FASCINATION OF

SHEET METAL

A material of limitless possibilities

ABOUT THIS PUBLICATION

This work is protected by copyright. All rights reserved, including the right
to translate, reprint, or reproduce this book or any part thereof. No part
of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means whatsoever, whether electronic,
mechanical, photocopying, recording, or otherwise, without the prior
written permission of the publisher.
While great care has been taken to ensure the accuracy of the contents
of this book, the author, the editor and the publisher do not assume any
liability for damages, direct or indirect, arising from the use of this book,
in part or total, except where prohibited by law.

Editor Dr. Nicola Leibinger-Kammller, TRUMPF GmbH + Co. KG, Ditzingen, Germany
Author Gabriela Buchfink
Translation Matthew R. Coleman
Project coordinators Frank Neidhart, Gabriela Buchfink
Project associates Dr. Nicola Leibinger-Kammller, Dr. Klaus Parey, Ingo Schnaitmann
Layout and design Felix Schramm, Karen Neumeister (SANSHINE GmbH, Stuttgart)
Text consultant Gurmeet Rcker
Translation coordination euroscript Deutschland GmbH, Berlin
Production coordination Jeanette Blaum (SANSHINE GmbH, Stuttgart)
Printing Rsler Druck GmbH, Schorndorf
Finishing Oskar Imberger & Shne GmbH, Stuttgart
Binding Josef Spinner Grobuchbinderei GmbH, Ottersweier
Image editing Reprotechnik Herzog GmbH, Stuttgart

Publisher Vogel Buchverlag, Wrzburg

ISBN-13 978-3-8343-3071-0
ISBN-10 3-8343-3071-X

1st edition 2006

SHEET METAL
THROUGH AND
THROUGH

SHEET METAL THROUGH AND THROUGH

S H E E T M E TA L H O L D S O U R W O R L D
T O G E T H E R. D O E S T H AT S O U N D A L I T T L E

12 |

FA R - F E T C H E D? I TS N O T. S H E E T M E TA L
HAS SERVED MANKIND FOR THOUSANDS
O F Y E A R S. T O D AY, S H E E T M E TA L PA R T S
A R E A N I N T E G R A L PA R T O F O U R L I V E S
S O M U C H S O T H AT W E H A R D LY E V E N
N O T I C E T H E M. TA K E A C L O S E R L O O K
A R O U N D Y O U; Y O UL L B E S U R P R I S E D
AT T H E VA R I E T Y O F M AT E R I A L S A N D
A P P L I C AT I O N S Y O U F I N D.

14 |

10

THE BRILLIANCE OF STEEL

What is sheet metal anyway?
Through the millennia
A case of mistaken identity?
SHEET METAL AS A BASIC MATERIAL
Why sheet metal?
More than meets the eye
Gauge, size, and grade
A matter of form
Joining forces

22 |

HOW SHEET METAL IS MADE

Back in ye days of olde
Keep it movin: steel rolling

24 |

A BRILLIANT FUTURE

11

The brilliance of steel

WHAT IS SHEET METAL ANYWAY?

Sheet metal is used as siding on many industrial buildings.

Armor at Erbach Castle

Couch, or kline, of the Celtic ruler buried at Hochdorf

Cant live with them, cant live without them: endless rivers of steel

Heiligs Blechle An expression used in the dialect of Swabia, a region

in southwestern Germany. The expression (literally: a holy tin) is used
to express astonishment or to designate that dearly loved object of the
Germans the automobile. Ein heiligs Blechle was originally a sort of
token made of tin that poor people could redeem at Church institutions.
People were usually given food in exchange for the tokens.

consist of a large rectangular sheet or a thin strip that has

Sheet metal, as the term suggests, is metal that has been

been wound into a coil. In both cases, the thickness is signi-

rolled into a sheet. In English, the word metal was borrowed

ficantly smaller than the length or width. Sheet metal can

from Old French metal, which in turn has its origins in Latin

be anywhere from 0. 05 millimeters to 15 centimeters thick.

metallum metal, mine, the product of mining, and Greek

Sheet metal with a thickness of less than 0. 2 millimeters is

metallon metal, ore, originally mine, quarry, pit. Today,

often referred to as foil or leaf. Sheets with a thickness of

when we speak of sheet metal, we are not only making spe-

several centimeters are called plate.

cific reference to the material used, but also to its shape and
application. Different types of metal can be used in sheet

THROUGH THE MILLENNIA

metal. While sheets used in mechanical engineering are

Sheet metal has been an extremely popular material since

made chiefly of steel, sheets in other industry sectors may

antiquity when it was used to make everything from gold

be made of copper, copper alloys, or precious metals.

jewelry, coins, and containers to farming tools and weapons.

Sheet metal is a semifinished product, that is, a material

Fabulous pieces of jewelry fashioned from gold plate date

from which a wide variety of other products can be fabri-

from the time of the Maya. The Romans reinforced their

cated from the second hand of a wristwatch to the hull

shields with metal plating, and medieval knights protected

of a supertanker. Sheet metal can take many forms. It may

themselves with metal armor. Advanced civilizations of the

past have also left us with examples of everyday objects and

furniture made of sheet metal. In Hochdorf near Stuttgart,
excavations of the burial chamber of a Celtic ruler have uncovered a movable couch, or kline, 2. 5 meters long. The
lavishly decorated kline is made of thin bronze sheets and is
over 2,500 years old!
A CASE OF MISTAKEN IDENTITY?

For some, sheet metal is a cheap, lightweight substitute

for more expensive, high -grade materials. The term sheet

12 |

Sheet metal through and through

metal seems to conjure up images of flimsy tool sheds,

of sheet metal. This is the high-grade sheet metal used in

cheap containers and other structures never meant to stand

expensive kitchen designs or home furnishings. The brilliance

the test of time. Oftentimes, what is regarded as sheet metal

of pure metal gives objects a modern look and a high-quality

is, in reality, the economical galvanized type, which is used

appearance. Unlike plastic, metal is a natural raw material.

because it is lightweight, cheap and convenient. But take

This means it is not only pleasant to look at, but also safe for

one look at the furnishings and appliances you have at home,

the environment since it can be melted down and reused to

and youre sure to find plenty of examples of another type

produce new parts.

13

Sheet metal as a basic material

WHY SHEET METAL?

As a material, sheet metal offers numerous advantages, making

Mild steel

Stainless steels

High -grade steels

It can be used to make products that have small

High -tensile steels

or large surface areas.

Light metals such as aluminum

It is very easy to work with from cutting and

Non -ferrous metals such as copper and brass

punching to forming and press brake bending all

Precious metals such as silver and gold

it particularly well suited to industrial processing. It is ideal

The most important materials are:

for a wide range of applications.

the way to welding and other joining processes.

It is elastic and easy to shape.

It easy to mount and recycle.

Different materials: steel, copper, brass, and aluminum

Ship ahoy! The Queen Mary II luxury liner is without doubt one of
the largest conglomerations of metal in the world. It is 325 meters long,
41 meters wide, and 72 meters high. The ship is so high that a person
standing on the upper deck can look the Statue of Liberty in the eye!

Material

Description

Typical applications

Steel

Generic term for materials made of iron (Fe) and iron alloys;

Mechanical engineering, scaffolding

often referred to as mild steel or structural steel

machinery, shipbuilding

Quality steels

Higher-quality ferrous steels or alloyed steels with fine grain

and few impurities

Materials differ from one another in weight, tensile strength,

corrosion resistance, appearance, and price. There are also
of mild steel, for instance, can be alloyed in different ways,

than other solid materials. The properties of a piece of sheet

thereby creating different levels of tensile strength.

Mechanical engineering, sheet metal

processing, architecture, automotive
industry, agricultural machinery

differences within certain groups of materials. Certain types

Plus, sheet metal is thin, lightweight, and more economical

systems, sheet metal processing,

automotive industry, agricultural

Stainless steels

Iron (Fe) with chromium (Cr), nickel (Ni), molybdenum (Mo),

Food industry, building cladding systems

and titanium (Ti) elements

metal are determined largely by the properties of the metals

High -grade steels

of which it is composed. The tensile strength of the sheet

These steel types have a high degree of purity and specific

Food industry, water and sewage,

properties that distinguish them from structural and quality steels,

furniture and fixtures

metal is crucial not only for the construction itself, but also

for instance, degree of heat resistance, corrosion resistance,

for its production. Tensile strength measures the amount of

and amenability to welding.

stress that a sheet is able to withstand.

In production, stress is deliberately applied to the sheet

Steels that are particularly hard and tough. Examples include nickel

Tool manufacturing, security and defense

metal so that it undergoes deformation or breaks. The finished

High -tensile steels

steel or multiphase steels exhibiting two or more compositional

technology, lightweight constructions

sheet metal part, however, should be able to withstand these

structures (called phases) within the metal.

loads. Nevertheless, there are exceptions to this rule. The

Light metals

crumple zone on a car, for instance, is intended to undergo

deformation, and some parts are even designed with prede-

Lightweight materials such as aluminum (Al), magnesium (Mg),

Aircraft construction, aerospace, automotive

and related alloys

industry

Copper-based materials comprising pure copper (Cu) or alloys

Electrical systems, cables and conduits,

such as brass (copper and zinc in various proportions).

art objects, jewelry

Precious metals include metals such as gold (Au), silver (Ag),

Jewelry

termined breaking points.

Non -ferrous metals

MORE THAN MEETS THE EYE

A wide variety of materials are available for use in industrial
applications. These materials consist of pure metals or alloys

Precious metals

platinum (Pt), and other alloys.

of different metals and other chemical elements. The properties of the materials determine their application and the
methods by which they are processed.

14 |

Sheet metal through and through

Variety is what makes them so versatile: popular materials and their applications

15

GAUGE, SIZE, AND GRADE

Various sheet thicknesses from 2 to 20 millimeters

of the nominal value. Thus, for a sheet with a nominal thick-

Units, conversions, and confusion Talk about missing the mark:

in 1999, NASAs Climate Orbiter flew right by Mars instead of entering
into orbit as it should have. The reason for the mishap: different teams
using different units of measurement. While one team was using the
metric system, another was making its calculations in feet and inches.

A similar problem exists in the world of sheet metal, where there is

no single international standard for dimensions, gauges, and grades.
Instead, it is the design engineers job to know which national
standards apply. Luckily, sheet metal working machines are designed
to handle a variety of measurement systems.

Steel strip, by contrast, may have a length of several hundred

and, if so, which types:

To order sheet metal, you need to know the gauge, size,

ness of 2 millimeters, the actual thickness can be anywhere

meters, but a width of only 2 meters or less. Coils can have

and grade. The gauge specifies how thick the sheet or strip

from 1. 9 to 2.1 millimeters. While higher grades such as cold -

a maximum diameter of around 2.3 meters and weigh up to

is, while the size refers to its width and length. The grade

rolled thin sheets offer greater accuracy, they are also more

40 tons. The thickness of strips, meanwhile, is usually under

indicates the surface quality.

expensive.

3 millimeters.

Standards governing the dimensions and grades of sheet

Keeping thickness deviation to a minimum is crucial

Pores: small depressions or holes

Bumps: small elevated areas

Grooves: visible marks caused by contact with other

Scratches: light scratch marks caused by contact with

objects; they can sometimes be felt with the finger tips

metal can often vary depending on the country or region. In

for sheet metal parts requiring extremely precise outside

Surface | The surface of the sheet is an important factor

Europe, for instance, all length specifications are stated in

dimensions or for parts that will later be bent. Bent angles,

to consider whenever the sheet is painted or coated or if the

millimeters. In the United States, on the other hand, lengths

in particular, can be affected by deviations in the sheet

sheet will be used to create a part that will be highly visible in

All surface imperfections can affect the appearance and func-

are generally specified in feet or inches. The European

thickness as small as several hundredths of a millimeter.

the final product. Cold -rolled thin sheets are especially well

tion of the finished part. While scratches can mar the appear-

suited to achieving a smooth surface.

ance of high-quality home accessories, other imperfections

Standard (EN) is the standard used in Europe. In many cases,

other objects

European Standards are transposed into German DIN stan-

Shape and format | Sheet metal can be purchased in

The quality of the sheet surface is specified according to

are more critical. For instance, imperfections preventing

dards. In Germany, harmonized standards such as these are

sheets or as strips that have been wound into coils. The

grade. The surface can be very smooth, smooth, matte, or

uniform application of the finish can later cause flaking and

indicated by the letters DIN EN.

maximum width and length of a sheet are determined by

rough. The smoother the surface, the shinier the sheet and

lead to corrosion. This is why customers purchasing sheets

the size of the rolling equipment. You can find sheets up to

the easier it is to apply foils or finishes more uniformly. Cus-

are given the option of specifying whether one or both sides

Gauge or thickness | Sheets can have a thickness

4 meters wide and 10 meters long.

tomers can also specify whether imperfections are allowed

of the sheets should be free of imperfections.

ranging from 0.05 millimeters to 150 millimeters. Within this

range, many thicknesses are available, making it easy to find
the right sheet for almost any application. The DIN EN 10079
standard distinguishes between:

Foil: thickness of less than 0.5 millimeters

Thin sheet: thickness between 0.5 and 3 millimeters

Plate: thickness of 3 millimeters and over

Some sheet formats are more popular than others:

Small format: 1,000 x 2,000 millimeters

Medium format: 1,250 x 2,500 millimeters

Large format: 1,500 x 3,000 millimeters

The sheet thickness specified in the manufacturers catalog

is considered the nominal thickness. Some areas of the
sheet, however, may deviate from the nominal thickness.
The degree of permitted deviation determines the thickness
tolerance. Expressed as a percentage of nominal thickness,
the tolerance can vary with the format and sheet thickness.
When purchasing sheets, customers can choose from a
variety of sheet grades. For standard sheets, the permitted
thickness deviation is approximately plus or minus five percent

16 |

Sheet metal through and through

Sheet metal is usually sold in sheets or coils that come in a variety of sizes and thicknesses.

17

A look inside the warehouse of a steel manufacturer

Profiles with circular, rectangular, and other cross sections

Sheets with different surfaces

Automotive body part with different sheet thicknesses

A little color makes all the difference Steel manufacturers offer

colored sheets that can be used for buildings and industrial facilities
to create a colorful appearance both inside and out. Different color
schemes can be used to help an industrial building fit in better with
its surroundings or make the interior more pleasant for the people
who work there.

A MATTER OF FORM

Surfaces with bite | Sheet metal surfaces can vary

Finished sheets | From washing machines to facade

The classic sheet is flat and unprocessed and has two smooth

considerably: ground surfaces, brushed surfaces, grooved

cladding many sheet metal parts are prefinished to provide

sides. It is also possible, however, to purchase preprocessed

surfaces, surfaces with a pronounced design, or surfaces

corrosion protection or to create a desired effect. Normally,

sheets. These sheets have already been prepared for specific

with a more subtle look. The type of surface you choose

the application of finishes is one of the last steps in the pro-

applications and make further processing easier.

depends primarily on the intended function of the product.

duction process. As an alternative, however, it is possible

For example, sheets with a pronounced, raised pattern are

to employ prefinished sheets. In a well-established process

Sheets with personality | Corrugated sheets and check-

used to provide a sure -grip surface on steps or catwalks.

ered sheets are examples of sheets with their own distinctive

Designer sheets are used for work tables, accessories,

personalities. They are more rigid and stable than flat sheets

elevators, and home furnishings. In applications such as these,

and have a more striking appearance. For this reason, they

having an attractive, high-quality pattern is paramount.

known as coil coating, sheets are coated while they are still
in the production line.
Special finishes are rolled onto the material, where they
bind with the sheet surface. The finishes are so durable that

are often used as cladding for buildings or roofs.

they are able to make it through producion without peeling off

Profile sheets such as these also include steel rods. Rods

or scratching. In addition to different colors and luster effects,

with round cross sections are called tubes. Rectangular or

you can find functional coatings for special applications.

square cross sections are also common. In addition, there

Coatings of this type include finishes that are specially de-

are nonstandard products available in just about any shape

signed to reflect heat. They are used for steel roofing and

imaginable for particular applications.

building facades and let through less than half as much heat
as other finishes.

Tailored blanks | The idea behind tailored blanks is

simple: create a product that has the right sheet thickness
and material quality in just the right spots. Tailored blanks
are made up of different sheets that have been welded
together. They are used in a variety of areas, for example
in the automotive industry to make body parts. Parts of the
sheet that have to withstand greater loads are thicker, while
areas subjected to lower loads are thinner. Tailored blanks
reduce weight and material costs.

Customizing | Many sheet metal suppliers offer to customize sheets to meet the specific requirements of their customers. This service includes cutting sheets to a particular
format, rounding off the edges, or applying a protective film
1

18 |

Sheet metal through and through

to stainless steel.

19

Lightweight or heavyweight? The dimensions and density of the

material are what determine the weight of a sheet. A medium-sized
sheet made of 1-millimeter thick steel weighs around 25 kilograms.
A 10-millimeter thick sheet, by contrast, already tips the scales at
250 kilograms. Because aluminum has a lower density, using it reduces
the sheet weight by two thirds.

JOINING FORCES

a material with lower heat conductivity. Material like this is

For many years now, sheets have been used in composite

used for covers or lids designed to provide insulation from

materials and structures.

heat or cold.

AN OLD PROCESS WITH NEW POTENTIAL

The idea of creating solid parts from individual sheet layers

Sandwich technology | Sandwich technology is used in

LOM technology | LOM stands for Laminated Object

is not new, emphasizes developer Daniel Graf at TRUMPF

products such as sandwich panels, which are used primari-

Manufacturing. In this method, flat sheets are stacked on

Werkzeugmaschinen GmbH + Co. KG in Ditzingen, Germany,

ly to build large factory buildings. The panels consist of a

each other and their surfaces joined to form one solid part.

when speaking to people about the design of the hydrau-

centimeter-thick layer of rigid foam that is covered on top

LOM technology is applied chiefly to steel parts. Copper,

lic punching head. The component is made up of around

and bottom by thin metal sheets. The rigid foam is incredibly

however, is also well suited to this method. Here, a special

150 layers and is responsible for keeping things moving in

strong and stable, while providing excellent heat-insulating

soldering procedure is used to laminate the layers together.

the punch press. People wondering why it is worth going to

properties. The metal sheets on both sides protect the foam

Aluminum layers, by contrast, are glued together.

core and give it a pleasant appearance. Sandwich panels are

all this trouble just to make a part will find the answer by

Sheets range from foil with a thickness of a tenth of a

taking a closer look inside. What looks like a compact steel

amazingly light: a single truck can sometimes carry all the

millimeter to sheets that are several millimeters thick. A

block from the outside is, in reality, an intricate structure with

material needed to construct an entire building.

30-centimeter high LOM part, for instance, is made up of

many hydraulic channels and cavities.

Building solid parts layer by layer: LOM technology enables the

construction of complex hollow structures.

In addition, there are other sandwich materials that are

150 blanks with a gap between layers that is ideally from one

The complex structure makes it possible to build a very

made exclusively of metal. In these types of materials, two

to two hundredths of a millimeter. At first sight, this may seem

compact punching head, while keeping the flow channels as

thin sheets are joined to form a composite. Sheets can be

overly complicated. After all, whats the point of laminating in-

short as possible, explains Graf. Manufacturing a part like

The next step was to lower the cost of joining the layers.

joined with a weld seam, studs or other method. The material

dividual sheets together when you can just use a solid block?

this using conventional methods such as drilling and milling

Graf explains: At first, we coated the sheets on both sides

created in this way is oftentimes lighter and more stable than

The LOM process is indeed expensive and, for this reason, is

is very difficult. Thats why we use LOM technology. Blanks

with copper and then soldered them together in a vacuum

a normal sheet of similar thickness.

only used in two cases: to produce cubic parts with complex

are punched or cut individually using a laser. Then they are

oven. It was a complex and costly procedure. Just coating

Sheet metal can also be combined with plastic materials.

internal geometries that cannot be otherwise obtained using

stacked on top of each other and joined. In reality, its noth-

the sheets with copper cost several hundred euros for each

Two layers of sheet metal, for example, can be used to surround

a cast, turned, or milled part or to create parts for which

ing new, says the developer.

component. To get around this, another method of applying

a plastic core. This method has the advantage of creating

other manufacturing methods would be more expensive.

But then why bother putting more energy into developing

the solder had to be found. The new method helped us elim-

the method? There are two answers to this question. Initially,

inate 98 % of the costs associated with coating the sheets

processes were not well adapted to serial production, and

with copper. The developer had reached his goal: finding

laminating the layers was too costly. On the first prototypes,

a new method based on LOM technology that is suitable for

I had to figure out the contours of the blanks manually using

serial production and makes sense from a cost perspective.

the 3D CAD model, recalls Graf. Now, this is done automat-

Graf concludes: LOM technology is certain to remain a

ically. In addition, the programming system is now capable

niche application. Nevertheless, we are now able to utilize

of placing the blanks on the sheet in the right order. That

the technologys potential to a greater degree and apply it to

means the unloading system can stack them automatically.

other components with complex internal structures such as

The first obstacle to serial production had been overcome.

cooling elements in power electronics.

Composite structures for tailored stability and weight. Metal sandwich material can be combined in a variety of ways.

20 |

Sheet metal through and through

21

How sheet metal is made

BACK IN YE DAYS OF OLDE

KEEP IT MOVIN: STEEL ROLLING

The first sheets had to be hammered into shape.

Rolling steel: a sketch by Leonardo da Vinci

Cold rolling: tandem mill at ThyssenKrupp Steel AG

The gap is considerably smaller than the slab, causing the

For many thousands of years, sheet metal was hammered

In the course of the 18th century, people began rolling steel.

slab to be flattened. The slab is flattened to a steel strip in

by hand out of single metal blocks. With each blow from the

This method gradually gained acceptance over the next

several stages, with the steel passing through different sets

hammer, the metal spread out and became flatter until the

100 years. Today, steel continues to be rolled. In this process,

of rollers until the strip attains its final thickness.

desired thickness and surface area were attained. This tech-

a rectangular rod of steel called a slab is guided through a

nique is still used today to create works of art and jewelry.

gap between two turning rollers.

Splitting hairs The thickness of ultra high -quality, cold -rolled sheets is
accurate to a thousandth of a millimeter. This corresponds to a hundredth
of the thickness of a single human hair. In order to produce such sheets,
rolling mills have to be equipped with high -precision components. Indeed,
with rollers weighing in at 80 tons and having a diameter of 1. 5 meters,
finding a roller manufacturer who has a tendency to split hairs can make
all the difference.

In the rolling mill | In the hot -rolling mill, the slab, which

If there was a river or stream nearby, people were able

can weigh up to 60 tons, is rolled into a hot -rolled strip with

to harness the power of the flowing water to operate the

a specific thickness (for example, 12 to 20 millimeters). When

hammer. Even so, it could take hours or even days to create

it passes through the mill, the steel is red hot. In this state,

a single sheet of metal.

the steel is easier to shape.

In Leonardo da Vincis time, people began pressing the

Afterwards, the hot -rolled strip goes to the cold -rolling

metal in addition to hammering it. Da Vinci designed a type

mill, where it is rolled to its final thickness, which may be as

of screw press that could be used to shape metal strips to

thin as 1 millimeter. The thinner the sheet, the faster it cools

the desired width and thickness. Leonardo da Vinci was also

during the rolling operation.

probably the first to suggest that steel strips could be manufactured using rollers. A sketch by da Vinci has been found

High -grade sheets | Cold rolling produces sheets of

that illustrates the principle of steel rolling and even shows a

higher quality than can be obtained by hot rolling. The thick-

manually operated rolling machine.

ness of cold -rolled sheets is more consistent. The internal

structure is made more uniform by subsequently heating the
metal until it is red hot. Surfaces are harder and smoother

and have fewer imperfections.

The temperature of the steel is kept within narrowly defined limits during hot and cold rolling operations. Minimizing

machines are used to cut the strip to the desired size. Thinner

temperature differences during the rolling process produces

strips can be cut with slitting machines, which work in much

an internal material structure that is more uniform and less

the same way as a pasta cutter that cuts dough into noodles.

stressed. Rolling speed is also an important factor: the lower

Cut-to-length lines are used to cut the sheets or strips to

the rolling speed, the higher the quality of the internal struc-

the right length.

ture and the surface.

More than just flat | Rolling produces not only flat strips.

22 |

Sheet metal through and through

Cutting to size | After the strip has been rolled to the

Almost anything required in one piece can be rolled. This

desired thickness, it still has to be cut to the right size for

includes rods, tubes, profiles, rails, and wire. Also, rollers

storage and sale to the customer. Before it is cut, thick steel

do not necessarily have to be smooth: they can have bulges,

strip may be up to 40 meters long. Shears or flame cutting

ridges, or other features.

23

A brilliant future

Sheet metal has been in use for ages. And, in the decades

more stringent. Sheet metal manufacturers are constantly

to come, sheet metal is sure to continue to play a crucial role

working to optimize their materials in order to keep pace with

as an industrial material and, thus, in our daily lives. Different

the steady advances in manufacturing technology.

Laser cutting today a standard operation

Lightweight sheet constructions are gaining in popularity

Barely visible: sheet metal framework in glass facades

types of metal have many attractive properties that can be

modified by adding other materials or employing various pro-

Trimming down | Lightweight design promises to be the

cessing methods. Sheet metal manufacturers are constantly

way of the future. Reducing weight while maintaining the

working to develop new materials with properties that are

same level of stability and performance is a trend that is

optimally suited to specific manufacturing methods.

gaining in popularity in the automotive industry and beyond.

To reach this goal, materials with a high tensile strength

Laser-friendly | The use of lasers to process materials

are used, making it possible to employ thinner sheets. At the

has risen dramatically since the beginning of the 1990s. Even

same time, the new high -tensile materials present new chal-

so, suitable materials are still required for lasers to be used

lenges to mechanical engineers, who have to adapt the per-

effectively. In recent years, suppliers have begun offering

formance of the machines and, most importantly, the tools to

sheets that, due to their structure and quality, are especially

the new materials.

well suited to laser processing. Sheets such as these include

Using composite materials made of sheet metal is another

fine -grain mild steels, which make it possible to achieve

way to reduce weight. Metal mesh between two thin aluminum

clean cutting edges that are free of burrs.

sheets is just one example of the many different types of

Reliable processing | The heat and stress that arise

and studied. The first lightweight vehicles have already been

during cutting and punching operations can cause the sheet

built in research laboratories. As soon as cost -effective pro-

to become deformed. This effect is magnified by stresses

duction of such vehicles becomes possible, the new materi-

that may have been present in the sheet before processing

als will begin to appear in production facilities.

sandwich constructions that are currently being developed

began. Upright parts caused by deformation can get caught

in the tools and bring the entire machine to a standstill. To

Conclusion | The properties and processing possibilities

ensure that this does not happen, stress -relieved sheets

of sheet metal have still yet to be fully explored. Indeed, there

are used that undergo as little deformation as possible. This

seem to be many brilliant facets of the material that are still

approach also reduces the amount of refinishing required. If

waiting to be discovered.

parts are deformed, they have to be straightened and flattened in a separate work cycle.

Higher demands | Each improvement to the properties

of the material yields better production results. As quality
2

24 |

Sheet metal through and through

demands continue to rise, tolerances become increasingly

25