Prototype to Production Metal Fabrication Services for Power Generation

Whether for wind, hydroelectric, or nuclear, power generation equipment requires custom prototype to production metal fabrication services. To meet unique design specifications and performance demands in these critical industries, customers tend to choose more experienced and versatile fabrication companies to complete these jobs. With decades of experience, a comprehensive set of service offerings, modernized equipment, and broad material experience, Precision Steel Services is the ideal candidate for metal fabrication services for power generation projects. This article offers a deeper look into some recent work completed by Precision Steel Services to provide prototype to production services for a nuclear power plant, and the various equipment and experience that made that project possible. 

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Case Study: Heat Exchangers for Nuclear Power Generation

To illustrate how Precision Steel Services can deliver effective metal fabrication services for power generation in real-world applications, the following case study highlights a recent project for a customer requiring several parts. This case study further demonstrates the company’s ability to solve both material and process challenges while meeting tight deadlines.

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The Challenges

A prospective customer in the power generation industry approached Precision Steel Services with an urgent need for various components. They were having difficulty achieving desired results with other fabrication companies as the project required intricate aluminum and stainless steel parts with extremely tight tolerances, all within a short lead time. During the prototyping stage, the team also discovered that the stainless steel components were warping when cut on a laser, creating additional challenges in maintaining dimensional accuracy and quality, necessitating a different fabrication process that reduced material waste and incorrect dimensions. 

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The Solutions

To meet the customer’s unique requirements and expected turnaround times, Precision Steel leveraged its advanced laser cutting equipment to produce the aluminum parts quickly and precisely, achieving the intricate part details and tight tolerances specified. For the remaining stainless steel components, Precision Steel avoided using heat-based cutting methods and altered their approach, switching instead to water jet cutting with abrasives to eliminate heat distortion along the cut edge. The water jet process also allowed them to scribe the parts with immense precision, ensuring the final parts met all specifications and required no additional deburring or polishing. This flexibility in choosing the right process for each material highlighted their versatility in providing metal fabrication services for power generation equipment.

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The Results

While the final results from some parts are still in the final stages, Precision Steel successfully delivered prototypes and a collection of production parts on time while adhering to all of the customer’s quality and tolerance specifications. By responding quickly with a quote, adapting their numerous metal fabrication services, and applying the appropriate technology, they helped the customer keep their project on schedule and ultimately developed a strong enough relationship to procure future projects. This case study demonstrates how Precision Steel’s custom-focused, responsive approach makes them an ideal partner for complex, low- to medium-volume projects in the power generation industry.

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Available Metal Fabrication Services at Precision Steel

This project is just one example of how Precision Steel Services leverages its extensive metal fabrication capabilities to meet unique demands for customers in the power generation industry among countless others. With a dedicated commitment to unmatched accuracy, production efficiency, and innovation through both processes and equipment, Precision Steel’s comprehensive in-house metal fabrication services allow them to tackle even the most complex projects with extreme confidence. Their skilled team and advanced equipment provide seamless support from start to finish, including:

• Laser Cutting: Utilizing state-of-the-art fiber laser and plasma cutting equipment to produce intricate, tight-tolerance parts with outstanding speed, repeatability, and edge quality. Perfect for both prototypes and high-volume production runs.
  
  
• Water Jet Cutting: Employing high-pressure water and abrasive cutting for materials sensitive to heat, such as stainless steel, aluminum, and various composites, ensuring clean, distortion-free edges that require minimal additional treatment.
  
  
• Extrusion Fabrication: Delivering expert and efficient processing of aluminum extrusions, including cutting, machining, notching, and finishing to meet custom design specifications and tight tolerances.
  
  
• AZON Thermal Barrier: Certified applicator of energy-efficient AZON thermal barrier technology to aluminum extrusions to improve thermal performance in architectural and industrial applications and prevent heat transfer and condensation.
  
  
• AWS-Certified Welding: Performing MIG, TIG, and spot welding by AWS-certified welders who meet stringent standards, ensuring the strength, integrity, and compliance of every welded assembly.
  
  
• Powder Coating: Providing high-quality, durable, and visually appealing custom powder coat finishes in a variety of colors and textures, with the capacity to handle a wide variety of part shapes, sizes, and volumes.

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Quotes for Metal Fabrication Services

With all these capabilities under one roof, Precision Steel Services offers unmatched flexibility and quality control to support the diverse and challenging fabrication needs of the power generation sector and beyond. Backed by recent successes working on projects in the nuclear power sector, Precision Steel demonstrates the incredible value of offering a wide range of metal fabrication services from laser cutting to water jet cutting, certified welding, powder coating, and more. Request a quote today to learn more about how Precision Steel can help meet your metal fabrication needs.

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