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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

Working with aluminium in your sheet metal fabrication project offers several advantages, including corrosion resistance, thermal and electrical conductivity, as well as its strong properties. So it’s no wonder it’s used in a variety of applications.

But, as well as metal fabrication services, just what applications is aluminum most suited for?

Well, we have all the answers and more in our blog below. Find out the top uses of aluminium, as well as why it’s a popular metal and even the potential drawbacks of using it.

So…what are the top 10 uses of aluminium?

We know that many companies appreciate the benefits of using aluminium. But just what industries do they operate in, and why is it a popular choice?

1. Architectural

Aluminium provides both strong and lightweight qualities – with an excellent strength-to-weight ratio. This makes it easier to fix buildings. For example, it uses fewer fixings than architectural projects utilising steel would need.

Moreover, it is easier to fabricate, which means it can be folded to fit any desired style or shape – suitable for architects and those in the construction industry looking to utilise it in a specific and complex project.

2. Consumer goods

Aluminium is easy to handle and efficient to manufacture – which is why it’s a popular choice when it comes to consumer goods. This might include the manufacturing of flat-screen TVs, laptops, mobile phones, and even some items of cookware.

What’s more, aluminium has a polished finish which makes it look aesthetically appealing; providing a modern and sleek look that remains timeless.

3. Electrical uses and power lines

Thanks to its low density, aluminium is commonly utilised in electrical applications. As it is a lightweight material, it’s ideal for power lines that span long distances.

Moreover, it’s easier to merge aluminium with wires as it is more ductile – which makes it a popular option over metals such as copper.

4. Packaging applications

Again, as a result of it being lightweight, flexible, and recyclable, aluminium is often utilised in packaging applications for the food industry. For example, in cans that hold food.

It is also hygienic and non-toxic so keeps the smell of food contained – ultimately preventing unwanted aromas.

5. Reflectivity and foil uses

Aluminium has a high level of reflectivity, which means it’s able to bounce back a large proportion of light – without needing to have additional coatings.

This means it’s a more cost-effective metal type to use when it comes to manufacturing mirrors or lighting fittings, which need reflectivity to function or for aesthetic appeal.

6. Transportation

In transportation and the manufacturing of transportation vehicles, aluminium is also a popular choice. It is lighter than other metals, making it an ideal option for reducing fuel emissions and thus enabling a higher level of energy efficiency.

Again, thanks to its lightweight properties, it increases the safety of transportation vehicles and reduces the risk of injury, as it has a higher level of energy absorption.

7. Ships

Again, with its high weight-to-strength ratio, aluminium is also a widely chosen material for help with ship manufacturing.

Ships made with aluminium will have a lower overall mass, allowing for more cargo – meaning more people can be loaded onto the vessel. Ultimately, this reduces the amount of trips these ships need to take to carry every load, so makes processes involving them more efficient.

8. Medicine and health care

As a lightweight material, aluminium is ideal for medical applications. This includes medical equipment such as wheelchairs, operating tables, and dental chairs – as it makes them easier to manoeuvre.

Aluminium is also non-toxic, which makes it safer to use when it comes to surgical instruments and other essential medical devices.

9. Sustainability

As previously discussed, aluminium is a very sustainable material. According to Aston Architectural Aluminium, aluminium uses 95% less energy when recycled than producing new aluminium from raw materials. Furthermore, this also reduces the amount of gas emissions because of the little energy used.

As a result, aluminium is most popular with manufacturers that are trying to obtain recognition as being eco-friendly – as they can say their packaging is 100% recyclable if they use aluminium.

10. Aircraft engineering

With its lightweight properties, strength, and high resistance to corrosion, aluminium is also an ideal material to use when it comes to aircraft engineering. Aluminium offers resistance to UV damage, which is why it is most suitable for aircraft construction.

Aerodynamic designs can also easily be made with aluminium as a result of its flexible formability – meaning they can easily be shaped and molded into complex aircraft components.

Uses of aluminium: FAQs

Does aluminium get rusty?

No, aluminium doesn’t get rusty because it doesn’t contain iron. But it does have the potential to corrode. More specifically, it corrodes when exposed to both oxygen and moisture. This is a process called oxidisation.

If you’re interested in learning what metals rust, you can check out our blog. 

Why is aluminium preferred over other metals in fabrication projects?

There are many advantages to using aluminium in metal fabrication projects. For example, some key advantages it offers are:

• Strength-to-weight ratio: Even though aluminium is a lightweight material, it is able to withstand considerable amounts of stress, making it a strong metal to use.
• Corrosion resistance: Thanks to the protective oxide layer it creates, it resists corrosion so doesn’t require additional treatments.
• Versatility: It’s easy to mould aluminium into a variety of shapes, so it’s perfect for complex projects that require specific shapes.
• Sustainability: In terms of sustainability, aluminium is able to be recycled again and again – without damage or loss to its properties.

What are the disadvantages of using aluminium?

Obviously, with any metal you choose for a fabrication project, there are going to be some drawbacks associated with it. For example, some challenges to using aluminium include:

• Prone to fatigue: Over time, aluminium can be prone to fatigue from excessive loading, which can create cracks and other damage.
• Reaction with acids: Certain chemicals can lead aluminium to discolour.
• Poor health: When exposed to high levels of aluminium, it’s possible for this to cause health problems to an individual. For example, it can contribute to conditions like Alzheimer’s when it accumulates in the brain in large quantities.
• Requires specific skills when welding: Welding aluminium can be harder to do than welding steel. In fact, it requires certain techniques, skills, and equipment.

To find out more about the differences between aluminium and steel, explore our blog.

Achieve Precision and Affordability with Salamander Fabrications in All Your Sheet Metal Projects

If you’re seeking a sheet metal fabrication project that provides precision as well as affordability, look no further than Salamander Fabrications.

Our team has experience in the sheet metal industry that spans decades, so we know what advice and services to provide when it comes to your specific project. When you work with us, our experts will be able to help your projects come to life with services such as laser cutting and powder coating, as well as much more.

Want to know more? Contact our team of experts today.

By Embryo

The market of metal fabrication services can be hard to navigate, especially when it comes to choosing the right metal for your project.

Committing to thorough research is your best bet, but this can be hard to perform when managing a project and/or your business. And sometimes, you just need the answer to whether one metal is more effective than another – such as mild steel vs stainless steel.

If you’re currently in this position and don’t know where to start, we’ve got you covered in our blog below. We’ll discuss the difference between mild steel and stainless steel, their varying properties, and their applications.

What is mild steel?

Mild steel is a metal-containing iron (meaning it’s ferrous) and is widely regarded within the sheet metal industry as suitable for a variety of engineering applications. As it is a type of carbon steel that has a low amount of carbon, it makes it easier to shape and machine.

What is stainless steel?

A solid metal alloy, stainless steel is made of iron, carbon, and other types of metals – typically chromium, nickel, and nitrogen. This helps make it a metal that can endure corrosion more than other types, so is perfect for specific applications – such as cookware manufacturing and medical instruments.

Mild steel vs stainless steel: corrosion

Let’s take a look at the difference between mild steel and stainless steel when it comes to both types of corrosion properties:

Mild steel corrosion

Mild steel does not have corrosion resistance. In fact, mild steel has to undergo a galvanisation process to prevent it from corroding. This is the act of coating a metal with zinc to help it avoid rusting. If mild steel doesn’t get galvanised, it will likely need more maintenance as the metal could potentially be weakened.

Stainless steel corrosion

As the name suggests, stainless steel is corrosion-resistant (hence stainless). This is due to the chromium it contains. This typically amounts to 10% and reacts with the oxygen in the air to form a protective layer – which makes it resistant to corrosion and rusting.

Mild steel vs stainless steel: strength

Is stainless steel harder than mild steel? We’ll explore this and the strength of both below:

Mild steel strength

The tensile strength (the amount of force a metal can withstand before it breaks/stretches) of mild steel is usually between 400 and 550 MPa – so a fairly average level. Its yield strength (the amount of stress the metal can take before it begins to deform plastically) is around 250 – 350 MPa.

Stainless steel strength

As there are 100s of types of stainless steel, the strength of it depends on the type of alloy used and its condition. In terms of tensile strength, this typically ranges from 500-720 MPa. For example, 304 stainless steel can reach a maximum of 625 MPa, meanwhile, its yield strength is approximately 205 MPa.

Mild steel vs stainless steel: weldability

Weldability refers to a metal’s ability to be welded without cracking or causing other defects.

Read on to see the comparison of mild and stainless steel when it comes to the different types of welding:

Mild steel weldability

As a result of its low ductility, mild steel is flexible and therefore easy to weld. When welding mild steel, it’s important to wear proper PPE to avoid exposure to welding fume; this can cause health problems such as lung cancer.

Stainless steel weldability

Whilst stainless steel is weldable, it can be harder to weld than other types of steel – such as carbon steel. Generally, mild steel is easier to weld, but stainless steel can be welded using special arc processes, such as TIG welding.

Mild steel vs stainless steel: malleability

A metal’s ability to be shaped without cracking is called malleability. Below we’ll explore the malleability of both mild and stainless steel below:

Mild steel malleability

Overall, mild steel is much more malleable than stainless steel. Again, this is the result of its low carbon content, which makes it easy to shape and bend. As a result, it’s the preferred choice for complex metal–forming projects.

Stainless steel malleability

Grade 304 and 316 stainless steel are the most malleable types of steel available, as they have a high nickel content. This means they are more suitable to be shaped without cracking – making them ideal for precise and intricate applications.

Mild steel vs stainless steel: applications

Now we’ve explored the differences between mild and stainless steel when it comes to their properties, let’s dive into the applications they’re best used for:

Stainless steel applications

There are a variety of applications in which stainless steel can be used. For example, It’s used in cookware because it has high heat resistance – and is easy to clean. What’s more, in the medical industry, it is used to create medical instruments as it is easier to sterilise than other types of metals.

Mild steel applications

Mild steel is used in a variety of industries, including construction, manufacturing, and automotive. It’s a popular choice due to its weldability, and its ability to be cut and coated in a bunch of different ways.

Mild steel vs stainless steel: cost comparison

Finally, let’s take a look at the most important factor pertaining to using a metal – the cost.

The cost of mild steel

Overall, the initial cost of mild steel is cheaper than stainless steel. This is because of its simpler composition and availability. However, it’s important to factor in the cost of maintenance as it is prone to corrosion.

The cost of stainless steel

As mentioned, stainless steel is more expensive as a result of the added alloying elements. For example, the addition of chromium to aid it in providing ultimate corrosion resistance. But over time, it will require less maintenance because of this resistance.

So…which one is better?

Overall, the most suitable option for you between mild steel and stainless steel depends on what you plan on using it for. Whilst mild steel is easier to weld and malleable, it is prone to corrosion, whereas stainless steel offers the opposite factors.

Ultimately, if you’re looking for a low-cost and low-maintenance solution, mild steel that has been galvanised is probably your best bet.

Work with Salamander Fabrications for cost-effective projects with precise results

At Salamander Fabrications, we’ve been in the sheet metal industry for over 40 years, and have seen a variety of projects come to life in that time. So when you need advice about which metal to choose for your specific project, we know what will suit your needs best.

When you work with us, our experts will be able to help your projects come to life with ISO-accredited services from CAD to welding.

Interested? Get in touch with our team of experts today.

Additional reading:

• Aluminium vs Steel: Understanding the Differences

By Embryo

Aluminium is a common metal used in a variety of projects. It’s economical and safe, as well as having several properties which make it incredibly versatile. After steel, it’s one of the most widely used metals, so it’s no wonder it’s a sought-after solution for different sheet metal fabrication services.

If you’re considering using aluminium in your next sheet metal project, you might be wondering what the specific advantages of aluminium are. Fortunately for you, we discuss this and more in our blog below…

So…what are the advantages of aluminium?

Aluminium is a commonly used metal, and it’s clear why when you explore its benefits. In fact, we’ve highlighted 11 we can think of below:

1. Corrosion resistance

One advantage of aluminium is its high level of corrosion resistance. After exposure to the air, the metal forms a thin oxide layer that helps to stop further oxidation. This layer also prevents the metal from being exposed to environmental damage, such as moisture, chemicals, or saltwater.

Unlike other metals – e.g., iron and steel – aluminium doesn’t have the potential to rust. What’s more, further coatings can enhance the metal for increased levels of durability. Using a corrosion resistant metal such as aluminium can help reduce maintenance costs – whilst ensuring the reliability of sheet metal fabrication projects in harsh weather conditions.

2. Conductor of heat and electricity

Aluminium is also a very good heat and electricity conductor. Whilst this might be less so than copper, aluminium benefits from being low in density, which makes it more lightweight and cost effective. This means it’s a popular choice for certain electrical applications – such as power transmission lines.

Thanks to its high thermal conductivity, aluminium enables more effective and quicker cooling within radiators, heat exchangers, and other electronic devices.

3. Highly reflective

As it has a high level of reflectivity, aluminium is particularly useful for light and heat management applications. As it reflects light and even infrared radiation, it’s ideal for lighting fixtures, solar panels, and thermal insulation.

With a high level of reflectivity, it helps reduce energy consumption within its applications, as well as better maintaining temperature control in both buildings and vehicles.

4. Non toxic substance

Some metals react poorly with food or beverages, and even release harmful substances. But, aluminium is non toxic, which makes it ideal for food storage and containers.

Moreover, in the medical industry, it is used within certain packaging and equipment, as it upholds a high level of hygiene.

5. Can be recycled

Thanks to aluminium’s non toxicity, it’s environmentally friendly, making it a recyclable material. This recyclability can even continue indefinitely, as it doesn’t lose any of its quality or properties. This means there is no need for raw material extraction.

Furthermore, recycling aluminium also requires much less energy than producing new aluminium from scratch – so it can lower carbon emissions and energy consumption significantly.

6. Extreme strength

Aluminium also offers exceptional levels of strength, whilst remaining lightweight. This means it’s perfect for demanding applications, especially as a preferred material in aerospace, automotive, and construction industries.

Alloys of aluminium can also be manufactured to match the strength of steel, whilst also being resistant to corrosion and environmental damage – something steel is not. Aluminium also maintains its strength in extreme temperatures – so it offers an enhanced level of reliability, longevity, and safety in a number of industries.

7. Ductile

Ductility is an often-sought-after property in metals, and aluminium has high levels of it. This means it can be stretched or shaped into a variety of shapes, such as thin wires and intricate forms – without being subject to cracking or breaking.

Thanks to this ductility, aluminium is easier to process via rolling and forging, meaning companies that use it can reduce production costs as well as material waste.

8. Impermeable

Being impermeable means a material does not allow gases, liquids, or light to pass through it – which is another ideal property of aluminium. As a result, this makes it a great barrier material.

Even in thin layers such as foil, aluminium retains this barrier, meaning its material usage can be reduced whilst upholding a high level of protection.

9. Paramagnetic

Paramagnetic metals have a temporary reaction to magnetic fields but do not uphold this magnetism once the field is removed. Aluminium is paramagnetic, so it’s a popular application in industries where non-magnetic materials are required.

For example, this includes MRI machines within the medical industry and other sensitive electronic devices. Unlike ferromagnetic metals, aluminium is not vulnerable to electromagnetic signals so it won’t cause interference – making it ideal for communication and shielding applications.

10. Noise-reducing properties

Aluminium also has exceptional noise reduction properties, so it’s considered a valuable metal within the construction and other industrial industries. It dampens vibrations and ultimately absorbs sound, so helps reduce levels of noise pollution in buildings, vehicles, and machinery.

Because of this property, aluminium is used as panels within architectural designs, helping to maintain a quieter environment in the home. What’s more, it enhances passenger comfort within cars as it minimises engine and road noise whilst in a vehicle.

11. Low in weight

As it is much lighter than other metals, such as steel or copper, using aluminium helps to reduce the overall weight of products. This is why it is commonly used within the aerospace and automotive industries, where less weight means an improvement in fuel efficiency and performance.

This level of light also helps to enhance the portable nature of certain consumer products, including electronics and packaging.

What projects should I use aluminium for?

Whilst there are many advantages to using aluminium, there are specific industries and projects it will have more suitability & uses in. For example:

Transport vehicles

Aluminium is lightweight, whilst also being strong and corrosion-resistant, which makes it perfect for the manufacturing of transportation vehicles. For example, it’s used in the mechanical parts of cars, such as the engine and suspension.

Construction and engineering

As a result of its sleek design – and the fact that it’s weather-resistant/durable, aluminium is used in window and door frames, as well as in beams and columns. Aluminium sheets are also utilised in roofing to provide protection against the elements.

Foil

Aluminium is also used to make foil by moulding the metal into a thin sheet. This is most beneficial for food packaging, as it can help to maintain the temperature of a food, and also within heat insulation for the same reasons.

Choose Salamander Fabrications for Budget-Friendly Projects with Unparalleled Accuracy

Having been in the industry since 1968, we’ve had our fair share of experience in a variety of sheet metal fabrication projects. This means we’re well-equipped to provide you with a fabrication service that will exceed your expectations.

When you work with us, our experts will be able to help your projects come to life with services from CAD to welding.

Want to find out more? Get in touch with our team of experts today.

By Embryo

Aluminium and steel are the most commonly used metals in various industries, applications, and sheet metal fabrication projects. This is because of their unique properties which makes them more durable. What’s more, they are also widely produced which makes them easier to source. 

But when it comes to aluminium vs steel, which one is better? 

Well, the answer depends on a number of factors; mostly their difference in properties. Read on to find out what these differences are, as well as the common applications of both metals in sheet metal fabrication services. 

Interested in another service? Get in touch at 01484 843599 to find out what else we offer.

Aluminium vs steel: what are the differences?

There are several differences between aluminium and steel. Let’s take a look at their properties in more detail so we can understand how both compare.

Physical state

Aluminium: The most abundant element on earth, aluminium is light and silvery-white in its appearance. Thanks to its aesthetic appeal – it’s ideal for use in kitchen appliances. 

Steel: Steel’s physical state will vary depending on the treatment it undergoes. Typically, it comes in a range of colours. For example, steel containing heavy amounts of carbon will be dark brown in appearance, whereas stainless steel is shiny and silver.

For more information on sheet metal finishes, take a look at our blog.

Maleability

Aluminium: Aluminium is the second most malleable metal, so it can be moulded into different shapes. In terms of malleability, aluminium is a more suitable option than steel. 

Steel: Steel is still highly malleable, meaning it can be shaped into many different forms. Because of this malleability, it’s also easy to join steel together to make intricate shapes. 

Ductility

Aluminium: Aluminium is the sixth most ductile metal in the world. So, it can be shaped into forms without risk of breaking, but there are still better alternatives out there. 

Steel: Generally, steel is able to be ductile, but this depends on the variation you choose. Ultimately in terms of ductility, aluminium would be a better option. 

Conductivity

Aluminium: Aluminium’s electrons can easily move between atoms making it a strong conductor of electricity.

Steel: Steel does conduct heat and electricity to a certain degree, but again, it depends on the variation of steel used. For example, stainless steel tends to be a poor conductor of heat as a result of its alloy structure. 

Density

Aluminium: The density of aluminium is about 2,710kg/m3, a fairly low amount, which is why it is lightweight and easy to move. 

Steel: Plain steel has a density of 7.85g/cm³, 7850kg/m³, making it a fairly dense metal. This makes it a sturdy and durable material for use in the construction and manufacturing of heavy-use objects. 

Luster

Aluminium: Aluminium has a dull lustre, typically the result of a thin layer of aluminium oxide. 

Steel: Whether steel has a lustre depends on the type you use. Mild and stainless steel have a shiny finish, whereas carbon steel does not. 

Melting point

Aluminium: Aluminium has a melting point of 660 Celsius (°C).

Steel: Steel has a melting point of 1,205-1,370 Celsius (°C).

Tensile strength

Aluminium: The tensile strength of aluminium is 90 MPa but this can be increased to over 690 MPa for some heat-treatable alloys. 

Steel: The tensile strength of steel depends on its variation but typically, high-grade steel has a high UTS of approximately 1,000 megapascals (MPa).

Corrosion resistance

Aluminium: Aluminium and its alloys have significant resistance to corrosion. But, when submerged in water it can be exposed to higher chances of corrosion. 

Steel: Steel containing carbon is not corrosion-resistant, due to the higher chances of it experiencing oxidation. Stainless steel however is corrosion-resistant. 

Overall, is aluminium stronger than steel?

Pure steel in general is stronger than aluminium, mostly because it is a much denser material. Furthermore, as aluminium is a high conductor of electricity, it is less resistant to corrosion, making it a weaker metal. 

But, when considering which of the two metals is stronger, sometimes weight can factor into the equation. For example, aluminium has a better strength-to-weight ratio than steel, meaning that although more aluminium is needed to support the same load as steel, it would weigh much less. 

Is aluminium cheaper than steel?

Whether aluminium is cheaper than steel depends on the type of steel you purchase. 

For example, steel varieties like mild steel and carbon steel are cheaper than aluminium. However, stainless steel carries a heavier price tag than aluminium. 

Aluminium: common applications and uses

The applications and uses for aluminium vary, but most commonly they are used in the following areas:

Infrastructure

As it is a low strength metal, aluminium is not an ideal material for building physical structures. However, it does have other benefits that make it desirable for the industry. For example, aluminium is commonly used to make roofing materials. 

This is generally more specific to Australia where many people opt for roofing types such as tiles and shingles. As it is corrosion resistant, it makes it an ideal option to protect a home from severe weather conditions. What’s more, thanks to its lightness and thinness it contains very little heat – keeping a home cooler in the summer months. 

Manufacturing

Aluminium is widely used in the construction industry for machine bearings. These are systems that assist an objects’ rotation within different types of machinery, including automobiles, planes, and electric generators. 

Aluminium is an ideal option for machine bearings because of its corrosion resistance, which helps to minimise damage and ultimately saves money on maintenance, repair, and replacement costs. 

Transportation

It has been estimated that 25% of the aluminium used in transportation is used in road and rail commercial transport. Most uses of aluminium in this industry come in the form of rolled products (sheets and plates) and extrusions, as it is easy to shape and bend. 

It’s also a common choice for aircraft construction, mostly because of its resistance to UV damage. 

Appliances

Aluminium is a significant conductor of heat, which makes it a great choice for the manufacturing of kitchen appliances that rely on generating heat, such as ovens, microwaves, and radiators.

It’s also used in handheld kitchen equipment, including pots, pans, and oven trays, because of its lightweight properties that make it easy to lift by an average user. 

Steel: common applications and uses

Steel is also used in the same industries as aluminium, but they have different purposes. For example, in:

Infrastructure

Steel is commonly used in the construction of certain types of infrastructure. This pertains but is not limited to, bridges, railways, train stations, and airports. 

Thanks to its significant strength, versatility, and cost-effectiveness, it’s a popular option for the construction of the above pieces of infrastructure. 

Manufacturing

As mentioned, because of its high tensile strength and low cost, steel is a popular choice in the manufacturing industry. 

For example, in ship manufacturing, high tensile steel is typically applied to areas of the ship that are exposed to larger amounts of mechanical stress, as well as the deck and bottom regions of larger tankers.

Transportation

In the transportation industry, most journeys and means of traveling are made possible because of steel. In cars, steel is a common choice for machine bearings and pipework, as well as car rims. 

It’s also used in many car engines because it can withstand high temperatures and varying pressures. 

Appliances

When it comes to kitchen appliances, stainless steel is predominantly used because of its finish, as well as its higher levels of resistance to types of corrosion, such as rust. 

But, pure steel is also used within the industry, predominantly for washing machines, as it makes them easier to repair and maintain than those using plastic components. 

Aluminium vs steel: FAQs

Aluminium vs steel – which lasts longer?

Aluminium and steel are both known for their durability and strength. Whether one lasts longer than the other also depends on the specific applications either are used in. However, aluminium will most likely last longer than regular steel because of its corrosion resistance. 

Steel is heavier and stronger than aluminium, making it a better choice for heavy duty projects and purposes. Meanwhile, aluminium is more flexible and bendable than steel, making it ideal for projects involving shaping. 

Which is better for an individuals’ health – aluminium or stainless steel?

Exposure to steel and aluminium will not be extremely harmful for an individual to experience, but it does depend on what the metal is being used for. 

For example, when it comes to food preparation and cooking, stainless steel is generally considered to be a safe option. This is for a number of reasons, including:

• Reactivity: Aluminium is more likely to react with acidic foods if used in excess, which ruins the taste of food and affects nutritional value.
• Oven safety: Stainless steel is oven safe whereas aluminium isn’t.
• Dishwasher safety: Stainless steel is dishwasher safe whereas aluminium isn’t. 

Choose Salamander Fabrications for Accurate Results

Your business might need sheet metal fabrication services, but that doesn’t mean that sourcing them has to be a chore. In fact, the experts at Salamander Fabrications can help provide you with the advice, guidance, and solutions you need to get your projects off the ground. 
If you want to get started with metal sheet fabrication, or simply want to find out more about our services, get in touch with our team of experts today.

Additional Reading

• Mild Steel Vs Stainless Steel: What’s The Difference?

By Embryo