Metal Fabrication Then and Now!

History of Blacksmithing

The use of iron or metals predates written history, but metal fabrication as an organized sector came into existence as late as 1400 AD. Blacksmiths came into the picture right from the moment iron extraction and smelting started in an unorganized manner.

Backsmiths, known as Vishwakarma existed in the Vedic Era in India. Hephaestus or Vulcan is mentioned in Greek and Roman mythology. The role of blacksmith is mentioned in many civilizations, often as associates of Gods, valued artisans who created intricate objects for them especially those used as weapons.

What began as skilled craftsmanship in the forgotten era turned into a team work with many processes taking place under one roof. The sole objective was to create metal structures or components used for various purpose in mass. Thus, the term fabrication became a part of industrial jargon with commercial and residential perspective.

Malleable metals found in nature were first used for the purpose of making objects by smelting and hammering, a primitive methodology that is still in use somewhat. During the Bronze Age people in Mideast advanced upon the simple techniques prevalent and began to smelt, cast and rivet and to forge, thus giving rise to contemporary fabrication techniques which are much advanced now.

Indispensable Alloys

Throughout the history we have witnessed discovery of metals and the development of techniques that resulted in creation of objects and structures. With advance in metallurgy, alloys came into the picture and this advancement experienced a spectacular enhancement during the industrial age in Europe.

Increased grade iron development in the Medieval Era ushered the industrial age in Europe in the eighteenth century. The initial forging has resulted in hardened steel alloys which now form basis for raw material used in modern fab shops globally. Alloys as meteoric iron used as composite formed with nickel were used as it is without any chemical changes during early times. The creation of alloys began as early as 2500 BC.

Alloys like wrought and cast iron, light weight structural steel are as a result of modern-day knowledge of chemistry and metallurgy. These raw materials are created using various metals and carbon in varying proportions, leading to alloys with diverse physical and chemical properties. These properties are kept in mind whence creating metal structures in the fabrication units. The suitability and benefits of an alloy is carefully considered in order to produce components and structures that are long lasting and malleable. Though some alloys of steel are commonly used by fabricators the rest are used as per the need basis, a continuous development is taking place in the metal fabrication industry which is a good sign.

Use of Iron Alloys

The first production of wrought iron which was ductile and malleable has been reported from Anatolia in Greece in 1800 BC, and by 800 BC iron smelting technology has spread to Europe.

Two types of iron alloys are much used in fabrication:

• Wrought Iron
• Cast Iron

Wrought iron has less carbon content as compared to cast iron. The former was extensively used before mild steel came into the picture. It was more workable, and could undergo various processes used in making into intricate components and structures as was the norm in the eighteenth century.

Mild Steel

Two process developed in the nineteenth century reduced the usage of iron alloys and the focus shifted to steel. These developments were revolutionary and changed the way components and structures are being made even today.

• Bessemer Process
• Siemens Martin Process

The two process facilitated the production of mild steel on large scale, and the use of wrought iron declined. It is no longer produced on commercial scale and what we find mentioned as wrought iron is actually mild steel. It is extensively used to fabricate building components such as gates, railing, staircase, windows, doors and bins to name a few.

Modern Day Fabrication

Hundreds of alloys are used by the industry to manufacture structures and components for buildings, railways, ships, machineries and so on. Light weight structural steel and mild steel find prominent use in the modern manufacturing. The preference is based upon properties as mentioned earlier and the cost as well, since in modern day economic perspective is always taken into the account.

The fabrication shops have become diverse thanks to emerging associated technologies which impact the processes, and the working of the units in order to hasten production and reduce costs. The equipment and tools used by the units differ as well and this depends much upon the nature of produce.

Apart from modernization and refining of all processes involved, automation in manufacturing, designing and finishing of final products have been facilitated by computerization. There is a sea change as to how the processes in the fab shops takes place now. These latest inductions have come about on need basis as some units are still using old methods and have not undergone changes since the need is simply not there. But sooner or later automation will creep in all types of units due to its immense benefit which is slowly and surely becoming apparent.

Metal Fabrication in Figures

Fabrication of building components and mega structures is a norm and is being done on immense scale. The global metal fabrication market is experiencing growth exponentially and the turnover till this date is nearing twenty billion USD.

Fabricated metals have created third largest sector in manufacturing, and hiring record number of employees. Although the progression of this sector is much dependent upon construction industry growth, nevertheless the diversification accords greater stability and less dependency on construction activities.

In US more than three thousand units are involved in manufacture of components and structure using wrought iron or mild steel and various alloys like light weight structural steel. The scope of industry is much larger if we take into account various segments associated with this industry directly and indirectly.

Trends and Analysis

Metal fabrication has become the largest sector globally in manufacturing and stands solidly as an important component of many modern-day economies. It becomes the largest industrial sector in the World whence the metal manufacturing ecosystem is taken into considered holistically.

Steel production is focused on tariffs applicable and the direct impact of increase is on the end product purchasers while the manufacturing concerns often make huge profits. In most of the segments in US there is a large-scale deficit or trade imbalance which is not good for the economic growth, this needs rectification urgently. Blockbuster profits at the cost of the purchaser is not a good sign either as the long-term impact could affect consumption negatively.

Since all sectors including the residential segments are using steel the outlook is promising for steel fabrication market. The market is dominated by APAC as large-scale development projects are taking place in China, India and Japan. The is further accentuated by the smart city projects demands in these countries.

Metal Fabrication finds use in construction, shipping, mining, automotive and civil infrastructure to name a few. Growth outlook hence seems promising. Modern day technologies like 3 D printing, use in energy sector are further enhancing growth.

The industry is facing challenges which can prevent exponential growth in time to come. Low grade raw materials being used in increasing manner can create carbon footprints on large scale and thus an alternative has to be found. Though figures projected promise robust growth till 2025 there can be a reduction if the factors responsible for the momentum recede. The industry has to figure how to remain viable. Metal Fabrication Then and Now!

History of Blacksmithing

The use of iron or metals predates written history, but metal fabrication as an organized sector came into existence as late as 1400 AD. Blacksmiths came into the picture right from the moment iron extraction and smelting started in an unorganized manner.

Backsmiths, known as Vishwakarma existed in the Vedic Era in India. Hephaestus or Vulcan is mentioned in Greek and Roman mythology. The role of blacksmith is mentioned in many civilizations, often as associates of Gods, valued artisans who created intricate objects for them especially those used as weapons.

What began as skilled craftsmanship in the forgotten era turned into a team work with many processes taking place under one roof. The sole objective was to create metal structures or components used for various purpose in mass. Thus, the term fabrication became a part of industrial jargon with commercial and residential perspective.

Malleable metals found in nature were first used for the purpose of making objects by smelting and hammering, a primitive methodology that is still in use somewhat. During the Bronze Age people in Mideast advanced upon the simple techniques prevalent and began to smelt, cast and rivet and to forge, thus giving rise to contemporary fabrication techniques which are much advanced now.

Indispensable Alloys

Throughout the history we have witnessed discovery of metals and the development of techniques that resulted in creation of objects and structures. With advance in metallurgy, alloys came into the picture and this advancement experienced a spectacular enhancement during the industrial age in Europe.

Increased grade iron development in the Medieval Era ushered the industrial age in Europe in the eighteenth century. The initial forging has resulted in hardened steel alloys which now form basis for raw material used in modern fab shops globally. Alloys as meteoric iron used as composite formed with nickel were used as it is without any chemical changes during early times. The creation of alloys began as early as 2500 BC.

Alloys like wrought and cast iron, light weight structural steel are as a result of modern-day knowledge of chemistry and metallurgy. These raw materials are created using various metals and carbon in varying proportions, leading to alloys with diverse physical and chemical properties. These properties are kept in mind whence creating metal structures in the fabrication units. The suitability and benefits of an alloy is carefully considered in order to produce components and structures that are long lasting and malleable. Though some alloys of steel are commonly used by fabricators the rest are used as per the need basis, a continuous development is taking place in the metal fabrication industry which is a good sign.

Use of Iron Alloys

The first production of wrought iron which was ductile and malleable has been reported from Anatolia in Greece in 1800 BC, and by 800 BC iron smelting technology has spread to Europe.

Two types of iron alloys are much used in fabrication:

• Wrought Iron
• Cast Iron

Wrought iron has less carbon content as compared to cast iron. The former was extensively used before mild steel came into the picture. It was more workable, and could undergo various processes used in making into intricate components and structures as was the norm in the eighteenth century.

Mild Steel

Two process developed in the nineteenth century reduced the usage of iron alloys and the focus shifted to steel. These developments were revolutionary and changed the way components and structures are being made even today.

• Bessemer Process
• Siemens Martin Process

The two process facilitated the production of mild steel on large scale, and the use of wrought iron declined. It is no longer produced on commercial scale and what we find mentioned as wrought iron is actually mild steel. It is extensively used to fabricate building components such as gates, railing, staircase, windows, doors and bins to name a few.

Modern Day Fabrication

Hundreds of alloys are used by the industry to manufacture structures and components for buildings, railways, ships, machineries and so on. Light weight structural steel and mild steel find prominent use in the modern manufacturing. The preference is based upon properties as mentioned earlier and the cost as well, since in modern day economic perspective is always taken into the account.

The fabrication shops have become diverse thanks to emerging associated technologies which impact the processes, and the working of the units in order to hasten production and reduce costs. The equipment and tools used by the units differ as well and this depends much upon the nature of produce.

Apart from modernization and refining of all processes involved, automation in manufacturing, designing and finishing of final products have been facilitated by computerization. There is a sea change as to how the processes in the fab shops takes place now. These latest inductions have come about on need basis as some units are still using old methods and have not undergone changes since the need is simply not there. But sooner or later automation will creep in all types of units due to its immense benefit which is slowly and surely becoming apparent.

Metal Fabrication in Figures

Fabrication of building components and mega structures is a norm and is being done on immense scale. The global metal fabrication market is experiencing growth exponentially and the turnover till this date is nearing twenty billion USD.

Fabricated metals have created third largest sector in manufacturing, and hiring record number of employees. Although the progression of this sector is much dependent upon construction industry growth, nevertheless the diversification accords greater stability and less dependency on construction activities.

In US more than three thousand units are involved in manufacture of components and structure using wrought iron or mild steel and various alloys like light weight structural steel. The scope of industry is much larger if we take into account various segments associated with this industry directly and indirectly.

Trends and Analysis

Metal fabrication has become the largest sector globally in manufacturing and stands solidly as an important component of many modern-day economies. It becomes the largest industrial sector in the World whence the metal manufacturing ecosystem is taken into considered holistically.

Steel production is focused on tariffs applicable and the direct impact of increase is on the end product purchasers while the manufacturing concerns often make huge profits. In most of the segments in US there is a large-scale deficit or trade imbalance which is not good for the economic growth, this needs rectification urgently. Blockbuster profits at the cost of the purchaser is not a good sign either as the long-term impact could affect consumption negatively.

Since all sectors including the residential segments are using steel the outlook is promising for steel fabrication market. The market is dominated by APAC as large-scale development projects are taking place in China, India and Japan. The is further accentuated by the smart city projects demands in these countries.

Metal Fabrication finds use in construction, shipping, mining, automotive and civil infrastructure to name a few. Growth outlook hence seems promising. Modern day technologies like 3 D printing, use in energy sector are further enhancing growth.

The industry is facing challenges which can prevent exponential growth in time to come. Low grade raw materials being used in increasing manner can create carbon footprints on large scale and thus an alternative has to be found. Though figures projected promise robust growth till 2025 there can be a reduction if the factors responsible for the momentum recede. The industry has to figure how to remain viable.

Uday writes often on Indian wildlife especially about the tigers. He works as a naturalist and is fond of travel. Uday also provides search engine optimization service and website contents in English.