Metal forming processes play a crucial role in powering our society, driving innovation across industries. They enable the creation of a wide range of products and components, from heavy machinery and infrastructure to cutting-edge technologies like microprocessors and artificial intelligence.
But have you ever wondered how metal is shaped? In metal manufacturing, there are multiple processes to choose from. Each process holds its own set of advantages and disadvantages, making them suitable for specific applications and different types of metal.
Some of the most common types of metal forming techniques are:
- Roll forming
- Extrusion
- Press braking
- Stamping
- Forging
- Casting
Explore the diverse world of metal manufacturing processes and discover the optimal techniques for shaping metal to meet your unique needs.
1. Roll Forming
In short, roll forming involves continually feeding a long strip of metal through drum rollers to attain the desired cross-section. This process is highly efficient and cost-effective, making it the preferred choice for producing long lengths of sheet metal with consistent profiles. Additionally, roll forming can handle various metals such as steel, aluminum, copper, and more.
Roll forming services:
- Allow for advanced inline addition of punched features and embossings
- Are best suited for large volumes
- Yield complex profiles with intricate bending
- Have tight, repeatable tolerances
- Have flexible dimensions
- Create pieces that can be cut to any length
- Require little tool maintenance
- Are capable of forming high-strength metals
- Permit ownership of tooling hardware
- Reduce room for error
- Create less scrap
Common Industries & Applications of Roll Forming
Industries
Aerospace
Appliance
Automotive
Construction
Energy
Fenestration
HVAC
Metal Building Products
Solar
Tube & Pipe
Common Applications
- Construction Equipment
- Door Components
- Elevators
- Framing
- HVAC
- Ladders
- Mounts
- Railings
- Ships
- Structural Components
- Tracks
- Trains
- Tubing
- Windows
2. Extrusion
Extrusion is a metal manufacturing process that forces metal through the die of the desired cross-section. It creates complex cross-sections and hollow parts with uniform wall thicknesses. Extrusion is a favored process for producing long lengths of metal with intricate cross-sectional profiles, and it's also highly efficient.
If you're thinking of pursuing extrusion metal forming, you should keep in mind that:
- Aluminum is primarily the extrusion of choice, though most other metals can be used
- Dies (aluminum) are relatively affordable
- Punching or embossing is done as a secondary operation
- It can produce hollow shapes without seam welding
- It can produce complex cross-sections
Common Industries & Applications of Extrusion
Industries
- Agriculture
- Architecture
- Construction
- Consumer Goods Manufacturing
- Electronics Manufacturing
- Hospitality
- Industrial Lighting
- Military
- Restaurant or Food Service
- Shipping & Transportation
Common Applications
- Aluminum Cans
- Bars
- Cylinders
- Electrodes
- Fittings
- Frames
- Fuel Supply Lines
- Injection Tech
- Rails
- Rods
- Structural Components
- Tracks
- Tubing
3. Press Braking
Press braking involves common sheet metal forming (usually), bending the metal workpiece to a predetermined angle by pinching it between a punch and a die. Press brakes are commonly used to bend metal sheets into V or U shapes for architectural, automotive, and other purposes.
If you're interested in press braking, be aware that it:
- Works best for shorter, smaller runs
- Produces shorter parts
- Is best suited for compatible shapes with more simple bend patterns
- Has a high associated labor cost
- Produces less residual stress than roll forming
Common Industries & Applications of Press Breaking
Industries
- Architecture
- Construction
- Electronics Manufacturing
- Industrial Manufacturing
Common Applications
- Decorative or Functional Trim
- Electronics Enclosures
- Housings
- Safety Features
4. Stamping
Stamping involves placing a flat metal sheet (or coil) into a stamping press, where a tool and die apply pressure to form the metal into a new shape or cut out a piece of the metal. Stamping is ideal for producing high volumes of parts with consistent, intricate designs.
Stamping is associated with:
- Single-press stroke forming
- Consistent pieces with fixed dimensions
- Shorter parts
- Higher volumes
- Creating complex parts in a short amount of time
- Requiring high-tonnage presses
Common Industries & Applications of Stamping
Industries
- Appliances Manufacturing
- Construction
- Electrical Manufacturing
- Hardware Manufacturing
- Fastenings Manufacturing
Common Applications
- Aircraft Components
- Ammunitions
- Appliances
- Blanking
- Electronics
- Engines
- Gears
- Hardware
- Lawn Care
- Lighting
- Lock Hardware
- Power Tools
- Progressive Die Stamping
- Telecom Products
5. Forging
Forging involves shaping metals using localized, compressive forces after heating the metal to a point where it's malleable. This process yields strong, durable parts that are resistant to wear and tear.
If you're considering forging, keep in mind that:
- Precision forging combines production and manufacturing by forming the raw material into the desired shape, with the lowest possible amount of secondary operations needed
- It requires little to no subsequent fabrications
- It requires high tonnage presses
- It yields a stronger end product
- It results in a product with high strength and hardness
Common Industries & Applications of Forging
Industries
- Aerospace
- Automotive
- Medical
- Power Generation & Transmission
Applications
- Axle Beams
- Ball Joints
- Couplings
- Drill Bits
- Flanges
- Gears
- Hooks
- Kingpins
- Landing Gear
- Missiles
- Shafts
- Sockets
- Steering Arms
- Valves
6. Casting
Casting is a process that involves pouring liquid metal into a mold containing a hollow cavity of the desired shape. As the liquid cools and solidifies, it takes on the shape of the mold. Casting is ideal for complex shapes and designs with intricate details that would be difficult or expensive to produce through other metal forming processes.
Those considering utilizing a casting metal forming process should keep in mind that it:
- Can use a wide range of alloys & custom alloys
- Results in affordable short-run tooling
- Can result in products with high porosity
- Is best suited for smaller runs
- Can create complex parts
Common Industries & Applications of Casting
Industries
- Alternative Energy
- Agriculture
- Automotive
- Construction
- Culinary
- Defense & Military
- Health Care
- Mining
- Paper Manufacturing
Common Applications
- Appliances
- Artillery
- Art items
- Camera Bodies
- Casings, Covers
- Diffusers
- Heavy Equipment
- Motors
- Prototyping
- Tooling
- Valves
- Wheels
Choosing A Metal Forming Method
Are you looking for a metal former for your project? The type of metal manufacturing method you choose will depend on many factors:
- What metal are you using?
- What's your budget?
- What do you need to create?
- How will it be used?
By understanding the different metal manufacturing processes available and their applications, you can make informed decisions when choosing the most suitable technique for your specific project requirements.
Is Roll Forming Right for You?
If your metal shaping needs demand high volume, intricate profiles, and exceptional durability, roll forming is a powerful solution worth exploring. Its efficiency, precision, and flexibility can significantly enhance your production processes and deliver superior-quality products. With its ability to both optimize existing designs and unlock innovative possibilities, roll forming is a valuable tool for any manufacturer looking to stay ahead in today's competitive landscape.
Find out why so many industries choose roll forming and if the process fits your needs. Check out our free guide:
(Editor's Note: This article was originally published in January 2017 and was recently updated.)
Steel is known for being lightweight but strong, making it suitable for a variety of industries and applications. Next to plastic and paper, steel is one of the most common materials seen in products used in our everyday lives. In the construction industry, steel is used in the creation of buildings and other structures for strength. Manufacturing processes, such as for cars, airplanes, and kitchen appliances, also rely on steel for production. Last but not least, steel is imperative for communication as it is used in the creation of transmission and cell phone towers.
Steel Manufacturing Process
Steel Manufacturing Process
The steel manufacturing process can be divided into six steps: Making the iron, primary steelmaking, secondary steelmaking, casting, primary forming, and secondary forming.
Step 1: Making the Iron
Steel is a metal alloy made of iron and carbon. Thus, the steel manufacturing process starts by making iron. To do this, limestone, coke, and iron ore are combined and put into a blast furnace. The elements are melted together to create a hot metal known as molten iron.
Scrap metal is dropped via a scrap bucket into the electric arc furnace.
Step 2: Primary Steelmaking
Scrap metal is dropped via a scrap bucket into the electric arc furnace.
The second step of the steel manufacturing process can be completed with two different pieces of equipment: a basic oxygen furnace and an electric arc furnace. With a basic oxygen furnace, the molten metal produced in step 1 is infused with scrap steel. Then, oxygen is forced through the furnace to remove the impurities in the molten iron. With an electric arc furnace, as the name suggests, electricity is forced through the furnace to purify the iron. The completion of step 2 results in raw steel.
Step 3: Secondary Steelmaking
Just like there are different grades and families of stainless steel, there are also different types of regular steel. The different grades are determined by the elements that remain in the metal at the completion of the manufacturing process. Secondary steelmaking refines the composition of the steel to create the desired grade. This is done with different techniques such as stirring and ladle injections.
Pouring slag, the impurities that float to the top during the melting process, into a receptacle.
Step 4: Casting
Pouring slag, the impurities that float to the top during the melting process, into a receptacle.
During the fourth step of steel manufacturing, molten iron is cast into molds for cooling. This process starts to set the shape of the steel and causes a thin, hard shell to form. The strands of the shell are malleable and can be worked into the desired shape of flat sheets, beams, wires, or thin strips.
Step 5: Primary Forming
Primary forming continues the shaping process. A hot roller is used to fine-tune the casting. The steel is molded into the desired shape and surface finish. Some examples include bloom, billet, and slab.
Cutting billets to length using torches on the continuous caster.
Step 6: Secondary Forming
Cutting billets to length using torches on the continuous caster.
The final step of the steel manufacturing process creates the final shape and properties of the steel. Secondary forming is accomplished with different methods such as shaping (cold rolling methods), machining (drilling), joining (welding), coating, heat treatment, and surface treatment. At the completion of step 6, the steel is fully shaped, formed, and ready for use and processing in various applications.
Dixon Products for Steel Mills
Dixon Products for Steel Mills
The harsh environment and extreme temperatures encountered in steel mills during the steel manufacturing process require high-quality equipment built to last. Dixon offers a variety of products suitable for steel mills.
GSM Armored Hose
Sizes:
Features:
- Extremely flexible armor protects from heat, slag splash, and harsh environments in mill applications
- Heat resistant to 1000°F (537°C)
- Temperature rating depends on specific applications, consult Dixon
Materials:
- Armor: Galvanized steel or stainless steel
- Wide selection of inner hoses specific to steel mill applications: industrial, hydraulic, metal, and PTFE
Dixon’s GSM armored hose was originally designed specifically for use in a steel mill. Read our blog post, A History and Overview of GSM Armored Hose, to learn more.
HTE-Series Correct Connect® Under Pressure Flush Face Female Plug
Sizes:
- Body: 3/8", 1/2", 5/8", 3/4", and 1"
Features:
- Can be connected with residual pressure in the plug up to 5,000 PSI
- Used in conjunction with Dixon HT-series and other ISO16028 couplers
- Smooth connection action up to full working pressure
- Flush face design is less susceptible to system contamination
- Compact design
- Threads: NPTF, BSPP, and ORB
HT-Series Correct Connect® Flush Face Flange Sleeve Coupler
Sizes:
- Body: 3/8", 1/2", 5/8", 3/4", and 1"
Features:
- Includes Correct Connect® color banding system
- Works with HT-series and HTE-series plugs
- ISO16028 flush face coupler x 3/8"-1" F-NPTF
- Flange makes it easy to grip with gloves to connect and disconnect, as well as twist the sleeve to lock and unlock the coupling connection
Material:
Swivels
Sizes:
Features:
- Full 360° rotational movement
- Precision-machined design ensures alignment and trouble-free service
- Various pressure seal designs to meet specific application requirements
- Hydrostatic testing is performed on all swivels before shipping
- Large bore swivels are also available, contact Dixon
Materials:
- Carbon steel, 316 stainless steel, aluminum, brass, and malleable iron
Sizes:
Features:
- Resistant to accidental disconnection when dragged
- 4 EZ Boss-Lock cam & groove handles enable increased working pressure
Material:
Venting EZ Boss-Lock
Sizes:
Features:
- EZLink® tabs are utilized as a secondary locking mechanism to capture the adapter in case of accidental uncoupling under pressure
- Designed vent paths to help control the direction of venting media
- EZ Boss-Lock cam arms for an additional level of safety
- Works with all standard cam & groove adapters
- Type B, C, D, and H
Materials:
- 356T6 aluminum and 316 stainless steel
Cam & Groove Swivels
Sizes:
Features:
- Live swivel is capable of 360-degree rotation under pressure
- Nitrile rubber X-ring seals at the swivel for reduced friction and high stability in dynamic applications
- Couplers include EZ Boss-Lock cam arms
- Type A, C, D, and E
Materials:
- 356T6 aluminum and 316 stainless steel
- Gasket: nitrile rubber and FKM
- Seal: nitrile rubber X-rings and FKM
Features:
- No mixing or measuring is required; easy to apply
- Quickly contains leaking substances, keeping a workplace safe
- Tenacious bond: 5 to 10 minutes; functional cure: approx. 30 minutes
- Suitable for use on acid lines, gas, most diluted chemicals, seawater, fuels, and oil
- Resistant to hydrocarbons, ketones, esters, alcohols, halocarbons, aqueous salt solutions, and dilute acids/bases
- Suitable for wet or dry pipe: apply under fresh and saltwater
- Temperatures:
- Continuous -40°F to 250°F (-40°C to 121°C)
- Intermittent -40°F to 300°F (-40°C to 149°C)
- Heat resistance: 300°F (150°C)
Materials:
- Bandage: woven fiberglass
- Resin: water-activated polyurethane resin
Summary
Summary
Although it can be simplified into six steps, the steel manufacturing process is complex and requires reliable equipment designed to withstand the harsh environment encountered in steel mills. Dixon manufactures and supplies products for every stage of steel production. From armored hose, fire jackets, and sleeving, to hydraulic quick disconnects, specialty fluid transfer products, swivels, and fire equipment, we are committed to providing real solutions for real challenges in the steel processing market. For more information, visit dixonvalve.com or call 877.963.4966.