Try to imagine life without sheet metal. Today’s plastics draw more attention, but unheralded sheet metal is everywhere. Just look around. Your car, the toaster, your travel mug, the washing machine — all sheathed in or formed from sturdy, versatile sheet metal.

Sheet metal has been around for about 6,000 years, dating to times when artisans used rocks to pound metals into body armor and jewelry. As humans developed more efficient ways to form metals, processes evolved into what we know as the modern automated assembly line.

Types of sheet metal

Sheet metal is the most common type of metal used in manufacturing. It is thinner than plate metal but thicker than foils. Aluminum and steel are the most widely used varieties, but copper, brass, tin, nickel and titanium are popular as well.  Silver gold and platinum sheets are used for decorative applications.

Measuring

Gauges are used to determine the thickness of sheet metals. The U.S. Standard Gauge for Sheet and Plate Iron and Steel is one system. Gauge numbers are inverse to the thickness of the sheet; the lower the gauge, the thicker the metal. The U.S. Standard ranges from 0000000 (0.50” thick) to 40 (0.0055”). Because thickness is a critical factor in selecting the workpiece, metal shops will have both a ferrous and nonferrous sheet metal gauge on hand to help with this decision.

Uses

Sheet metal is the primary material for HVAC ductwork, paneling and screens. It forms the housing for appliances of every kind, safety cabinets, airplane fuselages, automobile bodies and trailers. You’ll also find sheet metal used architecturally in siding and roofing, facades and entryways, or as molding or sculptures.

Cutting sheet metal

Metalsmiths have multiple options for cutting sheet metal, ranging from simple hand shears to power tools. Selection depends largely on the application, needed throughput and user preference.

Manual solutions:

• Aviation snips — Simple handheld scissor-like cutters for short lengths and trimming. Great for soft sheets of tin, aluminum, brass and 24-ga or thinner stainless steel.
• Hacksaw — Limited in direction (straight, mostly) and depth, but effective in a pinch.
• Bench shears — Old-fashioned but effective for straight lengths; arm-action, bench-mounted device.
• Beverly cutter — Similar to the throatless shear, but allows for cutting curves.
• Steel Metal Machine — All-in-one tool shears, brakes and rolls sheet metal up to 20 ga.

Powered solutions:

• Electric angle grinder with cut-off wheel — Better for straight cuts. High sparking.
• Jigsaw with metal blade — Quick cutter allows curved and unusual shapes. Not recommended for aluminum.
• Band saw — A slower option, more difficult to deviate from a straight line. Use a carbide-tipped or steel blade.
• Air nibbler — Air-powered tool cuts virtually any shape; almost as easy as drawing with a pen.
• Pneumatic or electric shears — For straights and gentle curves.
• Plasma cutter — A more expensive shop solution, but unlimited cutting directions.
• Laser cutter — High-end, for high-throughput work. Cuts all types of sheet metals (depending on model).

Sheet metal cutting is a function of the material, application and output rate. Consult your Blackhawk sales or customer service representative for advice in choosing the best cutting tool for your job.

WARNING: Always wear safety glasses and gloves when cutting metal.

For any questions about products sold by BlackHawk, give us a call. We’re happy to help. Our mission is to provide innovative, value-added services and products that reduce our customer’s total cost. Feel free to contact us for more information.

BlackHawk Industrial

1501 SW Expressway Drive

Broken Arrow, Oklahoma 74012

[email protected]

Toll Free: 855-610-1001