Sheet metal is a flexible construction material with many uses. From mundane things like storage sheds to complex things like aeroplane wings, it can be used for a wide variety of purposes.
There are many distinct types of sheet metal, each with its own advantages and disadvantages. The many types of sheet metal and the applications for each will be discussed.
Sheet metal is an alloy that combines iron with small amounts of other metals like copper, nickel, manganese, or chrome to achieve specific physical properties.
Stainless steel, which resists corrosion better than regular steel, and aluminium, which weighs less but is less durable than other metals, are both options for sheet metal.
Sheet metal can be used for anything from making signs to making automobiles.
Learn all the ways sheet metal can be put to use in the following text! In this article, I will discuss the many sheet metal types available.
Sheet metals are produced by rolling flat steel into a thin layer and then cutting it using a shear or die press machine.
Aluminum sheet metal is more common than other types of sheet metal made from metals like steel or copper.
Aluminum's adaptability and resistance to corrosion have led to its use in a wide variety of applications, from car frames to aeroplanes.
Sheet metal can be formed by joining two metal sheets and then stamping them into the desired shape.
Although steel and aluminium are the most common, sheet metal can be made from a wide variety of metals.
Sheet metal is used for a wide variety of products in the construction and manufacturing industries, from cars and aeroplanes to furniture and even toys for kids.
If you're curious about sheet metal and how you can incorporate it into your own projects, read our blog post!
Table of Contents
All About Sheet Metal – Materials, Standard Sizes & Forming Processes
The basis of modern engineering is sheet metal. It can be found everywhere, from vehicles and machines to storefronts and furniture.
It is imperative that engineers have a solid foundational knowledge of sheet metal before attempting to maximise its potential. Included are the usual units of measurement, materials, production variants, and possible shaping techniques.
What Is Sheet Metal?
Sheet metal is one of many metal products available. Sheet metal refers to any metal that is between half a millimetre and six millimetres in thickness.
Metals can be sorted into different groups according to their thickness, using a variety of different measurement systems.
Foils, sheets, and plates are all defined by their thickness.
Measurements of thickness can be taken in millimetres, mils, or gauges. However, mils and gauges see more widespread use in the manufacturing and engineering industries.
To use a different unit of measurement, one mil is equal to one thousandth of an inch. In the United Kingdom, millimetres are commonly referred to as "mils," which can be confusing.
Gauge is used to describe the thickness of metal sheets. Despite official guidelines discouraging the use of such gauges, they are still commonly employed.
Gauge is a unit of measure for the thickness of metal sheets, expressed in pounds per square foot. Therefore, the thinner the material, the higher the gauge number.
Depending on the metal's density, the actual thickness (in millimetres) of a given gauge can change (e.g. 12 mm steel vs 12 mm aluminium).
Foil, Sheet and Plate
Now that we've covered the most important types of measurements, we can start classifying foils, sheets, and plates. In the meantime, millimetres will remain the standard unit of measurement.
Aluminum foil is commonly referred to as "tinfoil" (a slang term). Normal foil thickness ranges from 0.02-0.3 mm.
Sheet metal work comes up next. Sheet metal can range in thickness from 0.5 mm to 6 mm. If it's thicker than that, it's a metal plate.
Metal can be easily shaped into thin sheets, and these sheets are both durable and useful. Due to its low price, it is a great option for most engineering projects. This explains why it seems to be everywhere.
Towards the end of the essay, we'll discuss several methods for forming sheet metal.
Common Materials
Almost any metal used in engineering can be purchased in sheet form. Some metals include carbon steel, stainless steel, copper, and aluminium.
Which one is best for your product will vary depending on its intended use and other factors.
Metal sheets have the same mechanical properties as raw metal. Due to their high tensile strength and durability, steel sheets are suitable for use in building and machinery.
Copper sheets are frequently used as a decorative finish in contemporary buildings.
Standardized Measurements
The thickness and width of sheets are both measured using the same system. There are methods for joining very large sheets together, but you can't just forget about the thickness tables.
It's also important to keep in mind the beginning and ending points. Requests for non-standard thicknesses are fairly common.
This table may contain a few outliers. We advise you to stick to these thicknesses due to the difficulties in sourcing the materials at other sizes. The aforementioned is commonly available at many sheet metal fabricators.
Hot-Rolled vs Cold-Rolled Sheet Metal
Sheet metal can be produced using either hot rolling or cold rolling. This is readily apparent in the standard thicknesses table presented previously.
Structural steels can only be cold rolled to a thickness of 3 mm.
To cut costs further, the sheets and plates are then hot rolled.
As opposed to that, all stainless steel sheets up to 6 mm thick can be processed via cold rolling.
When discussing engineering, it is essential to distinguish between the two. Since the final parameters of cold-rolled steels can be adjusted with greater precision, they are used for highly specific applications.
As a result, hot rolled steels can take on slightly different shapes after cooling due to the steel's natural tendency to contract upon cooling.
Forming Processes for Sheet Metal
Here we are at the sheet metal forming steps at long last. There are many paths you can take, so the decision is up to you.
The desired outcome will play a significant role in the choice.
But a few of these methods appear to yield identical or very similar outcomes.
It all depends on the price, the time frame, and the level of precision needed.
Sheet Metal Bending
When forming a sheet metal part, bending tension is applied to form the metal to the desired shape.
Sheet metal can be deformed plastically by bending. This prevents metal from regaining its previous form.
Parts with flanges and corrugations are formed via bending. Most bending occurs in a V shape.
The punch and V-shaped die work together to form the sheet into the required profile.
Flanges can be bent in this way using a punch and wiping die.
Sheet Metal Curling
Curling the edge of a metal sheet to form a circular band makes it easier to grip and transport.
An edge that is curled and one that is tear-shaped are two entirely different things.
A tear-shaped hem hides the raw edge, while curling involves rolling it into a circle.
In curling, you can perform either an off-center roll or an on-center roll. Off-center rolls have their centre above the metal sheet, while on-center rolls have their centre at the same height as the metal sheet.
Sheet Metal Decambering
Decambering is the process of removing a metal's camber. When metal is flattened into sheets, a horizontal bend is produced for strip-shaped pieces.
With decambering, the camber is removed by flattening the board's edges. When a straighter appearance is prefered, it is the edges that are corrected rather than the entire face. When performing this operation, only relatively short lengths of pipe are typically used.
Deep Drawing
In this metal forming process, a sheet of metal is cut and stretched using perforating scissors. There are more positives than negatives when it comes to the structural integrity of a diamond-shaped mesh.
This technique can be used to construct a wide variety of objects, including fences, catwalks, platforms, grates, and so on.
The unit is self-draining and sturdy enough to hold the load for which it was designed.
These items, which allow air or liquid to pass through but block larger particles, would be useful in a variety of sifting applications. Strength is not compromised from the original metal.
Hydroforming
Use the revolutionary process of hydroforming to form metal sheets into any shape you can imagine. In this method, the metal sheet is formed not by punching but by a high-pressure fluid.
When using this technique, more complex works can be made in less time. It's not only easier on the wallet, but on the body as well.
In addition, many different types of metals, including but not limited to stainless steel, aluminium, carbon steel, brass, and precious metals, can be hydroformed.
Hydroforming can be used to make non-standard shapes because matched dies are not required.
The Types of Sheet Metal Available
Sheet metal is metal that has been processed using a variety of industrial methods to form flat sheets of varying thicknesses, from lightweight foils to substantial plates.
It is widely employed in sheet metal fabrication processes for the production of industrial, commercial, and household products.
Different Types of Sheet Metal
Sheet metal can be made from a wide range of metals and metal alloys. Several of the most frequent enquiries are addressed below.
- Aluminium. Sheet metal fabrication uses aluminium because it is abundant, inexpensive, simple to work with, has a high strength-to-weight ratio, is highly conductive electrically and thermally, is resistant to corrosion, is non-toxic, and can be recycled in large quantities. Aluminum sheets have a wide variety of applications, including those in the automotive, electrical, and kitchen appliance industries.
- Corrosion-resistant steel that has been treated with an alkaline solution. To make aluminized steel, carbon steel is coated with an aluminum-silicon alloy. Strong and corrosion-proof alloys can be made by fusing aluminium and carbon steel. For use in high-temperature or corrosive environments, aluminized steel sheets are often incorporated into cookware and home appliances.
- Carbon-based steel. Carbon steel is the name given to iron-based alloys that contain carbon (up to 2.1 percent ). Increases in hardness and strength are seen at higher carbon contents, while ductility is seen at lower carbon contents and after heat treatment. Carbon steel is used to make a wide variety of products for a variety of markets.
- Copper. Copper is a more efficient heat and electrical conductor than aluminium. It's more expensive, though. Copper has many industrial applications and is commonly used in the construction of heat sinks, roofs, rain gutters, and doors.
- Galvanized steel is galvanised steel. To make galvanised steel, similar to aluminized steel, steel is hot dipped in zinc to increase its corrosion resistance. Galvanized steel sheets can be found in the construction of car bodies, water pipelines, and a wide variety of other building components like fences, roofs, and stairways.
- Galvalume refers to steel that has been galvanised with an aluminum-zinc-silicon alloy. The finished product is more sturdy and resistant to corrosion than galvanised steel.
- Due to its high corrosion resistance, galvalume sheets are commonly used in applications where they will be subjected to the elements, such as on roofs.
a type of iron alloy characterised by its extreme strength. Armor plates used in warfare are typically made of steel sheets. Hardness can be increased in steel by adding elements like carbon, manganese, and copper. - Steel that was rolled at a very high temperature. Costs to make hot rolled steel are significantly lower than those of cold rolled steel. Its high strength and durability mean it is frequently used in structural components like car body panels.
- Stainless steel of the finest 304 grade is the basis for this forged product. To be considered "stainless steel," a steel alloy must contain 11% chromium and no more than 1.2% carbon. The material has unrivalled resistance to corrosion, heat, and fire, as well as a high strength-to-weight ratio and the ability to be easily manufactured. Components of food processing machines, chemical storage tanks, and cooking utensils all benefit from using stainless steel sheet metal.
- Titanium. Titanium's favourable metallurgical properties make it useful in numerous industries. As a result of its high recyclability and biocompatibility as well as its high strength-to-weight ratio and corrosion resistance, it finds application in many different fields. Typical uses include in medical and building-related equipment.
How Thin Can Sheet Metal Get?
All metalworking methods vary in complexity according to the thickness of the material being worked. Welding, fabrication, and finishing all rely heavily on it, as do most other processes involving metal.
The primary factor that determines the thickness of a metal is its function. The thickness of a metal sheet can vary from 0.5 millimetres to 6 millimetres.
Read this article to learn about sheet metal thinning and its consequences.
Sheet Metal Thinning Processes
By decreasing the metal's thickness, the desired dimensions can be achieved. Before using sheet metal, its thickness may be decreased through thinning.
Foil metal can be as thin as 0.5 mm, but it can be even thinner.
The thinnest a sheet of metal can be is equivalent to metal foil. Sheet metal cutting is a challenging process that can be accomplished in several ways.
Cold and Hot Rolling
Sheet metal's uniformity may be improved by rolling in addition to its thickness being reduced. To achieve the desired thickness, sheets of metal are passed through a set of rollers.
Critical to the success of this method is the precise temperature at which it is applied. For instance, when rolling hot steel, the temperature reaches about 1400F. At this temperature, a sheet of metal could be melted down to a thickness of 1/16 of an inch.
With the help of rollers in the mills, metal is rolled thinner and longer to achieve the desired thickness. Changing the temperature can drastically alter the rolling process.
Both this and the thickness of the sheet are crucial in determining the smoothness of the surface.
Making sheet metal for specific uses is best accomplished through cold rolling. With cold-rolled steel, metalworkers have greater control over the precise dimensions of their finished products.
However, hot-rolled steel can have a variety of shapes and sizes due to its significant shrinkage after cooling.
Ironing
As an alternative to shearing, ironing can be used to selectively thin out areas of a metal sheet. Helps maintain a uniform wall thickness throughout production.
Ironing is also required during the production of a soda can. The can walls must be thinned to a specific thickness.
Many soda cans go through a multi-step ironing process using a variety of dies to achieve the desired thickness. In some cases, this method may be combined with deep drawing.
Deep Drawing
This method of metal forming uses circular tension-tangential compression to alter the shape and size of sheets of metal. By using a deep drawing process, flat metal sheets can be formed into hollow cylinders or boxes.
The vessels have various curved and straight or tapered edges.
The vessel's diameter is reduced while its length is increased through a series of dies during production. This takes place whenever there is only a marginal change to the wall's thickness.
Why Thin Sheet Metal?
This sheet metal can be used for many different things due to its versatility and long lifespan. It's an obvious choice for many because of how useful it is in a wide variety of industrial contexts.
Due to its durability, thin sheet metal can be used to fix just about anything. Unlike metal plates, which must be welded together every time they are used, sheet metal products never need to be repaired.
Conclusion
When producing sheet metal, iron is typically alloyed with smaller amounts of other metals to alter their physical properties. In order to make it, flat steel is rolled out into a thin layer and then cut with a shear or die press machine. It finds widespread application across a broad range of manufactured goods, from automobiles and aeroplanes to household furnishings and children's playthings. Engineers need a thorough understanding of sheet metal basics before they can fully exploit the material. The thickness of a sheet, plate, or foil can be specified in either millimetres or mils or gauges.
The thickness of metal sheets is measured in gauge, which is a system of measurement based on the pound per square foot density of the metal. "Tinfoil" refers to aluminium foil, which can have a thickness anywhere from 0.02 to 0.3 mm. Metal sheets can be as thin as 0.5 mm and as thick as 6 mm. Steel, stainless steel, copper, and aluminium are all frequently used. The same system is used for both the standardisation of measurements and the joining of very large sheets.
When comparing hot-rolled and cold-rolled sheet, Both hot and cold rolling can be used to create metal sheets. Cold rolling can only be done on stainless steel sheets up to 6 mm in thickness, while structural steels can only be done up to a thickness of 3 mm. Metal is formed into the desired shape by applying a bending tension, and the material cannot return to its original shape because it has been deformed plastically. While a tear-shaped hem covers the raw edge, curling the edge of a metal sheet into a circular band makes it easier to grip and transport. A metal can have its camber removed by flattening the board's edges, a process known as decambering.
Deep Drawing is a metal-forming technique in which a metal sheet is cut and stretched using perforating scissors. The revolutionary method of hydroforming allows metal sheets to be formed into any desired shape. Sheet metal can be crafted from a wide variety of metals and metal alloys, the most common of which is aluminium. Carbon steel is coated with an aluminum-silicon alloy, while aluminized steel is treated with an alkaline solution to prevent corrosion. Galvanized steel, also known as galvanised steel after being hot dipped in zinc to increase its corrosion resistance, is steel that has been galvanised.
Galvalume is an extremely durable iron alloy. High-temperature rolled steel is extremely strong and long-lasting, and it also resists corrosion, high temperatures, and fire. This forged item is made from premium 304 stainless steel. Titanium's high recyclability, biocompatibility, strength-to-weight ratio, corrosion resistance, and other properties make it a valuable metal in a wide variety of applications. Typically ranging in thickness from 0.5 mm to 6 mm, it finds application in a wide range of industrial, scientific, and practical contexts, including the medical and construction industries.
Thinning sheets of metal is a difficult process that can be done in a number of ways, including by using hot rolling or cold rolling. The exact temperature applied is crucial to the success of this method. Due to its adaptability and durability, thin sheet metal has numerous applications. However, due to its significant shrinkage after cooling, hot-rolled steel can be formed into a wide variety of shapes and sizes, which is why cold rolling is the prefered method. Metal sheets can be thinned out in specific areas by ironing, which is an alternative to shearing. Sheet metal can be formed and reduced in size via deep drawing, which employs circular tension-tangential compression.
Content Summary
- Sheet metal is a flexible construction material with many uses.
- There are many distinct types of sheet metal, each with its own advantages and disadvantages.
- The many types of sheet metal and the applications for each will be discussed.
- Learn all the ways sheet metal can be put to use in the following text!
- In this article, I will discuss the many sheet metal types available.
- Sheet metal is used for a wide variety of products in the construction and manufacturing industries, from cars and aeroplanes to furniture and even toys for kids.
- Foils, sheets, and plates are all defined by their thickness.
- Towards the end of the essay, we'll discuss several methods for forming sheet metal.
- Sheet metal can be produced using either hot rolling or cold rolling.
- Here we are at the sheet metal forming steps at long last.
- With decambering, the camber is removed by flattening the board's edges.
- Carbon-based steel.
- Read this article to learn about sheet metal thinning and its consequences.
- By decreasing the metal's thickness, the desired dimensions can be achieved.
- Before using sheet metal, its thickness may be decreased through thinning.
- Making sheet metal for specific uses is best accomplished through cold rolling.
- Ironing is also required during the production of a soda can.
- This sheet metal can be used for many different things due to its versatility and long lifespan.
- Due to its durability, thin sheet metal can be used to fix just about anything.
FAQs About Metal
Sheet metal is used in automobile and truck (lorry) bodies, airplane fuselages and wings, medical tables, roofs for buildings (architecture), and many other applications.
Sheet metal is made by running hot slabs of metal through a series of roughing rolling stands that makes them thinner and longer. To make them even thinner, these sheets go through finishing rolling stands and are then cooled and rolled into coils.
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Pressing grooves, ribs or designs into a piece of sheet metal will greatly increase the strength. Each groove, bead or line will compound the strength and can also add a design to the panel. The stretched metal in those areas will hold tension in the panel and give it structural rigidity.
Cracks can be caused by poor metal pliability or having a bending radius that is too small. To improve this for next time, try using softer materials or heating your metal and cooling it slowly so it becomes malleable and increasing the bending radius of the punch.