4 costly mistakes to avoid in metal fabrication

4 November 2015
 Categories: , Blog


In an industry that needs you to apply practical skills, making mistakes is one of the many ways to learn. It helps you realise the consequences of your actions and prevents you from repeating them. But in some instances, mistakes are a recipe for doom. They can get extremely costly and may also be dangerous. If you work for a metal fabrication business, such as Bronson Sheetmetal Fabrications Pty Ltd, and you want to keep your clients smiling, then here are some mistakes to avoid.

Storing the filler material in a moist area.

The filler material is what is used in the welding phase to join two metals together. It does an effective task of limiting the usage of binder, and thereby decreasing costs. One thing you need to know about these filler materials is that they suffer from the effects of corrosion just like other ferrous metals. Storing them poorly or in moist areas can lead to the formation of rust.

Moreover, once you use bad fillers, the end product is filled with weld defects and problems such as excessive splatter occur. This may require you to buy new metals and restart the process, which doubles the cost.

Striking the arc incorrectly.

Striking the arc is what produces the heat in welding. It needs to be done exactly where you want to start the weld. That's the best way to obtain perfect beads and not ruin the metal. One big mistake is striking the arc elsewhere (i.e., on a piece of scrap or welding table) and then taking it to the weld plate. Remember, you need to pull the welding rod away before it sticks to the plate. But do this with caution, because pulling it too far eliminates the arc.

Striking it elsewhere may not only ruin the material, it can also be dangerous. Imagine striking an arc onto a container with toxic substances or flammable material.

Don't always go for the strongest alloy.

It is not always necessary to use the strongest metal in your fabrication. Some processes need more of flexibility as opposed to strength. Simply picking a strong metal may deter you from properly manipulating it to the desired specifications. When working on designs with complicated shapes and sizes, go for materials with a higher flexibility. You can even find flexible custom made metals at hardware stores for such applications.


Rushing is perhaps one of the worst mistakes in metal fabrication. This is even more devastating when you're using a metal with concrete because it takes a while to harden. Working fast reduces quality. The product may need to be reworked and this raises the costs significantly.