At Die-Matic Corporation, we offer MIG, TIG, resistance, and Spot welding. Below we explain each type of welding.

MIG Welding

MIG Welding, or Gas Metal Arc Welding (GMAW), joins metal using a continuous consumable solid wire electrode fed through a welding gun at a predetermined speed. The electrically charged contact tip in the gun transfers current to the wire creating an arc between the wire and base metal. The arc produced enough heat to melt the wire and base metal, generating a weld pool, or weld puddle, which fuses the two pieces together. A shielding gas safeguards the weld pool from environmental contaminants, which could introduce defects.

MIG welders can cater to both thin and thick metals without the threat of burn-through or subpar weld quality because the power output range can be regulated. MIG welding can be used on various metals, such as carbon steel, stainless steel, and aluminum. However, one limitation is the creation of spatter during the welding process, making it most suitable for projects where weld aesthetics are not a paramount concern.

TIG Welding

TIG Welding is another arc welding process. It is also known as gas tungsten arc welding (GTAW). Unlike MIG welding, TIG uses a non-consumable tungsten electrode to create the weld. An electric arc is created between the tungsten electrode and the workpiece. This arc heats the metal, creates a weld pool, and allows the welder to join pieces of metal together. Filler material is added when there’s a need to build up the weld bead, bridge a gap between pieces, or when working with thicker metals that need added material for strength. Like MIG welding, a shielding gas protects the weld pool from contamination.

TIG welding typically requires more skill and finesse than other methods like MIG, primarily because it requires both hands and often involves a foot pedal to control the amperage (heat). However, it results in a more precise and cosmetically appealing weld with minimal post-weld cleanup.

Resistance Welding and Spot Welding

Resistance welding is a broad term for welding processes that use pressure and electrical current to create a weld between two metals. The welding heat is generated by the resistance of the material to the flow of electrical current. A low-voltage, high-amperage electric current is passed through the metal, which creates heat and melts the metal at the joint. The pressure of the welding electrodes holds the metal in place while it melts and cools, forming a strong weld.

Spot welding is the most common type of resistance welding. It is used to weld thin sheets of metal together by producing individual “spots” or points of weld rather than continuous seams. Two sheets of metal are placed between the upper and lower electrodes of the welding machine. Electrical current is passed through the electrodes, and the resistance to this current in the metals creates heat, melting the materials and forming a weld.

Partnering with Die-Matic for Welding

At Die-Matic, we are known for our precision metal stampings, but we offer much more. As a single-stop manufacturer, our range of services includes prototypes, value-added services (e.g., heat-treating, coating), assembly, and welding. If welding is needed for your project, our weld technicians or manufacturing engineers will choose the best method suited to your needs. Our skilled weld specialists have honed the art and science of proficient welding, focusing on quality and attention to detail with each job. Contact us to learn how we can add value to your precision metal stamping project.

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What is DFM?

DFM is an engineering and product design concept that involves creating products to optimize their manufacturing process. By considering manufacturing constraints early in the design phase, engineers can ensure that the product can be efficiently and cost-effectively produced. It aims to reduce product complexity, minimize defects, and improve overall product quality while reducing manufacturing times and costs. It also ensures that functionality, reliability, aesthetics, regulatory compliance, and customer satisfaction meet expectations.

The history of DFM is one of incremental changes through the decades. As technology advanced and products became more complex, it became clear that the traditional methods of designing a product first and then figuring out how to manufacture it later was highly ineffective. It wasn’t until the 1990s that design for manufacturability as an engineering discipline became formalized with processes for a wide range of product types.

Benefits of DFM for Precision Metal Stamping

It’s been said that 70 percent of the product cost is determined during the development phase, but engineering changes during the manufacturing phase can inflate your product costs and severely impact profitability. It is much more cost effective to design the part holistically, considering manufacturing, assembly, and even maintenance. Precision metal stamping is a process that can benefit from implementing DFM principles. Here are a few areas where DFM can make an impact:

• Material Waste – Optimizing your design for stamping results in less material waste. Parts can be optimally nested to reduce material waste.
• Production Costs – Since DFM is a holistic process that looks at more than just the part design, it can reduce production costs by removing or improving elements that make production or assembly challenging. It can also minimize the number of components required for assembly.
• Quality Issues – DFM can reduce the risk of quality issues, such as defects or errors, before parts are produced, preventing scrap, reworks, and lost time and money.
• Time to market – When processes are streamlined through part modification early in development, time to market decreases and profitability increases.
• Product Performance – DFM may increase product performance, resulting in increased customer satisfaction and potentially higher sales.
• Product Lifespan – When DFM principles are applied, the result can be more durable and longer-lasting products, reducing the need for costly repairs or replacements.

Precision Metal Stamping DFM

Engineers will want to know everything about your product and its use before making any changes. Some of the questions they may have include:

• What are the physical requirements for the part – strength, durability, etc.? There may be a less expensive material that will provide what you need.
• What environments will the part be exposed to, and how is it used? This will also help with material selection as well as any finishing or plating requirements.
• How do components interact with each other? Can we combine any to remove costs?
• How are parts assembled and maintained? Do parts need to come apart for maintenance? Can fastener insertion be done in die, or do they have to be welded? Will in-die clinching or staking work?
• Are non-critical features stated? Unnecessary precision can add costs.
• If you have multiple products, can similar components be standardized to be used across all of them?
• Can components be designed to be used on only one orientation when possible to mitigate the risk of improper assembly?

In addition, engineers will look at part complexity and tolerances to ensure their equipment can stamp the part efficiently and remove secondary operations when possible. Each type of metal will react differently and may have different degrees of resistance to bending, punching, and forming, so the engineer will need to understand the limitations of the material and make adjustments. In general, with the understanding that these can vary depending on the material being used, here are just a few basic guidelines engineers will follow.

Holes and slots – The diameter of tight tolerance holes and slots generally must be equal to or greater than the material thickness. However, this can vary with materials that have a high sheer strength. Holes and slots require a minimum distance of about twice the material thickness between each other or the edge of the part to prevent a bulging of the material. When near a bend, the distance should be 1.5 times the material thickness plus the bend radius. Punched holes have a slight taper, so if precision is required on both sides of the holes, a secondary operation may be needed.

Flange – The minimum width of a flange should be 2.5 times the thickness of the material.

Bend – Generally, the inside bed radius should be at a minimum equal to the thickness of the sheet metal and should bend in one orientation. The overall height of a bend should be at a minimum of 2.5 times the thickness of the material plus the radius of the bend. The material may tear if a bend is made close to an edge. To prevent this, the part designer may need to include an offset that is at least equivalent to the material thickness. Alternatively, bend relief notches can be used.

Corners – Blank corners should have a radius of at least half the material thickness.

Embosses – Embosses are created by stretching the material, and excessive depth can lead to thinning or fracturing. The maximum depth should be less or equal to three times the material thickness.

These are just a few considerations when designing a precision metal part for stamping. Working closely with your metal stamping partner during the design phase will ensure you receive a finished part that cost-effectively meets your expectations.

Speak to the Precision Metal Stamping Experts at Die-Matic

To ensure you receive a quality precision part at a competitive price, Die-Matic applies DFM principles to every part. Let us guide you toward the ideal product design for efficient manufacturing and assembly. Whether enhancing your original design or streamlining for cost savings, our expertise will make all the difference. Contact us to get started.

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