Steel is one of the most common materials used in precision sheet metal fabrication because of its strength, durability, and corrosion resistance. This versatile metal can be treated in several ways depending on the finish, intended use, and more.
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The steel type you select can make or break your part’s success, so it’s important to understand the nuances of each process. We’ll break down the characteristics, applications, and cost implications of the two primary steel treatments, hot-rolled and cold-rolled, and share our advice from over 70 years of experience in Texas sheet metal fabrication.
Hot-rolled and cold-rolled steel are the two most common steel treatments we see in our Texas sheet metal fabrication shop. Steel manufacturers heat large, rectangular pieces of steel to 1,700 degrees Fahrenheit, then roll the steel through the mill to reach the desired shape.
Both hot and cold-rolled steel go through this process, but cold-rolled steel is re-rolled at room temperature for further compression.
Each treatment has benefits and drawbacks, but we generally find that hot-rolled steel is the more cost-effective choice.
Hot-rolled steel is easily identified due to its scaled surface, slight distortions, and rounded edges. These imperfections develop as the metal cools down. Hot-rolled steel may require decarburization or other surface treatments to prepare it for subsequent operations.
Despite its rough appearance, hot-rolled steel has several advantages:
There are, however, some downfalls associated with using hot-rolled steel:
When customers work with All Metals Fabricating, our commitment to quality shines through. We source high-quality hot-rolled steel that will never have pitting, even when working with thicker sheets of steel.
Hot-rolled steel is suitable for many applications due to its cost-effectiveness and structural integrity from minimal processing. Powder-coating will increase the steel’s durability, even in extreme weather and under physical stress.
However, steel manufacturers have less control over the final shape, so hot-rolled steel is generally used for parts that don’t require tight tolerances.
Here are several applications where hot-rolled steel is ideal:
Unlike hot-rolled steel, cold-rolled steel is aesthetically pleasing, with a smooth and shiny surface that feels oily to the touch. The additional processing also creates perfectly squared angles with well-defined corners and edges.
Cold-rolling steel has many benefits, including:
Despite its superior appearance, there are several downsides to using cold-rolled steel:
The refined appearance of cold-rolled steel makes the cold-rolling treatment ideal for parts without surface finishes. The additional round of processing gives steel fabricators greater control over the final size of the sheet metal, so precision sheet metal fabrication parts requiring tight tolerances should use cold-rolled steel when possible.
Here are a few examples of applications that benefit from cold-rolled steel:
While hot-rolled and cold-rolled steel are the most common treatments in contract manufacturing, there are several alternative types with more specific applications:
Stainless steel is stronger than hot or cold-rolled steel, and it is much more weather and corrosion-resistant. This treatment is ideal for outdoor applications, especially near coastlines where corrosion from salt is prevalent.
Galvanized steel has a protective layer of zinc applied to the sheet. This material is long-lasting, making it an excellent choice for hard-to-reach applications like lines and equipment boxes. However, cutting galvanized steel exposes the raw steel, necessitating additional treatment for outdoor use.
AR500 steel is one of the hardest treatment types available. However, it’s also incredibly rigid, making it difficult to form. Steel with this treatment is most often used for targets in shooting ranges.
This treatment type is ideal for outdoor architectural and landscaping applications. Corten steel is also known as weathered steel because when left outside, it will develop a rust-like appearance, which provides a protective layer from corrosion and atmospheric elements.
Selecting a steel treatment is all about balance and finding the best fit for your part. For example, hot-rolled steel is often more cost-effective, but you likely should go with cold rolled steel if cosmetic appearance is important to you.
There are many considerations that go into choosing which type of steel to use! The AMF team has over 70 years of experience in selecting the best steel treatments, and we are always happy to work with customers to find the best solution for their parts.
The sheet metal used in your sheet meetal fabrication includes a very broad list of possible materials. Making the best choice for your products includes decisions about the type of metal, its thickness, and a choice of form. What you choose should be based on your overall expectations, desired end product, and recommendations from your sheet metal fabricator contractor manufacturing services
Sheet metal is made from a variety of metals that each have their own unique properties and offer unique benefits. A list of the most common sheet metal materials used for fabrication have been summarized below.
Hot rolled steel is produced when steel is processed by a series of roll presses at temperatures over °F. The process creates a steel that is easily formed or shaped into large pieces and is best used where tolerances aren’t as important.
Q235 and Q355 are 16 Mn steel grade with good formability and weldability properties. It’s commonly used for structural applications and parts for a variety of industries. Q355 offers better performance at low temperatures and offers better steel strength.
SAPH440 is commonly used for automotive frames, wheels, and other parts. It has very good tensile strength making it a good choice for load bearing or structural uses.
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Cold rolled steel (CRS) is essentially hot rolled steel that has gone through an additional rolling process at room temperature.
This additional processing produces a steel with closer tolerances and a broader range of finishes. The result is an increase in strength by as much as 20% compared to hot rolled steel. SPCC is commonly used for automotive parts and some construction applications. SPCC can be used for galvanized products, appliances, containers, and other products.
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The category of spring steel includes several high yield strength steels including low-alloy manganese, medium-carbon steel, or high-carbon steel. They are primarily used to manufacture springs as the steel will return to its original shape after twisting or load bearing.
A carbon steel can be used for small springs, but large springs are best when an alloy is used. High carbon spring steel is a common choice, inexpensive, and easily processed. It is not suited to extreme temperatures or for shock/ impact loads. Alloy spring steel are well suited to shock or impact loads or conditions with high stress. Stainless spring steel can be used in some forms at extremely high temperatures (288°C) and are corrosion resistant. 65Mn is a high carbon with manganese to improve hardenability. It has good wear resistance and good workability.
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Aluminum is a pure metal that is easily alloyed with small amounts of other materials like copper, manganese, silicone, or magnesium. It is not magnetic or combustible and is a good conductor of electricity. Aluminum offers good corrosion resistance and is generally easy to form and process. It comes in several different grades and is often used because of its weight. It weighs about 1/3 of other materials like iron, steel, copper, and brass. It conducts heat well and is non-toxic making it a good choice in a variety of applications.
AL is a wrought alloy with high electrical conductivity, corrosion resistance, and workability but somewhat low mechanical strength. It’s commonly used in electrical and chemical industries. AL is most often used for architectural applications or trimming. It has high tensile properties and offers good finish options. It also offers high corrosion resistance and is a good option for anodized applications. AL is the most flexible heat-treated alloy with excellent workability. It’s well suited to most processes and has good corrosion resistance. AL is the highest strength non-heat-treated aluminum alloy and offers very good fatigue resistance. Highly workable, AL can be formed into complex shapes and offers good saltwater corrosion resistance.
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Stainless steel includes a variety of sheet metals which contain at least 10.5% chromium. There are many different grades available, offering corrosion resistant and a commercially familiar appearance. Standard or austenitic stainless steel (300 series steels) is very common and does not require heat during the manufacturing process. They offer good corrosion resistance, formability, and weldability.
SS301 has high work hardening and is commonly used for trailer bodies and fasteners. SS304 has low carbon, is an economical grade but is not seawater resistant. SS316 has higher molybdenum content that improves its resistance to seawater corrosion. A lower carbon version (SS316L) is available for better corrosion resistance after welding.
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Cold galvanized steel has a zinc coating painted to the steel surface to protect it from corrosion. The coating will provide both a barrier protection and a galvanic protection to help extend the life of the product. It can be applied with brushes, rollers, sprayers, or through electro galvanizing. The paint includes special binders so it will mechanically bond to the steel. SGCCis a galvanized steel with good weldability and formability. It can have a pure zinc coating or have a Zn/Fe alloy coating.
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The yield strength of a metal is the point at which applied stress will cause it to deform and not return to its original shape. It provides an indication of a metal’s elasticity and the maximum force you can apply to it before it will permanently deform, buckle, or even fail. Processes like annealing can impact the yield strength of some materials.
Tensile strength refers to ability of a metal to resist force. Higher tensile strength requires more force to snap it for example. If the product you’re producing doesn’t need to bear any load, then a metal with less tensile strength might be the best choice. Keep in mind that how you form the sheet metal can impact its strength and the load it can bear.
The material you choose should take into consideration the environment it will be exposed to. Some metals respond better than others to factors like water, oxidation, or other elements it will be exposed to. Some metals, like stainless steel, won’t corrode but they can develop an oxide film. Also keep in mind that galvanic corrosion can occur when to dissimilar metals are in contact with each other.
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