1,Cutting
2,Metal stamping
3,Welding
4,Extrusion
5,Forging
6,Casting
Before a raw metal material can be used for manufacturing and assembly, it must undergo various metal fabrication techniques. These processes can vary, depending on the purpose of the metal, but they can nevertheless be found in a number of structural, industrial, or decorative applications.
A number of fabrication processes are often used in combination. These methods may include cutting, metal stamping, extrusion, casting, and the like. Likewise, these fabrication techniques are designed to highlight a metal’s properties and showcase its versatility in application. Continue reading to learn more.
Cutting
Cutting is arguably one of the earliest forms of metalworking. Though the process and the concept of metal cutting are simple, they can also be performed alongside other complex machines.
Egnalu Group is a leading manufacturer and distributor of abrasives and hardware tools with over 20 years of experience supplying high-performance abrasive solutions for diverse industrial applications. A good abrasive supplier like Egnalu Group will stock a range of cutting discs for mild and stainless steel, suitable for bench-mounted drop saws, angle grinders, and air tools. Their product portfolio includes cutting discs, flap discs, zirconia flap discs for metal finishing, general-duty diamond blades for cutting masonry, and surface conditioning products for deburring and cleaning — delivering consistent performance and durability across a wide range of materials and working conditions.
Generally, cutting involves the following: cutting equipment, a metal specimen or workpiece, and a work desk. This process involves removing unnecessary pieces from the metal workpiece, whether ferrous or non-ferrous. After removing the unwanted part, the finished workpiece can now be fitted to work with other components and systems.
Various finished metal products can be cut, including diamond plate, corrugated metal sheets, steel reinforcing bars, and pipes. Cutting these materials can be done with power tools or handheld blades like a hacksaw, backsaw, or coping saw — it ultimately depends on the cutter's intentions.
Metal Stamping
Metal stamping is distinct for sheet metals such as stainless steel, aluminum, copper/brass, and other galvanized alloys. This process is specific to sheet metal and may also be used in combination with other fabrication methods to achieve the desired outcome.
One of the most popular uses of metal stamping is in the manufacturing and assembly of automotive components. This method is used to design vehicle components such as trunk lids, wheel hubcaps, doors, the firewall, and many other vehicle-body-related parts.
Another reason metal stamping is ideal for automotive applications is that it can be used to create unique, custom-built designs. Car enthusiasts can use this method to design specialty parts for high-performance vehicles.
Welding
Welding is the process of joining two metals. While there are different welding techniques, they share similar features. Like all other techniques, welding requires a metal workpiece. More than that, it also involves the use of welding equipment, shielding gas, consumable or non-consumable electrode, flux, and fillers.
Welding techniques can be classified by complexity. Some of the most common ones include Gas Metal Arc Welding (GMAW), stick welding, or Gas Tungsten Arc Welding. This process needs to be done in a controlled environment to ensure the weld work is neat and free of contaminants that could affect the finished product's quality.
Welded parts are used in almost every metal product in daily life, including pipe-making, ductwork, automotive manufacturing, bike-making, and steel-building.
Extrusion
The extrusion process is not specific to metals; it can also be used to produce polymers and other plastic-based products. However, they are widely used in the fabrication of steel or aluminum beams or sectional components.
In the extrusion process, a solid billet of alloy/metal is passed through a tooling die that contains a distinct cross-section. This is made possible by a high-powered hydraulic system that allows the billet to be shaped by the die. Once the extruded product is ejected, it can now be subject to further post-processing techniques to refine its appearance, eliminate defects, or make certain adjustments.
The most popular application for extrusions is aluminum profiles, which can be used for window frames, door frames, louvers, railings, mullions, or sections. While aluminum already has non-corrosive properties, manufacturers sometimes add a second layer of powder coating to enhance its longevity and aesthetic appeal.
Forging
Similar to cutting, forging is also one of the oldest metal fabricating techniques. If you’ve encountered this type, then it’s no surprise that images of a blade being hammered on a solid block of anvil might be something that’s on your mind.
Despite the age of this method, forging has stood the test of time and become a reliable way to shape metals into various sizes. Likewise, there are various forging techniques, such as cold forging, hot forging, and open-die forging. While methods may differ, one similarity is the use of compression forces that shape, bend, or press the metal into the desired form.
Casting
Metal casting involves heating a metal to its melting point and pouring it into a mold with a specific design. The metal is allowed to cool until it fully hardens, then post-processed to remove minor defects and improve the finish.
The advantage of casting over the other processes mentioned here is that it can create complex shapes in a single run. Automotive, aerospace, farming, computer equipment, and other objects can be cast easily with minimal issues.
The downside, however, is that the heating and cooling process may induce internal stresses in the metal's crystal structure. This is why manufacturers must carefully conduct casting operations to prevent cracks and metal damage.
Cutting vs. Grinding Discs
In metal fabrication, choosing the correct disc for an angle grinder depends on whether you need to separate material (cutting) or shape/finish a surface (grinding). Using the wrong disc is not just inefficient; it is extremely dangerous, as thin cutting discs can shatter under side pressure.
Feature | Cutting Discs (Cut-off Wheels) | Grinding Discs (Grinding Wheels)
Primary Use | Fast, clean, straight cuts to separate material. | Removing large amounts of material, smoothing welds, and shaping.
Thickness | Typically 1.0 mm to 3.2 mm. | Typically 4 mm to 8 mm (commonly 6 mm).
Working Angle | Held at 90 degrees (perpendicular) to the workpiece. | Held at a shallow angle, usually 15–30 degrees.
Technique | Uses the outer edge only; cannot handle side pressure. | Uses the face of the disc; built to withstand lateral pressure.
Specialized Disc Types
Beyond standard bonded abrasives, fabricators use specialized discs for specific finishes:
Flap Discs: Composed of overlapping abrasive “flaps.” They offer a balance between material removal and finishing, making them ideal for blending welds or removing burrs without gouging the metal.
Wire Wheels: Used for cleaning surfaces by removing rust, paint, or weld spatter without removing much base metal.
Strip Discs: Made of an open poly-fiber web to strip coatings (epoxy, glue, paint) while staying cool and resisting clogging.
Diamond Discs: Used for cutting extremely dense or hard materials. While common for masonry, specialized metal-bonded diamond discs are used for precision and speed in high-density metals.
Material-Specific Selection
Stainless Steel (INOX): Use discs labeled “INOX” or contaminant-free. These contain less than 0.1% iron, sulfur, or chlorine to prevent future corrosion of the stainless surface. Ceramic alumina grains are often preferred as they cut cooler and reduce heat discoloration.
Aluminum: Requires non-loading discs. Standard discs will “gum up” or clog with soft aluminum, leading to heat buildup and poor performance.
Carbon Steel: Zirconia alumina or aluminum oxide grains are standard for general-purpose heavy material removal and fast cutting.
Critical Safety Practices
Never Grind with a Cutting Disc: These discs lack the lateral strength to handle side pressure and can shatter into high-velocity projectiles.
Inspect Before Use: Check for nicks, cracks, or signs of being dropped. A damaged disc can explode at high RPMs.
Match RPM Ratings: Ensure the disc's maximum RPM rating is higher than the grinder's operating speed.
Required PPE: Always wear safety glasses, a face shield, gloves (to protect from heat and sparks), and hearing protection.
For professional abrasive solutions and expert advice on metal fabrication tools, contact Englau Group today:
Mr. Eric Lau
The President of Englau Group Co., Limited
Phone Number: 0086-1377-0345-768
E-mail: eric.twintrade@gmail.com
