How to Choose metal stamped ornaments?

Metal stamping is a manufacturing process that involves shaping flat metal sheets into specific forms through dies and punches. This process is widely used in the automotive, aerospace, electronics, and appliance industries.

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Properly selecting materials is crucial in metal stamping, as it directly affects the final product's quality, cost, and durability. Choosing the wrong material can result in product failure, production delays, and increased costs.

This article will discuss the types of materials commonly used in metal stamping, the factors to consider when choosing materials, how to choose the proper materials, and the common problems encountered with improper material selection. By the end of this article, you will better understand how to choose the right materials for your metal stamping project.

Types of Materials Used for Metal Stamping

Two main categories of materials are used in metal stamping: ferrous and non-ferrous. Ferrous materials contain iron, while non-ferrous materials do not. Below are some common materials used in metal stampings, including some specific applications, and beneficial qualities for each that could influence one’s choice.

Ferrous Materials

• Carbon Steel

  • This material is made of iron and carbon and is known for its strength and durability. It is also relatively inexpensive and can be easily formed into different shapes. Carbon steel is available in various grades, each with different carbon content levels and other alloying elements. Low-carbon steel is softer and more formable, while high-carbon steel is stronger and more difficult to form. Carbon steel can also be coated with zinc, nickel, or chrome for added corrosion resistance. Carbon steel is commonly used in the automotive industry, the construction industry household appliances, industrial equipment, and the agricultural industry.

• Stainless Steel

  • This material is a type of steel that contains chromium, which gives it its corrosion resistance. It is available in various grades, each with different corrosion resistance, strength, and machinability levels. Stainless steel is commonly used in applications where the final product is exposed to harsh environments, such as marine, food processing, or medical equipment.

• Galvanized Steel

  • This material is made of carbon steel coated with a zinc layer, which provides added protection against corrosion. The galvanizing process involves dipping the steel in a bath of molten zinc, which creates a bond between the zinc and the steel. Galvanized steel is commonly used in outdoor fencing, roofing, and gutters.

Non-Ferrous Materials

• Copper

  • This material is highly conductive and has excellent corrosion resistance. It is commonly used in electrical and plumbing applications, as well as in decorative applications, due to its attractive reddish-gold color. Copper is also a soft metal, which makes it easy to stamp and form into different shapes.

• Brass

  • This material combines copper and zinc and is known for its bright gold-like appearance. It is commonly used in decorative applications such as hardware, ornaments, and musical instruments. Brass is also a relatively soft metal, which makes it easy to stamp and form.

• Aluminum

  • This material is lightweight, strong, and has excellent corrosion resistance. As a result, it is commonly used in the aerospace and automotive industries and in consumer products such as appliances and electronics. Aluminum is available in various grades, each with different strength, corrosion resistance, and formability levels. It can also be coated for added protection against corrosion.

Factors to Consider When Choosing Materials for Metal Stamping

When selecting a material for metal stamping, it is important to consider the specific properties required for the final product. For example, durability, formability, thickness, hardness, and corrosion resistance should be considered. These qualities are explained in greater detail below.

• Durability
  • Durability refers to the material's ability to withstand wear and tear, fatigue, and other forms of stress. The level of durability required will depend on the intended application of the final product. For example, a product exposed to heavy use or harsh environments will require a more durable material.
• Formability
  • Formability refers to the material's ability to be formed into different shapes without cracking or breaking. The level of formability required will depend on the complexity of the part to be stamped and the type of stamping process to be used.
• Thickness
  • The thickness of the material will affect its strength, formability, and cost. Thicker materials are stronger but less formable, while thinner materials are more formable but less durable.
• Hardness
  • Hardness refers to the material's resistance to deformation, scratching, or abrasion. The hardness required will depend on the intended application of the final product. For example, a product subject to high levels of wear and tear will require a harder material.
• Corrosion Resistance
  • Corrosion resistance refers to the material's ability to resist degradation due to exposure to moisture, chemicals, or other corrosive substances. The level of corrosion resistance required will depend on the final product's intended application and the environment it will be exposed to.

When selecting a material for metal stamping, it is important to consider all of these factors and determine the optimal combination for the specific application. For example, a product used in a corrosive environment may require a material with high corrosion resistance but may sacrifice some formability or durability. On the other hand, a product that requires intricate stamping may require a more formable material but may sacrifice some durability or hardness.

Common Problems Encountered with Improper Material Selection

Improper material selection can lead to various problems impacting stamped parts' quality, performance, and production. Here are some common problems that can arise from using the wrong material for metal stamping:

• Wear and Tear
  • If the material is not strong enough to withstand the intended use, it may experience excessive wear and tear, leading to premature failure of the part.
• Tooling Damage
  • The stamping process can cause significant stress on the tooling, and if the material is too hard or too soft, it can cause damage to the tooling, leading to increased tooling costs and production delays.
• Surface Finish Issues
  • Some materials may be difficult to stamp or may result in a poor surface finish, which can affect the part's appearance, functionality, and overall quality.
• Production Delays
  • If the material is unsuitable for the stamping process, it can lead to production delays and increased costs due to rework, tooling adjustments, or even the scrapping of defective parts.

These problems can have significant consequences, including increased costs, decreased quality, and reduced customer satisfaction. Therefore, selecting the appropriate material for metal stamping is crucial to avoid these issues and ensure that the stamped parts meet the required specifications and performance standards.

How to Choose the Proper Materials for Metal Stamping

Choosing the proper material for metal stamping requires carefully evaluating several key factors. Here are the main steps to follow:

• Determine the End-Use Application
  • The first step is to determine the intended use of the final product. This will help identify the environmental conditions, load requirements, and other factors affecting the material's selection. For example, materials with high-temperature resistance may be required if the product is used in a high-temperature environment.
• Identify the Required Characteristics
  • Once the end-use application is established, the next step is identifying the required material characteristics. This includes strength, formability, corrosion resistance, and hardness. These characteristics will depend on the specific requirements of the end-use application.
• Consider the Cost
  • Cost is always a factor when choosing a material for metal stamping. For example, materials with high strength, formability, or corrosion resistance may be more expensive than those with lower performance characteristics. Therefore, balancing the cost with the required material characteristics is important to ensure the final product is effective and cost-effective.
• Evaluate the Fabrication Process
  • The final step is to evaluate the fabrication process used to stamp the material. Different stamping processes require different material characteristics, so it is important to consider the specific process used. For example, if the stamping process involves deep drawing or other complex forming operations, materials with high formability may be required.

When evaluating different material options, it is also important to consider the material supplier's reputation and track record. Materials from reputable suppliers are more likely to meet the required specifications and have consistent quality. It is also important to work closely with the material supplier and the stamping service provider to ensure that the chosen material is appropriate for the intended application and the specific stamping process.

In summary, choosing the appropriate material for metal stamping requires carefully evaluating several key factors. By following these steps, selecting a material that meets the required specifications, is cost-effective, and can be successfully stamped into the desired shape is possible.

Conclusion

In conclusion, proper material selection is essential for high-quality, cost-effective metal stamping. By considering the necessary factors and working with a trusted material supplier, selecting the appropriate material that meets the specific requirements and delivers reliable, high-quality stamped parts is possible.

Factors such as durability, formability, thickness, hardness, and corrosion resistance should be considered when choosing materials for metal stamping. In addition, the end-user application and the specific fabrication process must also be evaluated.

Partnering with a trusted material supplier is also essential for successful metal stamping. A reputable supplier can help ensure that the material meets the required specifications, has consistent quality, and can be successfully stamped into the desired shape.

For expert help choosing the best material for your project please call us at 262-677-5100. 

Corkie Bolton BEGINNERS
11 minute read

When it comes to ordering silver sheet and wire for jewelry making, as a beginner all the different options can often become overwhelming. When you are starting out creating jewelry you don’t want to break the bank buying a bunch of materials you may never utilize! You want to have the ability to be thoughtful about your design, considering which thickness of metal will be appropriate for executing your vision and also strong enough to hold up during daily wear.

In this comprehensive guide, I will provide visuals to help demystify the different options so that the next time you purchase materials for a project you can do so in confidence! Whether you're a seasoned artisan or a budding jeweler, understanding the nuances of the different options is crucial for bringing your designs to life.

WHAT METAL ARE WE USING?

Before we talk about anything we must discuss the different options for purchasing silver. The most common is sterling silver (.925) which has 7.5% copper giving the sterling durability and strength but increasing its susceptibility to firescale and tarnish. The other main option is fine silver (.999) It’s significantly softer than sterling, has a whiter appearance and is way less prone to tarnishing as it is almost entirely pure silver. Fine silver can be fused.

My perspective for beginners is that fine will generally be too soft for ring bands and structural parts of your jewelry designs, it can dent and bend. It can however be nice for a bezel wire.Then there is Argentium Silver which comes in two grades .940 and .960. It has increased tarnish resistance, a whiter color and a firestain-free surface. Argentium guarantees traceability of its raw silver, it is certified to be produced using only recycled silver. It can also be fused unlike sterling silver. Sounds amazing, but I confess I have very little personal experience with it, it wasn’t very popular when I came onto the jewelry making scene in 2005. There are some differences between working with Argentium and Sterling so if you choose this path be sure to read up on it!

Most jewelers especially beginners will likely learn with Sterling, it is the most affordable and the durability aspect is very important!

WHAT THE HECK IS A GAUGE ANYHOW?

When you go to buy a sheet of silver you are going to have to select a “gauge”. This is the common measurement used here in United States. Gauge is a standardized measurement, the lower the gauge number the thicker the metal is and that is where much of the confusion begins! It is also important to understand the corresponding measurements in millimeters which I will also provide.

WHICH GAUGE SHEET TO BUY?

Sheet metal is going to be one of your most commonly used forms of silver when making jewelry. Sheet is available for purchase from jewelry supply companies here in the United States from 8g (3.2mm) to 34g (0.2mm) so that is quite the range! In this article I’m going to focus on sterling silver (.925) when making my recommendations.

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To answer the above question I have to start with the annoying response “it depends”. Without knowing what you are designing I can’t provide an exact answer but I can explain a good place to start as a beginner and why.Generally speaking if your plan is to have sheet on hand to use as the baseplate of bezel settings and pendants or perhaps sheet for earrings…you cannot go wrong with purchasing 18g (1mm) it is thick enough to be stamped, light enough to construct earrings and strong enough to back a bezel without warping. While on the thinner side it could also be used to create a ring band making it a very versatile purchase. If it is within your budget I would also recommend some 20g (.81mm) and some 16g (1.2mm) having these slightly thinner and thicker options will give you more versatility as you continue on making jewelry. My preference with my jewelry business (corkieboltonjewelry.com) is to make jewelry that is on the thicker side, not heavy or chunky but just substantial.

WHAT DOES “DEAD SOFT” AND “HARD” MEAN?!?

On top of selecting the metal type (sterling or fine) and the gauge you will also have the options for different tempers. Temper refers to the hardness of the metal. The options are: dead soft (annealed), ¼ hard (a bit resistant to bending but readily takes shape) , ½ hard (has been worked a bit, tightening the grain at the molecular level. You can still bend the metal a bit, with force), and spring hard (thoroughly hardened and has basically no malleability.) If you will be soldering on the piece you’re making, you may as well start with dead soft because it’s easy to work with and any hardness the metal may have will be lost when you apply heat to solder. Here is an example of when to order a harder sheet: Let’s say all I’m doing is sawing out a design and cold connecting it, a harder option gives strength to my piece, and that strength will be maintained since I’m not soldering.

So with those options in mind, here are a few questions you can ask yourself when designing your project and selecting the sheet: Is the project I’m making going to get a lot of wear and tear (like a ring or a bracelet?) If the answer is yes, sterling is your best choice (since fine silver is softer). Next you need to choose a gauge heavy enough to experience the wear and tear but light enough to be comfortably. Heavy earrings for example can be uncomfortable and a while delicate ring can be cute it can also get squished. Maybe you are making a bunch of bezels and using simple backplates 20g (.81mm) would likely save you a little money but still be strong enough!

When it comes to ordering metal for jewelry making all the different options can often become overwhelming. There are so many varieties of sheet metals, wires and decorative metals. So I partnered with Rio Grande to provide a guide with some helpful tips and considerations for confidently buying materials for your next project!

PURCHASING ROUND WIRE

Wire is going to be your next most commonly used form of silver in jewelry making and thankfully it is not as much of an investment to purchase different gauges because you can buy a single foot of wire pretty inexpensively. Wire can be commonly found in even more gauges 0 (8.26mm) - 32 (.2mm). Wire is used in so many different ways you will want to consider once again: what kind of project am I making? Where on the body will it be worn? If we use the image of rings as an example we can see that the 10g (2.5mm) wire will provide us with more strength than the 14g (1.6mm). It is probably that a 14g ring like this in sterling silver would become mishappen in no time at all, but it could make a beautiful hoop earring! So choosing the gauge wire you will need for a project definitely depends on the amount of wear and tear (for example bangles and rings gets more wear and tear than earrings and pendants). 

For earring posts and French wires I have found that 20g (0.80mm) is good for most customers. The hardness of the wire you choose is once again all about application, if you are soldering the wire it becomes annealed, but if you are making an earring wire which will simply be formed and cold connected, you could in this case benefit from working with half-hard or hard since it will maintain that hardness and give the earring wire strength! You can also use hard wire for wrapping wire or creating rivets.

WHAT ABOUT HALF ROUND WIRE?

I wanted to include an image of half round wire as well because it is extremely popular, and if you order it based off of what you know about round wire you might end up with wire a bit thinner than you expected! Half-round has a flat side and a round sound making it a great option for ring bands and cuffs! The gauge is determined by the thickest part of the wire, but because it doesn't have this thickness throughout it is a daintier wire! So personally I would purchase 8g or thicker for a ring and I'd experiement with gauges 0-4 for cuffs! You want those to be sturdy!

PURCHASING BEZEL WIRE

One of the most common questions is: what gauge bezel wire should I purchase? It typically comes in gauges 24 (.51mm) - 30 (.25mm) and in various heights. First, let’s focus on gauge. If you are newer to bezel setting, consider 28g-30g because it’s easier to push over, especially if you’re doing it all by hand using a bezel rocker tool and a burnisher. You might even consider a fine silver bezel because it will push over more easily. If you’re hammer setting, either with a hammer hand piece or manually, you can use a thicker gauge bezel wire.

Next, consider the stone you plan to set and look up the stone’s hardness (MOH scale). If the stone is delicate you should set by hand (as opposed to hammer) and therefore can use a thinner gauge (28-30g). Softer stones can be set with thicker bezels but this takes some practice, when I was starting out I accidently hammered many an opal!

Regarding bezel height, take the shape and height of your cabochon into consideration. Order a few heights of bezel wire so you have options, if it’s too tall you can always trim it down or sand it. If you like to use a variety of cabochons in your work you’ll find having a variety of bezel wire on hand very helpful. In my book I dedicated an entire section to choosing the right bezel height and other bezel setting tips!

WHAT ABOUT DECORATIVE WIRES?

There are tons of gallery wires, decorative bezels and patterned wire options available  to purchase. With the knowledge you now how you can look at the listing and see how thick these items are, how tall they are if you are using them to set a stone. Whether they are a good choice for your design. Sometimes the heart wants what the heart wants, you are drawn to a wire and you buy it and figure out a design later and that’s okay!

Gallery wires should be annealed (carefully) prior to forming due to how they are produced they can be a bit brittle when you form them, same is true of some of the beaded wires! You want to form all of these gently and be careful not to mar your metal! I know melting is definitely an issue many beginners experience so when you work with decorative wires be gently with your heat. Directing your flame from below instead of putting the flame directly onto the decorative wire can help prevent melting. 

WHERE CAN I PURCHASE SHEET METALS AND WIRES FOR JEWELRY MAKING?

You can find jewelry making materials form the following retailers:

HALSTEAD BEAD

STULLER

RIO GRANDE

If you are interested in learning more definitely check out my book Metalsmith Society’s Guide To Jewelry Making. It covers all the tools you need to get started making jewelry, safety, all the basic techniques and includes ten simple projects to get you going! I have a shopping list for each project so if you are lookinh for a basic project to get started grab a copy of my book today! 

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