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Metal FormingMetal forming encompasses a wide variety of manufacturing processes that are performed on comparatively thin sheets of metal or metal plates and are used to fabricate metal components. Traditional metal forming processes include broaching, boring, welding, turning, counterboring, spotfacing, countersinking, reaming, milling and bending. Non-traditional forming methods cover a broad range of mechanical, electrical, thermal and chemical processes, which are slower and require higher energy but are necessary for applications in which traditional methods are not effective. Metal formed parts typically fall into two categories: parts requiring heavy fabrication such as bridge, crane and ship structures, and parts requiring light fabrication, such as automobile bodies, water tanks, electronic enclosures and metal cabinets. Other products fabricated through metal forming processes include frames, brackets, plates, shelving, panels, grills, outdoor sculptures and automotive parts. Steel forming and aluminum forming are material-specific processes that use the two most common materials found in metal forming. Metal forming companies serve a wide range of industries including automotive, electronics, marine, defense, aerospace, construction, appliance, furniture, HVAC and medical. Metal forming processes can be roughly classified into five categories: mechanical working, casting, powder and fiber metal forming, electroforming, and joining processes. Mechanical working is when metal is subjected to a physical change whether it is a change in its shape, properties or structure. Mechanical working processes include forging, extrusion, hammering, rolling and drawing. Casting, commonly referred to as die casting, is a metal forming process in which molten metal is forced into mold cavities, or dies, under high pressure then cooled in order to form solid metal parts. Die casting is a high volume, low cost means of forming relatively complex metal parts. Powder and fiber metal forming are very similar processes; however, powder metal forming put metallic powers under pressure and heat to form metal components while fiber metal forming uses metallic fibers. Electroforming is a highly specialized electroplating process that forms metal parts through electrodeposition in a plating bath over a pattern or mandrel which is afterward removed. This metal forming service is used when intricate or relatively thin shapes are required. Joining processes include welding, soldering and brazing. The most common joining process is metal welding, which uses coalescence, meaning that joining is accomplished through heating the metals enough to melt into one another. Brazing and soldering are very similar to welding, but require a filler material in order to create the actual bond.
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