint. It requires more heat than soft soldering, which is typically provided by a blowtorch. This usually makes it more expensive. Oxidation can also occur if flux is not used properly.

• Temperature range: 450°C to 900°C
• Solder material: Silver-based or brass-based alloys
• Flux used: Borax-based flux
• Common tools: Blowtorch, propane torch, oxy-acetylene torch

Brazing (high temperature soldering process)

Brazing operates at an even higher temperature. The filler metal (often brass or copper-based alloys) creates an extremely strong and heat resistant bond. This requires high temperatures, specialised tools, and skilled labour – which, of course, makes it more expensive than soft or hard soldering. It’s also not suitable for delicate electronics due to extreme heat.

• Temperature range: Above 900°C
• Solder material: Brass, copper, or aluminium-based alloys
• Flux used: Borax-based flux
• Common tools: Oxy-acetylene torch, induction heating, furnace brazing

What is soldering vs welding?

A metallic bond occurs in all welding services, brazing, and soldering processes. However, with brazing and soldering, the base metals being joined together are not melted. Whereas, when it comes to welding, they are. With both brazing and soldering, the filler metal has a melting point lower than the metal parts being joined together. 

Many welding processes do not even require a filler metal. They rely solely on melting and fusing the base materials together, while others use a filler metal to strengthen the joint.

Soldering process variables

Here, you’ll find a set of process variables that need to be managed to ensure the quality and strength of the final solder joint.

Time and temperature

Together, these factors control how much dissolution occurs, which refers to the process where the base metal gradually dissolves into the molten solder. It also controls how thick the intermetallic compound layer becomes. Temperature primarily controls the speed at which the solder occurs and the type of compounds that form.

Amount and type of flux

The flux cleans the surfaces of all components and keeps them from oxidizing when soldering. The type you use affects how it reacts with the metals and the range of temperature. The amount you use affects whether or not the solder joint forms before oxidation. In some cases, a shielding gas may also be used to help prevent oxidation.

Joint geometry

This affects the strength of the final solder. If optimum, the joint will pull filler metal in and hold it in place. If the joint gap is too big, the strength of the joint is dictated by the properties of the solder. If it’s too tight, the strength of the joint begins to weaken, and solder flow can be nipped off. 

Specialised soldering techniques

The benefits and applications of welding

Welding services offer a range of benefits over soldering and brazing, and they are more commonly used for mass production and more industrial applications.

The benefits of welding services include:

• creating permanent, high strength connections
• versatility with the ability to weld various metals, alloys, and even thermoplastics
• being cost-effective and efficient for mass production and repairs
• precision and customisation with advanced methods allowing detailed and complex fabrications
• the ability to integrate robotic systems for automation compatibility

Here at Salamander Fabrications we use a number of different types of welding techniques, such as MIG, TIG, and spot welding. Our team consists of qualified, well-trained welders who have meticulously built up their expertise and use cutting-edge tools on every job. Our welding capabilities are also coded in line with numerous standards and specifications.

Would you like some more information on welding services? You can take a read of our blog – ‘5 Types of Welding Joints Explained’

Our welding specifications

• EN 15614-1: Specification and qualification of welding procedures for metallic materials. Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys.
• EN 15614-2: Specification and qualification of welding procedures for metallic materials. Part 2: Arc welding of aluminium and its alloys.
• EN 9606-1: Qualification testing of welders. Fusion welding – steels.
• EN 9606-2: Qualification test of welders. Fusion welding – aluminium and aluminium alloys.

Other metal forming techniques

Let’s take a look at some other metal forming techniques:

Cutting and shaping

Metals can be cut and shaped using methods like shearing, sawing, laser cutting, and plasma cutting. Here at Salamander Fabrications we use a fibre laser as it is a more efficient choice that requires fewer external gases when compared to a CO2 laser. Fibre lasers allow for smooth cutting, fast speeds, more flexibility, and less wastage. This can be used to create components for structural frames, machinery parts, and other custom products.

We have two Bystronic lasers, one 3kw and one 6kw. The bed size for our laser cutter is 3000mm x 1500mm, which allows us to take on a range of different projects.

Machining

Turning, milling, and drilling can be used to achieve precise dimensions and finishes. Metals such as high-carbon steels are commonly machined for parts that require high strength and precision.

Sheet metal folding

Sheets of ferrous metal are bent into shape using a CNC press brake or folding machine. Sheet metal folding allows for accurate bends and angles, and maintains strength and structural integrity.

We use laminating techniques that allow us to make our own bespoke tooling. This allows us to provide more bespoke solutions. We offer both Amada and Bystronic press brakes, which improve our programming quality and speed.

Heat treatment

Heat treatment can be used to change the mechanical properties of metals to improve hardness, strength, and ductility. These processes can include annealing, quenching, and tempering.

Coating and finishing

Commonly, a lot of metals will undergo a final coating or finishing process, like painting or powder coating services. This is done to improve aesthetic appearance and provide resistance to corrosion, especially in outdoor environments.

Casting

Investment casting and sand casting can be used to create complex shapes from molten metals, like cast iron. The resulting cast can be used for engine blocks, pump housings, and decorative items.

Sheet metal fabrication services from design to delivery

Here at Salamander Fabrications, we have over 50 years’ experience providing end-to-end machining and fabrication services throughout the UK.

Our company provides a complete range of CNC machining services. We are extremely proud of our ability to offer both full service sheet metal fabrication and sub-contracting services.

If you would like some more information or advice, please feel free to contact us. Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com. Our friendly sales team will be more than happy to help.

By Embryo

In basic principle, the melting point of metals is the temperature that changes them from solids to liquids. This measurement affects how and where they can be used. It also affects fabrication and workability, meaning how the metal is manufactured.

The melting point of metals is also directly related to thermal conduction and thermal expansion. This and the melting point will ultimately affect how a metal is used. The lower the melting point, the more thermal conduction or expansion it demonstrates. 

Metal melting points are also particularly important when it comes to welding services, which is just one of the sheet metal fabrication services we offer here at Salamander Fabrications. Our dedicated team of experts is happy to talk to you about our services any time you like, but for now, continue reading for more information on the melting point of metals.

Why is the melting point of metals so important?

The melting point of any metal affects how the metal is alloyed. This refers to the process of combining a metal with one or more other elements, and it must occur in a liquid state. Metal melting points also dictate how the metal is used. For example, the aerospace or oil and gas industries often require metals that can handle extreme heat.

Melting point of metals chart

Our handy melting point of metals chart shows a number of common and also rare metals, along with their properties, applications, benefits, and melting points.

How to measure the melting point of metals

There are several methods for measuring melting points, each with its own benefits and limitations.

Differential Scanning Calorimetry (DSC)

This is a highly accurate method often used in research and industry. The technique works by measuring the heat flow required to increase the temperature of a sample piece of metal. When the sample reaches its melting point, there is a change in the amount of heat needed, which can be detected precisely. This is highly accurate but involves expensive equipment and a time consuming process.

Pyrometry (optical methods)

Pyrometers are used to measure temperature remotely without direct contact with the sample piece of metal. This is especially useful for metals with high melting points, where conventional thermometers may be ineffective or dangerous to use. The accuracy depends on the material and surface properties of the metal.

Thermocouples

These are widely used in industrial settings to measure temperatures in a variety of processes other than just metal melting. A thermocouple is made of two different metals joined at one end, creating a voltage that changes with temperature. The voltage can then be correlated with the temperature of the metal. This is inexpensive, widely available, and versatile. However, calibration is required, and it offers limited precision at extremely high temperatures.

For more information, you can check out our other blog on metals – ‘The Different Types of Metals; Their Properties, And Their Applications’. 

Factors that affect the melting point of metals

Metal melting points depend on several factors that can influence the strength of atomic bonds and structural arrangements.

Atomic bonding

Metals are characterised by metallic bonding. The strength of metallic bonds correlates with how much energy is needed to separate the atoms and cause the metal to melt. Stronger bonds need more heat and vice versa. 

Atomic structure

The arrangement of the atoms in a metal also denotes how tightly they are packed together. The tighter they are, the more energy is required for them to change state. Face centred cubic (FCC) structures are less resistant to temperature change, which often results in a lower melting point. Body centred cubic (BCC) and hexagonal close packed (HCP) structures tend to have higher melting points due to tighter atomic interactions.

Impurities

When a metal is impure, the atoms are arranged irregularly, which creates defects in the atomic structure. This can either lower or raise the melting point, depending on the impurity.

Pressure

Higher pressure generally results in a higher melting point because atoms are forced into tighter arrangements, making it harder to separate them. This typically applies to high-altitude or deep earth applications.

Atmospheric conditions

Oxygen levels or the presence of oxidizing agents can affect a metal’s melting point.

Pure metal vs. Alloy melting points

There are some interesting differences when it comes to comparing the melting points of pure metals and their alloys. Pure metals usually have a specific melting point that corresponds to the temperature at which their atomic bonds break down.

On the other hand, as alloys are mixtures of two or more metals, they can often have a wide range of melting points rather than a single point. For example, brass (an alloy of copper and zinc) melts between 900°C and 940°C, while pure copper melts at 1,085°C specifically.

Some alloys are designed to have lower melting points, especially for their use or application. For example, solder (a tin-lead alloy) has a melting point ideal for joining electronic components, as it can melt easily without damaging sensitive parts. Equally, some alloys are designed for high temperature applications. For example, stainless steel (iron-based alloy) has a high melting point due to the addition of chromium, which enhances the alloy’s strength.

The importance of the melting point of metals in terms of welding services

The melting point of metals is crucial in welding because it determines the amount of heat needed to join metals together without causing excessive distortion or damage. Metals with high melting points require more heat and specialised welding techniques. Metals with low melting points risk overheating or warping. Understanding melting points helps in selecting the right welding method, filler material, and heat control to ensure strong, defect-free joints.

Here at Salamander Fabrications we use a number of different types of welding techniques, such as MIG, TIG, and spot welding. Our team consists of qualified, well-trained welders who have meticulously built up their expertise and use cutting-edge tools on every job. Our welding capabilities are also coded in line with numerous standards and specifications.

Our welding specifications

• EN 15614-1: Specification and qualification of welding procedures for metallic materials. Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys.
• EN 15614-2: Specification and qualification of welding procedures for metallic materials. Part 2: Arc welding of aluminium and its alloys.
• EN 9606-1: Qualification testing of welders. Fusion welding – steels.
• EN 9606-2: Qualification test of welders. Fusion welding – aluminium and aluminium alloys.

Other metal forming techniques

Below, we’ll explore some other metal forming techniques:

Casting

Casting processes like investment casting and sand casting are used to create complex shapes from molten metals like cast iron. The casting equipment must have a higher melting point than the metal being cast, or it will be unable to fulfil its function.

Cutting and shaping

The melting point of metals isn’t relevant here, but this is still an extremely popular metal fabrication technique. Metals can be cut and shaped using various methods such as shearing, sawing, laser cutting, and plasma cutting.

Heat treatment

Heat treatment can include annealing, quenching, and tempering. These are used to improve hardness, strength, and ductility. The melting point will undoubtedly influence the effectiveness of heat treatment, as more heat may be needed for success.

Sheet metal folding

Sheets of metal can be bent into shape using CNC press brakes or folding machines. Sheet metal folding allows for accurate bends and angles, essential for manufacturing parts with tight tolerances.

Coating and finishing

Coating and finishing processes like painting or powder coating services are used to improve aesthetic appearance and corrosion resistance. This is particularly useful for outdoor applications where durability and appearance are key.

Forming and fabrication

Sheet metal fabrication may involve bending, rolling, or stamping metals into various forms. These methods are used to produce sheet metal parts, structural sections, and other custom components.

Contact Salamander Fabrications for all of your sheet metal fabrication enquiries

Here at Salamander Fabrications, we’re happy to share our knowledge and expertise for any project you have in mind.

We have been the UK’s chosen choice for sheet metal fabrication solutions for over 50 years, with an expert team providing end-to-end machining services. If you would like some more information or advice, please feel free to contact us, give us a call on 01484 843599 or send an email to sales@salamanderfabs.com. Our friendly sales team will be more than happy to help!

By Embryo