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Laser Engraving vs CNC Engraving: How Should You Mark Your Metal Parts?

Laser Engraving vs CNC Engraving: How Should You Mark Your Metal Parts?

June 18, 2022

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Laser Engraving vs CNC Engraving: How Should You Mark Your Metal Parts?

Laser Engraving vs CNC Engraving

After they’re machined and cleaned, many parts are engraved or marked. Engraving is commonly used to identify the metal alloy of the part, track part lot numbers, or add specific part numbers.

For example, a stainless steel component might be engraved with:

SS303
#002

That would indicate to people that the part is made of 303 stainless steel, and is the second lot of parts. 

Anything can be engraved on metal parts, but it is a secondary process that happens after machining, so it adds to the manufacturing time and costs. You only want to engrave information that’s necessary.

The two most common ways to engrave metal parts are laser engraving, and CNC engraving. The same general principles apply, but they are two different machines, and mark the parts differently. In some cases, laser engraving is better, and other times CNC engraving is best.

We’ll explain how each process works, and what its recommended use cases are.

Quick comparison

The biggest difference between laser engraving and CNC engraving is the actual engraving process. They both achieve similar results. 

A laser engraver uses a high-power laser to heat and vaporize a tiny amount of material off the surface of a part. Because there’s no contact, the part generally doesn’t need to be fixed.

A CNC engraver uses a sharp cutting tool that touches the surface of the part to remove material. This process usually engraves a single part at a time, and the part is secured in a vice.

CNC Engraver | Laser Engraver

How does laser engraving work?

The first laser engraving machine was purchased over 40 years ago, in 1978. Since then, the technology has improved drastically, and laser engravers are more accessible. Laser engravers use heat to burn and permanently mark a surface. 

They can be used to create artwork on a piece of wood, glass, or metal. The machine works similarly to a CNC machine. You use a computer program to upload the image and text you want engraved, hit go, and the laser moves around, etching your design onto the surface.

Different settings can be adjusted depending on the material you’re engraving and increase or decrease the intensity of the laser marking. If you want a more prominent marking, the speed can be slowed down, so the laser burns the material for longer.

Setting up the laser engraver can take some time, and you might need to make adjustments if the marking isn’t clear enough. It can also be challenging to mark a curved or uneven surface. But, once you get the right settings right, laser engraving is a quick process. And a tray of 100+ parts can be set in the engraver to be marked simultaneously. 

Laser engraving is used for simple part numbers, and more complex engravings like a barcode or QR code.

How does CNC engraving work?

A CNC engraver setup is more like a drill press. There is a sharp, pointy cutting tool that’s dragged across the part surface to mark the surface of the part. The engraver is connected to a computer program where the marking details are entered. 

Generally, this engraving process is used specifically for hard metal parts.

The parts are held in a vice attached to the engraving table while the cutting tool moves around to mark the part or lot numbers. Unlike a laser engraver, a CNC engraver usually works on one part at a time. The engraving takes a few seconds, and then the cutting tool resets and is ready for the next part. Because the parts need to be switched out one by one, this engraving requires more human attention.

CNC engraving is commonly used in the automotive, aerospace, healthcare, and oil and gas industries. It’s used to add simple numbers to parts, and not ideal for more complex engravings.

Pros and cons of each method

These part marking processes are similar, but they both have specific pros and cons. 

Pros and cons of laser engraving

  • Laser engraving can be used on a wider variety of materials.
  • The parts being engraved don’t need to be held in a vice.
  • Laser engraving can be faster than CNC engraving, especially for large quantities of parts.
  • Laser engraving makes a clear and crisp finish even for intricate and small markings.
  • Laser engraving can wear off softer metals over time.

Pros and cons of CNC engraving

  • CNC engraving can provide a deeper, longer-lasting engraving.
  • CNC engraving provides comparatively greater material flexibility.
  • CNC engravers can offer a simpler and faster set up. 
  • CNC engravers require the parts to be more secured during the engraving.

Engraving parts is a common secondary process. Both laser engraving and CNC engraving are great ways to add important numbers and markings to your parts. Reach out to our team to learn more about our secondary manufacturing operations.

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What is a Metal Alloy?

What is a Metal Alloy?

June 11, 2022

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What is a Metal Alloy?

What is a Metal Alloy

You’ve likely heard of the term alloy, but what exactly does that mean? Metal alloys are used everywhere. From the tiny screws that hold eyeglasses together, to the frame of a skyscraper. Parts of the phone or computer you’re reading this on are metal alloys.

Most of the metal parts and structures you see are metal alloys.

In simple terms, a metal alloy is a specific mixture of metallic and nonmetallic elements. The elements used to make the alloy are melted down into a liquid, mixed together, and then cooled to resolidify. This process is sometimes called alloyization.

Why are metal alloys used?

You’re probably familiar with most of the metallic elements in the periodic table. Metals like aluminum, iron, copper, gold, and titanium are naturally occurring elements. You might be surprised to learn that the majority of the elements are classified as metals.

Metal, Metalloid, & Non-Metal Elements

Not every element is naturally occurring, but for the ones that are, you can dig them up from the ground, and process them into metal bars or plates.

Alloys are used because in most cases, a pure, single metallic element isn’t ideal for parts or building structures.

Adding other metal or nonmetal elements improves specific properties of the alloy. The strength, durability, color, flexibility, machinability, and corrosion resistance can all be significantly improved.

For example, adding a small amount of lead or sulfur to alloys improves the machinability of metals. And adding carbon increases hardness, but decreases machinability.

Because the percentages of the elements used in alloys can be easily adjustable, there are 100s of different alloys–each having specific pros and cons.

What are the most common metal alloys?

Metal alloys usually have a base metal that makes up the majority of the composition. In addition to the base element, there are common additions. You’ll see numbers that are used to identify the different alloys, like 303 stainless steel, or 2011 aluminum.

Here are a few of the common metal alloys used in precision machining.

Stainless steel alloys

Stainless steel is one of the most commonly used alloys. Stainless steel alloys have an iron base, usually around 25-35%. Another 20-30% of chromium and nickel are added to the iron to improve corrosion resistance and prevent the metal from rusting.

The remainder of stainless steel alloys are made up of 7-10 other elements. Stainless steel alloys can contain smaller amounts of sulfur, silicon, copper, carbon, nitrogen, and manganese. These elements can make the alloy harder or softer, improve machinability, and increase the corrosion resistance.

Steel alloys

Steel is another commonly used metal alloy that’s incredibly diverse. Steel alloys are made with 95-99% iron. Surprisingly, pure iron isn’t useful for parts or building materials because it’s soft and brittle. It’s easily bent and malleable, until other elements are added to create a steel alloy.

Adding a small amount of carbon to the iron makes it hard, and usable for durable parts and building materials. But, adding too much carbon makes the alloy more difficult to machine. To improve machinability, elements like sulfur and lead are added.

Aluminum alloys

Pure aluminum is a great material, but it lacks strength and durability needed to make usable parts. To increase the tensile strength, zinc and manganese are added to aluminum alloys. Chromium can also be added to increase the corrosion resistance of the aluminum parts. 

Most aluminum alloys are 85-95% aluminum. This keeps the benefits that aluminum offers–mainly the excellent strength-to-weight ratio.

Copper alloys

Copper is one of the best conductors of electricity and heat. So, pure copper (99%+) is used for electrical wiring. But, copper is soft and flexible, so copper alloys are used for parts that need more strength and durability.

Copper has a wide variety of alloys that include different copper alloys, brass, and bronze. Free machining copper is 97-99% copper, and small amounts of lead, beryllium, cobalt, and/or tellurium.

Brass alloys are a combination of copper, zinc, and lead. The zinc adds hardness and durability to the parts. 

Bronze alloys are a mixture of copper and tin. Bronze is even harder than brass alloys, so it’s used when more durability is needed.

Learn about the difference between copper, brass, and bronze.

Nickel alloys

Nickel is a metal that’s added in smaller amounts to stainless steel alloys. Nickel offers some of the best corrosion resistance. It’s also more expensive than most other metals. Nickel based alloys are often considered super alloys, because of the high corrosion resistance and strength.

Monel is a nickel-copper alloy that contains around 65% nickel and 30% copper. 

Inconel is a nickel-chromium alloy that’s roughly 70% nickel, 15% chromium, and 8% iron.

Hastelloy is a nickel-chromium-molybdenum alloy. It contains 55-60% nickel, 15% chromium, and 15% molybdenum.

Those are some of the most common metal alloys used for precision machined parts. But, the properties of the alloy can be changed by adding 0.2% of a certain element. This makes the combinations and applications of different alloys limitless.

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What is the Difference Between Copper, Brass, and Bronze Parts

What is the Difference Between Copper, Brass, and Bronze Parts

June 7, 2022

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What is the Difference Between Copper, Brass, and Bronze Parts?

What is the Difference Between Copper, Brass, and Bronze Parts

Copper, brass, and bronze are three different metals used for a wide variety of parts and applications. These three have a lot of similarities, so it can be difficult to tell the difference, and understand which one is better for your project.

To start, brass and bronze are alloys that include copper. So it makes sense why you might think the metals are essentially the same thing. Copper is an element, but pure copper isn’t typically used to make copper parts. 

That means, in most cases, copper, brass, and bronze parts are all slightly different mixtures of pure copper and a few other metals like tin, lead, and zinc.

Keep reading to better understand the differences between the three materials and choose what’s best for your parts and components.

The most important differences

You probably know that pure metals are rarely used for anything. Different elements are mixed together to form a metal alloy. This is done with high precision to enhance certain properties of the metal parts.

For example, a tiny amount of lead can be added to a copper alloy to improve the machinability of the metal. The differences between copper, brass, and bronze are because of the different elements added to the alloys.

Copper

As mentioned, copper is a pure metal. Pure copper (99.95% copper) is used for wiring, or applications where conductivity is a high priority. Even a slight drop in the purity can have a significant impact on the electrical conductivity. 

Pure copper is a softer, malleable metal, so it’s great for wiring and sheet metal, but not as good for parts that need more durability. Copper alloys usually have a small amount of beryllium, tellurium, or lead to improve machinability and durability.

Copper can be used in a CNC mill, CNC turning machine, or a Swiss screw machine to manufacture parts. Because it’s a softer metal, it has a lower machining cost. 

Copper is used for: 

  • Fittings
  • Bolts
  • Electrical contacts
  • Bushings
  • Bearings
  • Fasteners
  • Pump and valve components

Brass

Brass is one of the easiest metals to machine. Machined brass parts are durable, cost-efficient, and create a tight seal for fittings. Brass parts also have great heat and corrosion resistance. 

Brass alloys are a mixture of about 65% copper and 35% zinc. Other trace elements like lead, zinc, and iron are added to improve certain characteristics. 

Because of the added zinc, brass parts are significantly stronger than copper. Brass is also less expensive compared to copper. Brass parts don’t have the same conductivity as copper, so they’re less common in electronics, or systems where conducting heat is needed. 

Brass parts are commonly used in applications in the engineering, plumbing, and steam industries because brass fittings offer a low friction coefficient and high corrosion resistance. Because brass is a harder metal, it’s more subject to cracking compared to copper.

Brass is used for: 

  • Fittings
  • Gears
  • Bearings
  • Valves

Bronze

Bronze is a copper-based alloy that consists of varying amounts of copper and tin. Trace amounts of other metals, like aluminum, manganese, phosphorus, and silicon, are also found in bronze alloys.

The primary difference is the strength of the alloy. Bronze is stronger and more durable than copper and brass. Bronze can withstand more weight, and has a higher yield and tensile strength. Higher strength means that bronze parts are used in applications where parts are more subject to denting or wearing down. Like copper and brass, bronze is also a “no-spark” metal. And because it’s stronger, bronze is used for hammers, mallets, and wrenches that won’t spark when they’re struck against another metal.

Bronze is used for: 

  • Automotive fittings
  • Bearings and bushings
  • Cylinders
  • Gears and sprockets
  • Impellers
  • Plates
  • Pump and valve components
  • Washers

How can you tell the difference?

The easiest way to spot the difference between copper, brass, and bronze parts is the color. But, depending on the alloy and secondary operations, the metals can look similar. 

Most copper alloys have a reddish-brown color. Brass has a brighter yellow-gold appearance. And bronze is usually a duller gold or sepia color.

Choose the right metal for your project

Choosing the right metal for your part is critical. And with three different options that can look very similar, you need to know what to pay attention to. Here’s what you should keep in mind when deciding between these materials.

Copper has the highest flexibility and conductivity. That makes it better for parts that need to flex under pressure without cracking. And copper is best for parts that need to conduct heat or electricity. 

Brass is often considered the most suitable for general applications. It’s malleable, easy to cast, relatively inexpensive, and low-friction.

Bronze is the hardest metal alloy, and best suited for saltwater and sea environments. Parts used in marine environments need to have high corrosion resistance. Higher durability and hardness also make it better for high stress marine applications.

Spex is an ISO 9001:2015 certified precision machine shop in Rochester, NY. We machine thousands of unique metal and polycarbonate parts every month for different industries around the world. Reach out to our team to see if we can help with your next project. 

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Surface Roughness Guide For Precision Machined Parts

Surface Roughness Guide For Precision Machined Parts

June 4, 2022

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Surface Roughness Guide For Precision Machined Parts

Surface Roughness Guide For Precision Machined Parts

Any time metal parts are machines, there is a level of roughness on the part surface. The level of roughness varies depending on the manufacturing process used, part design, material, and secondary operations.

Your first thought might be that the part surface finishing isn’t all that important.

That’s not the case at all. The surface finish impacts the part’s corrosion resistance, friction and durability, adhesion of coatings and paints, and the visual appeal.

A smooth finish has benefits like less friction, and less chance of surface irregularities. On the other hand, a slightly rougher finish makes it easier to apply paint or coating to the part. 

The surface finish or roughness of a part is measured in Micrometers, which are 1/25400 inches. These very small differences in roughness can have a significant impact on your parts, so it’s important to understand.

How is surface roughness measured?

Because the differences in surface finish can be so small, it’s difficult to measure accurately. You might be able to feel the difference between a smooth and rough finish, but there’s a lot in between.

It’s similar to the different sandpaper grits. You can easily tell the difference between 30 grit sandpaper and 2,000 grit. But the difference between 80 grit and 120 grit is impossible to know by looking at it or feeling it. 

The surface finish of a part is usually measured by the roughness, waviness, and lay of the surface.

There are different tools and processes that help get an accurate measurement.

The first tool is called a CNC probe. This is a tool installed inside the CNC machine. The probe helps align the raw material, cutting tools, and can also measure the surface roughness. This eliminates the need to measure the surface roughness after the part is machined.

Another tool used is a handheld surface roughness tester. This has a sensor that measures the surface roughness. The device isn’t the most accurate measuring method, but it’s easy to use anywhere. 

There are other ways to measure roughness by using light or sound. The light is shone on the part, and the reflection is used to measure peaks and valleys on the surface.

Why is surface roughness important?

The surface of the part is just as important as the material that’s used for the part. Just like you need to understand the differences between aluminum, stainless steel, or copper, you also need to understand the various surface finishes. 

The surface finish of the part impacts the effectiveness of the part and how it works with the other components it touches.

Here are a few reasons why the right surface finish is essential:

  1. The surface roughness impacts corrosion resistance. A rougher finish offers less corrosion resistance because there is more surface area that the chemicals or corrosive material touches.
  2. The adhesion of paint changes. If you need to apply paint or primer to the part, it will stick better to a rougher surface. 
  3. The wear resistance is affected. A smooth surface reduces friction and helps moving parts last longer.
  4. The surface roughness changes the conductivity of the parts. A smooth surface offers significantly better conductivity. This study (https://homepages.rpi.edu/~galld/publications/PDF-files/Gall-66.pdf) compared a perfectly flat surface to a rough surface. It found that adding one atom on top of the flat surface to simulate roughness decreased conductivity by 33%.
  5. The surface finish impacts the chances of surface defects. A rougher surface increases the chances of surface defects developing. When a part surface is rougher, there are more tiny indents on the part. Over time, these can become more prominent.

How the manufacturing process impacts surface finish

There are many different ways to manufacture parts. Each manufacturing process is designed to produce a usable surface finish. Each process has an expected surface finish tolerance. For example, broaching offers an expected surface roughness of 0.8-3.2μm. In some cases, a secondary process like grinding or polishing is needed to reduce surface roughness.

In metal forming, when a metal is poured into a die or mold, the surface of the die determines the surface of the part. 

When the metal is cut, like in a CNC machine or lathe, the surface finish is determined by the hardness of the metal, the cutting speed, and the cutting tools. A harder metal needs to be cut with sharper tooling, and that needs to be changed out more often.

Usually a smoother surface finish means higher manufacturing costs. But, in cases where a smooth finish is a priority, it means the part will last longer because of reduced friction.

Here are some of the expected surface roughness levels for different manufacturing processes:

Manufacturing Process Surface Finish
Manufacturing Process Surface Finishes

Surface Roughness Chart

You might be wondering what surface finish you need for your part. Each project is unique, but this chart can help you decide. 

Micrometers Rating (μm) Microinches Rating (μin) Applications
25
1,000
This is a low-grade surface from saw cutting or rough forging that shouldn't be used for parts touching other moving componenets.
12.5
500
These surfaces are still considered to have a high level of roughness, resulting from heavy cuts and coarse feeds. These cuts tend to be the result of industrial processes like disc grinding, turning, and milling.
6.3
250
This is a surface finish that occurs from drilling, milling, and disc grinds. This roughness should be used for clearance surfaces that have special design or stress requirements.
3.2
125
The is usually the roughest surface recommended for precision parts. It's also used for parts subject to vibrations, heavy loads, and high stress.
1.6
63
This is a good machine finish when production is done under controlled conditions. It also involves fine feeds and relatively high cutting speeds.
0.8
32
This is a high-grade machine finish, which requires close control. It's relatively easy to achieve with a cylindrical or surface grinder. It's used for products that don't require continuous motion or heavy loads.
0.4
16
This is a high-quality surface produced using buffing, lapping, or coarse honing. This finish is a great option when smoothness is more important.
0.2
8
This is a fine, high-quality surface finish produced by lapping, buffing, or honing. Machinists use this when components need to slide across the part surface grain.
0.1
4
A refined surface that manufacturers use only if there are mandatory design requirements. This is the best finish in gauge and instrument parts.
0.025-0.05
1-2
This is the most refined surface finish produced with the finest buffing, honing, or superfinishing. This is best used for sensitive precision gauge blocks.

Spex is an ISO 9001:2015 certified precision machine shop in Rochester, NY. We machine thousands of unique metal and polycarbonate parts every month for different industries around the world. Reach out to our team to see if we can help with your next project. 

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Types of Rivets: Learn About Different Rivets and Their Common Uses

Types of Rivets: Learn About Different Rivets and Their Common Uses

May 30, 2022

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Types of Rivets: Learn About Different Rivets and Their Common Uses

types of rivets

Rivets are a common type of fastener used to hold two or more parts together. Rivets are designed to be a more permanent faster, and out of all the different fasteners, rivets are most similar to nails. 

Rivets are used in many different mechanical operations, and have been for a long time. The concept is very simple, and in fact, the first rivets were used around 3,000 BC. Rivets were used to hold ancient tools together, like the head and handle of a hammer, and to attach a carrying handle to a jar.

The rivets used today are more precise and durable, but they have the same general design and purpose. Rivets can be used for lightweight purposes, and heavy duty machines like tanks or aircraft. 

How does a rivet work?

A rivet is similar to a nail, but they’re not exactly the same. Rivets usually don’t have threading, and they have a flat or rounded head. Unlike nails, rivets usually don’t have a sharp pointed end. Rivets also have a larger body, similar to a bolt.

When rivets are being used, a hole is drilled into the materials that the rivet is holding together. The hole drilled is slightly larger than the rivet. Then, the rivet is inserted, and the back end of the rivet is smashed or deformed so it’s larger than the hole drilled. This creates a tight connection between the two materials. And the rivet would need to break before the materials separate. 

Smaller rivets are installed with a handheld tool called a riveter or rivet gun. Larger industrial rivets, like the ones used for bridge construction work the same way. But, those need to be heated up before the end is smashed so it can be deformed.

How rivets work

What are the different types of rivets?

Rivets are a basic type of fastener, but there are some different types designed for specific uses. 

Solid rivets

Solid rivets are just what they sound like. They have a solid round body and either a flat or rounded head.

The rivet is inserted into the hole and the end is smashed with a hammer, or other squeezing tool. Depending on the size of the rivet, a lot of force can be required to deform the end so it stays in place. 

Solid rivets are the most secure and can bear the most weight and are the most reliable. They’re used for load bearing applications like building frames and bridges, Solid rivets are also used in aircraft, cranes, and other vehicles.

Tubular rivets

Again, tubular or hollow rivets are exactly what they sound like. They look the same as solid rivets, but the body is a partially or fully hollow tube. With these rivets, the tail end isn’t solid, which makes it much easier to deform. These rivets require about 25% of the force to secure compared to solid rivets. 

Countersunk rivets

Countersunk rivets or flat rivets are designed to not stick out once they’re installed. There’s a small hole for the rivet, and a slightly larger hole made for the head of the rivet. These are used to improve dynamics on vehicles, and on sliding tracks where something needs to slide over the rivet without hitting it. 

Split rivets

Split rivets have a split end. Usually there are two small legs on the end of the rivet that are spread apart to secure the rivet. These are commonly used with softer materials like drywall, leather, wood, or plastic. 

Blind rivets

Blind rivets are unique because they can be installed without accessing the other side of the rivet. These rivets are technically two different parts. The rivet has a pin that pulls out when it’s installed. The pin is pulled out and squishes the end of the rivet to secure it. Blind rivets are used in aircrafts, watercraft, and electronics. 

How are rivets manufactured?

There are two primary ways that rivets are manufactured.

Thinner rivers are made by cold forming. A round wire is fed into a machine and cut to the desired length. Then the piece of wire is punched into a dyes, or cutouts, to form the shape of the rivet. It takes a few different dyes to fully form the rivet body and head. But, this process all happens very quickly. Hundreds of rivets are made every minute, and they’re fairly accurate. 

Rivets can also be made using Swiss screw machines. This process is used for solid rivets, when stronger materials are needed, and when more precision is needed. Since rivets have a simple design, Swiss screw machines are still efficient and keep manufacturing costs low.

What materials are rivets made with?

Rivets are made with a wide variety of metals. The harder metals offer greater strength, but they also require more force to install the rivet. Softer metals like copper or brass can’t handle as much stress, but they’re easier to install. 

Rivets are commonly made with

  • Stainless steel
  • Steel
  • Aluminum
  • Copper
  • Brass

Spex is a precision machine shop located in Rochester, New York. We manufacture a wide range of precision parts and fasteners including rivets. If you need rivets, or other precision parts, fill out the form to connect with our team.

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Titanium vs Stainless Steel: Which Metal is Right for Your Project

Titanium vs Stainless Steel: Which Metal is Right for Your Project

May 21, 2022

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Titanium vs Stainless Steel: Which Metal is Right for Your Project

Titanium vs Stainless Steel

Titanium and stainless steel are metals known for their high strength and corrosion resistance. They also tend to be more expensive raw materials, and more expensive to machine. 

Both materials are used for a wide variety of parts and building materials. There are also a variety of alloys for each material. Figuring out which one is the best option for your next project can be challenging. 

In this article, we’ll share a few of the key differences that will help you and your team choose the best material for your machined parts and components. 

What are the key differences?

The primary differences between titanium and stainless steel come from the fact that titanium is an element and stainless steel is an alloy. The properties of titanium are naturally found in the metal. While stainless steel is a mixture of iron, chromium, nickel, and other elements. 

This difference means that the properties of stainless steel can be altered more than titanium, making it more versatile for different uses than titanium.

  • Titanium is more expensive than stainless steel.
  • Titanium is stronger when temperatures fluctuate. 
  • Titanium is nontoxic and often used for medical purposes.
  • Titanium is softer, and it’s generally more prone to scratches. 
  • Stainless steel is heavier than titanium.
  • Stainless steel is less expensive to machine.
  • Stainless steel is more formable and weldable.
  • Stainless steel is more subject to fatigue and shattering.

Machining and using titanium

Using titanium for precision machined parts can be difficult. Titanium has a machining cost factor 30x greater compared to steel. 

Even though titanium is expensive as a raw material, and expensive to machine, it has a lot of great benefits. Titanium has a similar strength compared to stainless steel, and it’s significantly lighter. Titanium is about 50% as dense as stainless steel, and it provides the same amount of strength as stainless steel at 40% of its weight.

Titanium parts are often used in the aerospace industry where weight reduction is a priority. They’re also used for medical parts because titanium is biocompatible.

Machining and using stainless steel

Stainless steel is one of the most commonly used metals in every industry. Stainless steel offers great strength and corrosion resistance. To be considered stainless steel, the alloy mixture needs to have at least 10.5% Chromium, which gives the metal better corrosion resistance.

There are a wide variety of stainless steel alloys, which have unique properties and are used for different purposes. The alloys are classified into numbered families. The 300 grades of stainless steel are the most commonly used for precision machined parts.

Which metal is right for your project?

Both materials are viable options for projects that require high strength and lasting durability.

Titanium is a better choice when reducing the weight of the part is important, and in use cases where there are more extreme temperature changes. 

Stainless steel is better when keeping costs lower is a higher priority. The different stainless steel alloys also make this metal suitable for different applications, like parts that need to be welded.

Spex is an ISO 9001:2015 certified precision machine shop in Rochester, NY. We machine thousands of unique metal and polycarbonate parts every month for different industries around the world. Reach out to our team to see if we can help with your next project. 

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Anodizing vs Powder Coating: Choose the Best Aluminum Finish

Anodizing vs Powder Coating: Choose the Best Aluminum Finish

May 19, 2022

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Anodizing vs Powder Coating: Choose the Best Aluminum Finish

Anodizing vs Powder Coating

Aluminum is one of the most commonly used metals for precision parts. Aluminum is lightweight, strong, and easy to machine. 

Oftentimes, manufacturers use a secondary process like anodizing or add a powder coating to increase the durability of the aluminum parts. These processes also add visual appeal to the parts.

These two processes have their own pros and cons, and use cases. This post will help you decide which finish is best for your aluminum parts.

What is anodizing?

Naturally, aluminum doesn’t rust, but it does corrode over time. Over time, a thin layer of oxidation forms on the outside of aluminum. This layer provides some protection from corrosion.

Anodizing is a chemical process that increases the layer of oxidation. The parts are placed in an electrolytic solution like sulfuric acid, and an electrical current is passed through the part. The increased oxidation layer increases the resistance to wear and corrosion, increases heat dissipation, and improves glue and primer adhesion.

Anodized aluminum usually has a matte finish. Natural dyes can also be added during the anodizing process, so different colors can be added to the parts. When the parts are colored, they have a more metallic finish. The color is also added under the surface of the part, so it can’t be scratched off.

What is powder coating?

Powder coating is a dry paint process done to add a decorative and durable coating to parts. After the parts are machined, they’re sprayed with a powder that attaches to the metal. Then the parts are heated or baked in an oven to cure the powder coating.

Powder coating offers a strong layer of protection, and the amount can be adjusted to add more or less. Powder coating is a very environmentally friendly form of finishing.

You can also adjust the look and color of powder coating, making it more or less glossy, and more or less textured.

Anodizing vs. Powder Coating

Both of these finishing options provide great physical and visual benefits. They do have some key differences that make them better for specific uses. Usually a part can’t be anodized and powder coated, so it’s best to choose one or the other. 

In some cases, anodized parts can be painted, but it’s not ideal.

Anodized Powder Coating
The anodized layer can be very thin, and only slightly change the part dimensions.
It’s very difficult to obtain a thin layer of powder coating.
Offers a variety of metallic colors and smooth finishes.
Offers a wide variety of colors and various textures.
With proper recycling processes, anodizing is very environmentally friendly.
No solvents are used in the process, making it very environmentally friendly.
Anodizing provides excellent wear, scratch, and corrosion resistance.
Good corrosion resistance, but it is more subject to wear and scratches than anodizing.
Resistant to color fading as long as the dye is UV resistant and it’s sealed properly.
Very resistant to color fading, even when exposed to constant UV light.
Anodizing makes the aluminum non-conductive.
Has limited electrical conductivity compared to bare aluminum.
Anodizing can be more expensive.
Powder coating is more cost-effective.

Is anodizing or powder coating cheaper?

Powder coating parts is usually less expensive than anodizing. Both processes are cost-efficient, and the coating lasts a long time. There are many factors that impact the price of both services. The part shape and size, coating thickness, dyes, and quantity of parts are all important to consider. Because anodizing won’t scratch off like powder coating, the costs can even out over time. 

Most companies will charge a minimum for anodizing and powder coating parts.

Common uses for each finish

Because these finishes offer great protection, you’ll see them both used on most aluminum consumer goods. Aluminum is a great metal to use, but adding a finish increases the longevity of the parts.

Anodized Powder Coating
Automotive parts
Automotive parts
Aerospace parts
Appliances
Appliances
Lawn equipment
Electronics
Playgrounds
Sporting goods
Outdoor equipment and furniture
Furniture
Jewelry and artwork

Which aluminum finish should you choose?

Your choice of finish ultimately depends on how your part and product is going to be used. Anodizing and powder coating are both great finishing options for aluminum parts.

Anodizing is ideal if you need to maintain tight dimensionals. You’ll get excellent corrosion and wear resistance, and have an attractive metallic look without increasing the size of your part too much. Anodizing is also the better choice when your part needs to dissipate heat, or if you’ll be using any glue or primer on it.

Powder coating is the better option when you want vibrant colors and unique textures that will last. The coating will last even when exposed to the outside elements. Powder coating also offers good protection at a lower cost than anodizing.

Spex is an ISO 9001:2015 certified precision machine shop in Rochester, NY. We machine thousands of unique metal and polycarbonate parts every month for different industries around the world. Reach out to our team to see if we can help with your next project. 

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Different Types of Lock Nuts

Different Types of Lock Nuts

May 15, 2022

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Different Types of Lock Nuts

Different Types of Lock Nuts

Lock nuts are a special part that’s designed to hold parts and assemblies together. These parts are built to be used for long periods of time.

Spex machines different types of precision lock nuts for various industries and uses. Today we’ll share some info about how lock nuts are manufactured and used.

What are Lock Nuts?

A lock nut is a type of nut that’s designed to not loosen over time. There are different methods to keep the nut secure, including adhesive, pins, and features that increase friction. Some lock nuts are designed for single use, making them less effective or unusable after they’re removed.

In general, nuts are used for assemblies that need to be disassembled. That’s helpful when different parts need to be cleaned or to perform regular maintenance. Lock nuts are more difficult to assemble and disassemble, but they provide greater security and less risk of parts coming loose. 

Lock nuts are commonly used for assemblies where there are moving parts or vibration, which causes other nuts to loosen over time.

How do lock nuts work?

There are a few different ways that a lock nut stays secure. The three common ways are adhesive, friction, and pins.

Adhesive

The most common type of lock nut has some type of adhesive. This could be a type of glue, or a nylon ring that creates a tight seal on the bolt. 

Friction

Some lock nuts have specific features that increase the friction. Some have grooves on the bottom of the nut, which increases friction with the surface that the lock nut is touching. Other lock nuts have specific threading that increases the friction between the nut and bolt. Both of these designs make it more difficult for the nut to come loose.

Pins

Lock nuts that use pins have a hole or groove cut into them. Once the nut is tightened onto the bolt, a pin is inserted through a hole in the nut and bolt to prevent it from spinning off. A cotter pin can also be added on top of a lock nut with grooves cut in the top.

5 Different Types of Lock Nuts

5 Different Types of Lock Nuts

1. Nylon insert lock nuts

These lock nuts have a nylon ring or patch on the inside threading of the nut. When they’re threaded onto the bolt, the nylon creates a seal. These nuts are subject to high temperatures which could melt the nylon, and they require more torque to assemble. 

2. Hex jam nuts

Jam nuts are actually two nuts that are used on top of each other. The second nut is jammed on top of the first one, preventing it from spinning off the bolt. 

3. Center lock nut

A center lock nut has a hold drilled into the center of it. Once the nut is tightened, a punch is used to distort the threading on the bolt, which prevents the nut from loosening. 

4. Serrated Flange lock nut

The serrated lock nut has grooves on the back side of the nut. These nuts are usually used against sheet metal. The grooves on the back of the nut rub against the surface and prevent it from backing out.

5. Castellated nut

A castellated nut has grooves on the top, which look similar to the top of a castle. These lock nuts are used with a bolt that has a hole drilled in it. Then, a pin is inserted through the top of the nut and bolt to secure it in place.

What are lock nuts made of?

Because most lock nuts are used for heavy-duty and industrial applications where strength is a priority, most are made with stainless steel or mild steel. Stainless steel is the most common material because it’s strong and resistant to corrosion. Zinc and brass locking nuts are also fairly common. 

In cases that require less strength, nylon or plastic lock nuts are popular because they’re less expensive to manufacture and lightweight.

Spex is an ISO 9001:2015 certified precision machine shop in Rochester, NY. We machine thousands of unique metal and polycarbonate parts every month for different industries around the world. Reach out to our team to see if we can help with your next project. 

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Phone: (585) 467-0520

Email: sales@spex1.com

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Overview of 303 Stainless Steel for Precision Machining

Overview of 303 Stainless Steel for Precision Machining

May 10, 2022

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Overview of 303 Stainless Steel for Precision Machining

303 Stainless Steel for Precision Machining​

Stainless steel is one of the best and most commonly used materials for precision machined parts. There’s a seemingly endless variety of stainless steel alloys, which makes it difficult to choose the best one for your parts.

Spex uses 303 stainless steel to manufacture tons of different parts. 303 is a free machining alloy, meaning that its properties make it a great choice for precision machining.

We’ll provide you with an overview of the material and help you decide if it’s the right choice for your project.

What is 303 stainless steel?

303 stainless steel was developed specifically to increase machinability while maintaining the positive aspects of stainless steel. This alloy has the benefits of stainless steel: good strength and high resistance to corrosion. 

Stainless steel is a hard metal, so it’s more difficult and expensive to machine parts. 304 stainless steel is a general purpose alloy, and other elements are added to increase or decrease certain properties of the metal. To increase the machinability, sulfur is added to 303. 

To classify different alloys, there are families of stainless steel, and specific grades. 303, and other 300 grade stainless steels, are in the austenitic family. This is the most widely used family across the world.

The austenitic stainless steels are made with austenite base, which is a combination of carbon and a nonmagnetic form of iron.

Composition

Element Percentage
Iron (Fe)
29.5 - 33.5%
Chromium (Cr)
17 - 19%
Nickel (Ni)
8 - 10%
Manganese (Mn)
2%
Silicon (Si)
1%
Copper (Cu)
1%
Nitrogen (N)
0.10%
Carbon (C)
0.10%
Phosphorous (P)
0.045%
Sulfur (S)
0.015 - 0.35%

Common applications

As we mentioned, SS303 is very common–especially for machined parts. 303 stainless steel is used to machine:

  • Nuts
  • Bolts
  • Screws
  • Fasteners
  • Shafts
  • Aircraft fittings
  • Electrical components
  • Gears
  • Automotive parts
  • Aerospace components
  • Medical instruments and other parts.

Because of the added sulfur, this alloy loses some of its hardness and corrosion resistant properties. Parts aren’t designed for marine environments, and shouldn’t be used constantly at working temperatures above 1400°F.

303 also isn’t recommended for parts that need to be welded. This alloy also can’t be heat treated, but it can be cold worked to increase the hardness and tensile strength.

Machinability

Free machining alloys like SS303 are ideal for parts that require extensive machining. The metal produces better chips while it’s being cut. That means there aren’t long strings of metal coming off, and tight tolerances are easier to achieve. Because the metal is softer, the cutting tools last longer, making it less expensive to machine.

303 has a machining cost factor of 2.7 when compared to standard steel. The machining cost factor is about half of 304 and 316 stainless steel.

Corrosion resistance

303 has relatively good resistance to mild environments, but it’s significantly less than 304 stainless steel. When 303 is in a moist environment, it forms rust and is subject to rapid-pitting corrosion.

Also, most austenitic stainless steels will start cracking in chloride environments above 140°F.

Heat resistance

Stainless steel usually has good heat resistance. 303 grade doesn’t have the best heat resistance, but it can withstand mild heat fairly well. 303 has a higher carbon content so it’s also vulnerable to sensitisation, which is a negative effect of high and changing temperatures.

You can visit our material page to compare the different options for your next CNC machining project. If you have any other questions about choosing the right materials, reach out to our team.

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5 Advantages of Using Brass CNC Machined Parts

5 Advantages of Using Brass CNC Machined Parts

May 5, 2022

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5 Advantages of Using Brass CNC Machined Parts

5 Advantages of Using Brass CNC Machined Parts

Precision machined brass parts are very common in various industries. Brass is a soft metal, which makes it one of the easiest to machine. Brass also has great electrical conductivity, and doesn’t rust–which is why it’s commonly used for plumbing and electrical parts.

Spex uses brass to machine precision fittings, adapters, and connectors. No metal is perfect for every job, but brass is very useful and versatile. Here are 5 benefits to using brass for CNC machined parts.

1. Brass is easy to machine

The two common brass alloys used for machined parts are 353 and 360 Brass. Both of these alloys are about 62% copper, 35% zinc, 2-3% lead, and trace amounts of iron. 

360 brass has slightly more lead, which makes it the easiest to machine. Generally, machining brass costs about 60-70% of machining steel. 

Because it’s easier to machine, brass parts are less expensive to manufacture, and complex part designs can be machined quickly and efficiently.

2. Brass is resistant to corrosion

Iron is the element that causes most metals to rust and deteriorate. That’s why most metals and water don’t mix well. Because brass has very small amounts of iron, it isn’t susceptible to rust. In the right conditions, brass parts can be used for hundreds of years.

Brass tarnishes easily, so it can lose some of its luster, or shine, but that’s purely cosmetic and doesn’t affect performance or durability.

You’ll find lots of brass connectors and fittings used in plumbing fixtures. Even when there’s poor water pH conditions, the most corrosive water won’t deteriorate the brass. Machined brass parts also have a low friction coefficient, which means they don’t wear down quickly when they’re moving and rubbing against other materials.

3. Brass is highly conductive

Conductive metals like copper and brass are often used in electrical and plumbing systems. Brass isn’t as conductive as copper, but it’s still a great conductor of heat and electricity. 

Brass is also harder and more durable than copper, so it’s used in applications where there’s more friction and pressure.

Precision brass parts are used for transporting water, chemicals, flammable gasses, slurries, and other substances, and the high conductivity helps increase efficiency.

4. Brass can handle high temperatures

Another great benefit of brass is that it can handle very high working temperatures without losing functionality. 

This makes brass a great part material for hot water systems. The brass parts continue to provide an excellent watertight seal despite hot temperatures. This increases the efficiency of the system and prevents water leaks. 

Because brass parts can handle higher temperatures, they’re also useful in the manufacturing industry.

5. Brass is anti-bacterial

The copper that’s in brass makes the parts naturally anti-bacterial. Copper and brass are often used in water filtration systems and sanitation systems. 

The copper produces special ions that attack protein in single-celled organisms, killing them instantly in the process. This is very helpful when maintaining sanitation is a priority.

What are the disadvantages to using brass parts?

Brass isn’t perfect for every situation. There are a few disadvantages to using brass, and sometimes using a different metal is the better choice. It’s important to consider your specific needs.

Because brass is harder than copper, brass parts are more prone to cracking or splitting. Since copper is a softer alloy, it can be bent with a lower risk of cracking.

Brass parts are also subject to tarnishing. Tarnished brass loses its shine and starts to darken. As we mentioned earlier, this usually doesn’t impact the part function, but if aesthetic appeal is important, brass parts require some regular maintenance.

Overall, brass is one of the best metals to use for a variety of industrial, marine, and electrical applications. Spex offers customer precision machined brass components for a wide variety of industries.

Reach out to our team to learn more about our brass precision machining services.

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