Metal Fabrication Industry Terminology

Alloy

A metallic material made by combining two or more elements to achieve targeted properties such as strength, hardness, corrosion resistance, or machinability.

Switch to a 6061 aluminum alloy for better formability.|This gusset is an alloy steel with added chromium for strength.|Call out the alloy per the ASTM material spec on the drawing.

Annealing

A heat treatment that softens metal, relieves internal stresses, and improves ductility by heating to a specified temperature and then controlled cooling.

We should anneal after rolling to relieve residual stress.|Annealing will improve ductility before the deep-draw step.|Include an anneal cycle in the router before final forming.

ASTM (American Society for Testing and Materials)

A standards organization that publishes consensus specifications and test methods for materials, products, and processes; also refers to the standards themselves.

Order the sheet per ASTM A240 304L.|The tensile test follows ASTM E8.|Certs must list the applicable ASTM standard.

Bend Allowance

The arc length of the neutral axis through a bend, used to compute flat patterns so the formed part meets finished dimensions.

Use a bend allowance of 4.2 mm for this 90° bend.|The flat pattern is off because the bend allowance is wrong.|We updated the CAD to calculate bend allowance automatically.

Bill of Materials (BOM)

A structured list of all parts, raw materials, subassemblies, and consumables required to build a product, often with quantities and revisions.

Add hardware and weld wire to the BOM as consumables.|The assembly BOM rolls up to the finished goods item.|Engineering released REV C of the BOM to ERP.

CAD (Computer-Aided Design)

Software used to create and manage 2D drawings and 3D models of parts and assemblies for design and documentation.

Please send the STEP file from your CAD system.|Update the CAD model to add a 3 mm fillet.|The drawing is derived from the CAD master.

CAM (Computer-Aided Manufacturing)

Software that converts CAD models into manufacturing instructions such as toolpaths, nests, and machine code for CNC equipment.

CAM will nest these parts for the fiber laser.|Regenerate the toolpaths before posting.|We need a CAM post for the new brake press.

CMM (Coordinate Measuring Machine)

A precision metrology device that uses probes to measure coordinates of part features to verify dimensions and GD&T callouts.

Run a CMM program to verify true position.|The CMM report shows a flatness of 0.12 mm.|Create a CMM routine aligned to datums A, B, and C.

CNC (Computer Numerical Control)

Automation of machine tools using programmed instructions, typically G-code, to control motion and process parameters.

Post the program for our Fanuc CNC.|We’ll cut this profile on the CNC router.|CNC parameters include feed rate, spindle speed, and offsets.

Cycle Time

The elapsed time to complete one unit of work from start to finish for a given process or operation.

Bending cycle time is 42 seconds per part.|We reduced cycle time by combining two operations.|Cycle time must be below takt to meet demand.

Deburring

The process of removing sharp edges, burrs, and tool marks after cutting, machining, or forming to improve safety, fit, and finish.

Send parts to the tumbler for deburring.|Edge-break and deburr before powder coat.|The spec requires no sharp edges; verify deburring.

Die

A hardened tool used to shape, cut, or form material under force, such as in press brake bending, stamping, or punching.

Set up the V-die at 16 mm for air bending.|This job needs a hemming die on the press brake.|The punch-die clearance affects burr height.

Design for Manufacturability (DFM)

An engineering approach that simplifies fabrication and assembly, reduces cost and risk, and ensures the design can be produced with available processes and tolerances.

DFM suggests using standard bend radii to reduce setups.|We consolidated welds per DFM recommendations.|DFM review cut the cost by 18%.

ERP (Enterprise Resource Planning)

An integrated business system that plans and tracks orders, materials, capacity, inventory, and financials across the enterprise.

Release the work order in ERP.|ERP backflushes raw steel when the job closes.|Lead times and inventory live in ERP.

Fixture

A device that locates and securely holds a workpiece during machining, welding, inspection, or forming for repeatability and accuracy.

Design a welding fixture to control distortion.|This fixture locates on the datum holes.|Quick-change fixtures will cut changeover time.

G-code

The programming language used to control CNC machines, specifying motions (e.g., G00, G01), feeds/speeds, and auxiliary functions (e.g., M-codes).

Use G01 F1000 for the contour pass.|Add M08 for coolant before the drill cycle.|Can you post-process to Fanuc G-code?

GD&T (Geometric Dimensioning and Tolerancing)

A symbolic system on drawings that defines allowable geometric variation for form, orientation, location, and profile relative to established datums.

True position is 0.25 to datums A|B|C.|The flatness callout is 0.2 mm on the base.|Add a profile tolerance instead of tight linear dims.

HAZ (Heat-Affected Zone)

The portion of base metal adjacent to a weld or thermal cut whose microstructure and properties have been altered by heat.

Minimize HAZ with faster travel speed.|The HAZ tempered the base metal near the weld.|Laser cutting yields a narrower HAZ than plasma.

ISO 9001

An international standard that defines requirements for a quality management system focused on process control and continual improvement.

We’re ISO 9001 certified.|This process change needs ISO 9001 document control.|Internal audits are scheduled per ISO 9001.

JIT (Just-in-Time)

A lean principle that produces or replenishes only what is needed, when it is needed, in the quantity needed, to minimize inventory and waste.

Implement JIT deliveries from our steel supplier.|We sized kanban for JIT replenishment.|JIT reduced WIP and freed floor space.

Kanban

A visual pull system that controls inventory and work-in-process using cards or signals to trigger replenishment.

Set kanban cards for laser-cut blanks.|The kanban signal triggers a press brake setup.|Adjust kanban size for the higher demand.

Kerf

The width of material removed by a cutting process; critical for dimensional accuracy and nesting.

Use 0.15 mm kerf compensation on the laser.|Waterjet kerf is about 1.0 mm with this abrasive.|Plasma kerf varies with amperage and speed.

K-Factor (Bending)

The ratio that locates the neutral axis through the thickness during bending; used to calculate bend allowance and flat patterns.

Assume a K-factor of 0.38 for 1.5 mm CRS air bends.|We derived an empirical K-factor from test coupons.|K-factor drives flat pattern accuracy in CAD.

Laser Cutting

A thermal cutting process that uses a focused laser beam (often with assist gas) to cut sheet, plate, or tube with high precision.

Run this on the 6 kW fiber laser.|Optimize pierce time and assist gas.|Tight corners need micro-tabs to prevent tip-ups.

Lead Time

The total elapsed time from order to delivery, including queue, processing, move, and wait times across operations.

Quoted lead time is two weeks ARO.|Reduce lead time by parallel processing.|Supplier lead times impact our MRP plan.

Lean Manufacturing

A production system that maximizes customer value while minimizing waste through flow, pull, standard work, and continuous improvement.

We held a kaizen event to reduce changeover.|Standard work stabilized the cell.|Value stream mapping revealed bottlenecks.

MIG Welding (GMAW)

A welding process that uses a consumable wire electrode and shielding gas to create an arc and deposit filler metal efficiently.

Switch to 90/10 gas for spray transfer.|Set wire feed to 300 ipm for this joint.|Use pulse MIG to reduce spatter.

MRP (Material Requirements Planning)

A planning method that calculates what materials to buy or make and when, based on BOMs, forecasts, orders, and inventory.

Run MRP to release POs for steel coil.|MRP netted demand against on-hand inventory.|The BOM change will affect MRP signals.

NDT (Non-Destructive Testing)

Inspection methods that assess material integrity without damaging the part, including UT, MT, PT, RT, and visual testing.

Perform UT on the welds per the spec.|Use dye penetrant (PT) on the machined surface.|Mag particle (MT) found a crack at the root.

Nesting

Arranging part profiles on raw sheet or plate to maximize material utilization, minimize scrap, and reduce cutting time.

The new nest improved material yield to 88%.|Tight nesting requires part tabbing to prevent tip-up.|Group jobs to nest across common material and thickness.

OEE (Overall Equipment Effectiveness)

A metric that quantifies manufacturing productivity as Availability × Performance × Quality to identify loss sources.

Yesterday’s OEE was 72% on the laser.|Availability dropped due to unplanned downtime.|Quality losses from rework hurt OEE.

OSHA (Occupational Safety and Health Administration)

The U.S. agency and body of regulations governing workplace safety and health; commonly used to reference compliance requirements.

Follow OSHA requirements for LOTO.|Update the SDS binder to meet OSHA rules.|OSHA audit emphasized PPE near the plasma.

Plasma Cutting

A thermal cutting process that uses an ionized gas arc to melt and eject material, effective on thicker plate and structural shapes.

Cut 1-inch plate on the high-def plasma.|Bevel head will prep the weld joint.|Expect a wider kerf than laser on thin gauge.

Powder Coating

A dry finishing process where electrostatically charged powder is sprayed onto a part and then cured to form a durable coating.

Specify RAL color and gloss for powder.|Cure at 190°C for 12 minutes.|Mask threaded holes before powder.

Press Brake

A machine tool that bends sheet or plate using a punch and die, with methods like air bending, bottoming, and coining.

Program the press brake with angle compensation.|Use a gooseneck punch for clearance.|This bend needs 135 tons with a 16 mm V-die.

QMS (Quality Management System)

The framework of policies, procedures, and processes used to ensure quality requirements are met and continuously improved.

Update the QMS procedure for inspection sampling.|Corrective actions are tracked in the QMS.|Auditors will review our QMS documents.

RFQ (Request for Quotation)

A formal request to suppliers asking for pricing, lead time, and terms to manufacture specified parts or assemblies.

Send an RFQ with drawings and annual volumes.|Vendors responded to the RFQ by Friday.|We revised the RFQ after the design change.

Rockwell Hardness

An indentation hardness test reported on scales such as HRC or HRB, indicating resistance to penetration and correlating with strength.

Spec calls for HRC 40–45 after heat treat.|Use the HRB scale on thin sheet.|Verify hardness at three locations.

Shearing

Mechanical cutting of sheet or plate using opposing blades to separate material along a straight line.

Shear the blanks before punching.|The shear leaves a rollover and fracture zone.|Adjust blade clearance to reduce burr.

SPC (Statistical Process Control)

The application of statistical methods, including control charts, to monitor and control process variation in real time.

Track bend angle on an X-bar/R chart.|Cp and Cpk improved after the tool change.|That point is outside the control limits—stop and investigate.

Stainless Steel

A family of corrosion-resistant iron-based alloys with at least ~10.5% chromium (e.g., 304, 316), used for strength and corrosion resistance.

Use 304L for better weldability.|Separate stainless tools to avoid contamination.|Passivate after welding per the spec.

Surface Roughness (Ra)

A parameter that quantifies the average deviation of a surface profile from the mean line; commonly specified as Ra for functional or cosmetic requirements.

Finish to Ra 1.6 µm on the sealing face.|The mill finish exceeds the Ra requirement.|Post-process sanding to hit the Ra spec.

Takt Time

The rate at which a product must be completed to meet customer demand, calculated as available time divided by required quantity.

Takt time is 90 seconds per unit.|Rebalance the cell to meet takt.|Cycle time must be less than takt time.

TIG Welding (GTAW)

A welding process using a non-consumable tungsten electrode with shielding gas to produce precise, high-quality welds, especially on thin or reactive metals.

Back-purge the stainless tube while TIG welding.|Use a 1.6 mm 2% thoriated tungsten at 70 amps.|TIG gives a cleaner bead on thin gauge.

Tolerance Stack-Up

The cumulative effect of individual part tolerances in an assembly, which can impact fit, function, and manufacturability.

The hole pattern stack-up leaves only 0.2 mm clearance.|Use a datum scheme to control the stack.|We ran a worst-case stack-up analysis.

Tonnage

The force required for a forming operation, such as press brake bending or stamping; often used to size equipment and tooling.

Bend force calculation shows 85 tons required.|We’re at the press’s tonnage limit on this tool.|Reduce V-die width to lower tonnage.

Tooling

The collective term for specialized tools, dies, punches, fixtures, and accessories required to perform manufacturing processes.

We’ll amortize the tooling cost over 10,000 units.|Order a custom punch-and-die set.|Standardize tooling to reduce changeovers.

Waterjet Cutting

A cold cutting process that uses a high-pressure water stream (often with abrasive) to cut materials without thermal distortion or HAZ.

Waterjet avoids a heat-affected zone.|Add taper compensation on thick plate.|Kerf is about 1 mm with 80-mesh abrasive.

Weldment

An assembly of components joined by welding and treated as a single part for fabrication, inspection, and documentation.

Ship this frame as a weldment for machining.|The weldment drawing lists subcomponents and WPS.|Control distortion on the weldment with fixturing.

WPS (Welding Procedure Specification)

A qualified document that defines essential welding variables—process, materials, parameters, positions—to ensure consistent, compliant weld quality.

Follow WPS W-13 for this fillet weld.|Welders must be qualified to the WPS.|The PQR supports this WPS for 6 mm to 12 mm thickness.