Media Blasting: A Brief History

First developed in the 1930s, the abrasive blasting process has continued to change and improve in the decades since.

What does the future of abrasive blasting hold? Only time will tell — but these current trends provide new opportunities for what may come next.

1. DUSTLESS BLASTING (Vapour Blasting)

Dustless blasting is a unique and innovative process used for stripping paint and cleaning an array of surfaces. In fact, it can remove almost any coating from any surface. The dustless alternative removes old coats quickly, leaving a smooth, clean surface in its wake. Abrasive and water are mixed inside a blast tank. During the blasting process, the abrasive is encapsulated by the water, and the coating present is removed. Rather than the dust of the coating being airborne, the abrasive is trapped and falls to the ground. This keeps all nearby surfaces free from any mess. Dustless blasting ramps up the speed of the process, allowing for improved efficiency while also enhancing the quality of the final result. This method leads to lower costs and production time — and workers can enjoy better air quality. Dustless blasting may just be the mainstream of abrasive blasting in the future.

Today’s safety and technology trends set the stage for tomorrow’s advancements.

These current trends show how the abrasive blasting process may adapt in the future.

2. EMPHASIS ON SAFETY

There is no doubt that safety has become an increasing concern across the world, especially during the COVID-19 pandemic. The current trend of improved safety has led to increased precautions when using abrasive blasting machinery and blast cabinets. These steps emphasize cleaning and disinfecting every surface that’s been touched. This trend is expected to continue increasing in the near future following the current global health crisis.

3. TIME AND COST-EFFICIENCY

Efficiency remains a top priority for users, influencing the way we design, buy, use and blast machinery. Today's technology enables wet blasting abrasives to be used for almost any surface preparation project. With more and more alternative materials - such as glass sand and sodium bicarbonate - industry experts are trying out ways to achieve the same results at a quicker, more cost-effective pace.

FINAL THOUGHTS

In short, environmental-friendly, safety, and efficiency are the mainstream for abrasive blasting in the future. That’s also why Green Diamond Performance Materials, dustless blasting and full-automatic blasting are more and more popular nowadays. and with the UAE 2030 sustainability agenda [link to ae gov] in the fore front of our mission and vision for ProQualea in mind we are confident and proud to introduce Green Diamond Performance Blast materials to Abu Dhabi and the UAE infrastructure, marina and maritime, shipping, energy, construction and transport, and logistics sectors.

Dustless Blasting may be the mainstream of blasting in the future

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Types currently & Previously used

damage caused historically

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WHAT IS ABRASIVE CLEANING?

ABRASIVE BLASTING IS THE OPERATION of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface, or remove surface contaminants. A pressurized fluid, typically air, or a centrifugal wheel is used to propel the media.

Abrasive blasting of steel substrates can provide the best possible surface preparation for coatings adhesion. If done properly, abrasive blasting thoroughly cleans the surface and creates a surface profile for mechanical adhesion. To achieve the economy available through abrasive blasting, the operator must maintain the productivity and efficiency of the cleaning system through careful attention to all of its components.

CHAPTER 1. Industry Overview of Abrasive Blasting Media Market

1.1. Definition and Scope

1.1.1. Definition of Abrasive Blasting Media

1.1.2. Market Segmentation

1.1.3. Years Considered for the Study

1.1.4. Assumptions and Acronyms Used

1.1.4.1. Market Assumptions and Market Forecast

1.1.4.2. Acronyms Used in Global Abrasive Blasting Media Market

1.2. Summary

1.2.1. Executive Summary

1.2.2. Abrasive Blasting Media Market By Type

1.2.3. Abrasive Blasting Media Market By Application

1.2.4. Abrasive Blasting Media Market By End-Use Industry

1.2.5. Abrasive Blasting Media Market By Region

CHAPTER 2. Research Approach

2.1. Methodology

2.1.1. Research Programs

2.1.2. Market Size Estimation

2.1.3. Market Breakdown and Data Triangulation

2.2. Data Source

2.2.1. Secondary Source

2.2.2. Primary Source

CHAPTER 3. Market Dynamics And Competition Analysis

3.1. Market Drivers

3.1.1. Driver 1

3.1.2. Driver 2

3.2. Restraints and Challenges

3.2.1. Restraint 1

3.2.2. Restraint 2

3.3. Growth Opportunities

3.3.1. Opportunity 1

3.3.2. Opportunity 2

3.4. Porter’s Five Forces Analysis

3.4.1. Bargaining Power of Suppliers

3.4.2. Bargaining Power of Buyers

3.4.3. Threat of Substitute

3.4.4. Threat of New Entrants

3.4.5. Degree of Competition

3.5. Market Concentration Ratio and Market Maturity Analysis of Abrasive Blasting Media Market

3.5.1. Go To Market Strategy

3.5.1.1. Introduction

3.5.1.2. Growth

3.5.1.3. Maturity

3.5.1.4. Saturation

3.5.1.5. Possible Development

3.6. Technological Roadmap for Abrasive Blasting Media Market

3.7. Value Chain Analysis

3.7.1. List of Key Manufacturers

3.7.2. List of Customers

3.7.3. Level of Integration

3.8. Price Trend of Key Raw Material

3.8.1. Raw Material Suppliers

3.8.2. Proportion of Manufacturing Cost Structure

3.8.2.1. Raw Material

3.8.2.2. Labor Cost

3.8.2.3. Manufacturing Expense

3.9. Regulatory Compliance

3.10. Competitive Landscape, 2022

3.10.1. Player Positioning Analysis

3.10.2. Key Strategies Adopted By Leading Players

CHAPTER 4. Manufacturing Plant Analysis

4.1. Manufacturing Plant Location and Establish Date of Major Manufacturers in 2022

4.2. R&D Status of Major Manufacturers in 2022

CHAPTER 5. Abrasive Blasting Media Market By Type

5.1. Introduction

5.2. Abrasive Blasting Media Revenue By Type

5.2.1. Abrasive Blasting Media Revenue (USD Billion) and Forecast, By Type, 2020-2032

5.2.2. Silica/Si Sand

5.2.2.1. Silica/Si Sand Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

5.2.3. Aluminum Oxide Grit

5.2.3.1. Aluminum Oxide Grit Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

5.2.4. Coal Sag

5.2.4.1. Coal Sag Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

5.2.5. Corn Cob Grit

5.2.5.1. Corn Cob Grit Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

5.2.6. Glass Beads

5.2.6.1. Glass Beads Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

5.2.7. Acrylic

5.2.7.1. Acrylic Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

5.2.8. Crushed Glass Grit

5.2.8.1. Crushed Glass Grit Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

5.2.9. Silicon Carbide

5.2.9.1. Silicon Carbide Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

5.2.10. Others

5.2.10.1. Others Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

CHAPTER 6. Abrasive Blasting Media Market By Application

6.1. Introduction

6.2. Abrasive Blasting Media Revenue By Application

6.2.1. Abrasive Blasting Media Revenue (USD Billion) and Forecast, By Application, 2020-2032

6.2.2. Paint Spraying & Coating

6.2.2.1. Paint Spraying & Coating Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

6.2.3. Communication

6.2.3.1. Communication Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

6.2.4. Aircraft Maintenance

6.2.4.1. Aircraft Maintenance Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

6.2.5. Construction

6.2.5.1. Construction Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

6.2.6. Metalworking

6.2.6.1. Metalworking Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

6.2.7. Home Appliances

6.2.7.1. Home Appliances Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

6.2.8. Others

6.2.8.1. Others Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

CHAPTER 7. Abrasive Blasting Media Market By End-Use Industry

7.1. Introduction

7.2. Abrasive Blasting Media Revenue By End-Use Industry

7.2.1. Abrasive Blasting Media Revenue (USD Billion) and Forecast, By End-Use Industry, 2020-2032

7.2.2. Automotive

7.2.2.1. Automotive Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

7.2.3. Building & Construction

7.2.3.1. Building & Construction Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

7.2.4. Industrial

7.2.4.1. Industrial Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

7.2.5. Consumer

7.2.5.1. Consumer Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

7.2.6. Aviation

7.2.6.1. Aviation Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

7.2.7. Others

7.2.7.1. Others Market Revenue (USD Billion) and Growth Rate (%), 2020-2032

CHAPTER 8. North America Abrasive Blasting Media Market By Country

8.1. North America Abrasive Blasting Media Market Overview

8.2. U.S.

8.2.1. U.S. Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

8.2.2. U.S. Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

8.2.3. U.S. Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

8.3. Canada

8.3.1. Canada Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

8.3.2. Canada Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

8.3.3. Canada Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

8.4. North America PEST Analysis

CHAPTER 9. Europe Abrasive Blasting Media Market By Country

9.1. Europe Abrasive Blasting Media Market Overview

9.2. U.K.

9.2.1. U.K. Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

9.2.2. U.K. Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

9.2.3. U.K. Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

9.3. Germany

9.3.1. Germany Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

9.3.2. Germany Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

9.3.3. Germany Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

9.4. France

9.4.1. France Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

9.4.2. France Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

9.4.3. France Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

9.5. Spain

9.5.1. Spain Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

9.5.2. Spain Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

9.5.3. Spain Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

9.6. Rest of Europe

9.6.1. Rest of Europe Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

9.6.2. Rest of Europe Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

9.6.3. Rest of Europe Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

9.7. Europe PEST Analysis

CHAPTER 10. Asia Pacific Abrasive Blasting Media Market By Country

10.1. Asia Pacific Abrasive Blasting Media Market Overview

10.2. China

10.2.1. China Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

10.2.2. China Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

10.2.3. China Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

10.3. Japan

10.3.1. Japan Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

10.3.2. Japan Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

10.3.3. Japan Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

10.4. India

10.4.1. India Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

10.4.2. India Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

10.4.3. India Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

10.5. Australia

10.5.1. Australia Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

10.5.2. Australia Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

10.5.3. Australia Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

10.6. South Korea

10.6.1. South Korea Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

10.6.2. South Korea Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

10.6.3. South Korea Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

10.7. Rest of Asia-Pacific

10.7.1. Rest of Asia-Pacific Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

10.7.2. Rest of Asia-Pacific Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

10.7.3. Rest of Asia-Pacific Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

10.8. Asia Pacific PEST Analysis

CHAPTER 11. Latin America Abrasive Blasting Media Market By Country

11.1. Latin America Abrasive Blasting Media Market Overview

11.2. Brazil

11.2.1. Brazil Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

11.2.2. Brazil Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

11.2.3. Brazil Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

11.3. Mexico

11.3.1. Mexico Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

11.3.2. Mexico Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

11.3.3. Mexico Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

11.4. Rest of Latin America

11.4.1. Rest of Latin America Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

11.4.2. Rest of Latin America Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

11.4.3. Rest of Latin America Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

11.5. Latin America PEST Analysis

CHAPTER 12. Middle East & Africa Abrasive Blasting Media Market By Country

12.1. Middle East & Africa Abrasive Blasting Media Market Overview

12.2. GCC

12.2.1. GCC Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

12.2.2. GCC Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

12.2.3. GCC Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

12.3. South Africa

12.3.1. South Africa Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

12.3.2. South Africa Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

12.3.3. South Africa Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

12.4. Rest of Middle East & Africa

12.4.1. Rest of Middle East & Africa Abrasive Blasting Media Revenue (USD Billion) and Forecast By Type, 2020-2032

12.4.2. Rest of Middle East & Africa Abrasive Blasting Media Revenue (USD Billion) and Forecast By Application, 2020-2032

12.4.3. Rest of Middle East & Africa Abrasive Blasting Media Revenue (USD Billion) and Forecast By End-Use Industry, 2020-2032

12.5. Middle East & Africa PEST Analysis

CHAPTER 13. Player Analysis Of Abrasive Blasting Media Market

13.1. Abrasive Blasting Media Market Company Share Analysis

13.2. Competition Matrix

13.2.1. Competitive Benchmarking Of Key Players By Price, Presence, Market Share, And R&D Investment

13.2.2. New Product Launches and Product Enhancements

13.2.3. Mergers And Acquisition In Global Abrasive Blasting Media Market

13.2.4. Partnership, Joint Ventures and Strategic Alliances/ Sales Agreements

CHAPTER 14. Company Profile

14.1. Saint-Gobain S.A.

14.1.1. Company Snapshot

14.1.2. Business Overview

14.1.3. Financial Overview

14.1.3.1. Revenue (USD Billion), 2022

14.1.3.2. Saint-Gobain S.A. 2022 Abrasive Blasting Media Business Regional Distribution

14.1.4. Product /Service and Specification

14.1.5. Recent Developments & Business Strategy

14.2. 3M Company

14.3. Abrasives Inc.

14.4. Abrasive Technology Inc.

14.5. Clemco Industries Corp.

14.6. Graco Inc.

14.7. Guyson Corporation of USA

14.8. Kramer Industries Inc.

14.9. Norton Sandblasting Equipment

14.10. Torbo Engineering Keizers GmbH

14.11. Trinco Trinity Tool Co.

14.12. Vixen Surface Treatments Ltd.

Contents of Industry Paper 2024-2030

NEEDS rewording in gpt

all of the guide material below needs rewording and put onto nchatgpt

the source in from Kramer Industries, Inc (www.kramerindustriesonline.com)

Abrasive Blasting Guide

Abrasive blasting will produce an effect that may combine both a cleaning and finishing action. The finishing effect may vary by controlling such factors as hardness of the abrasive, abrasive particle size, velocity of abrasive stream, angle of abrasive gun, distance from the work, method of application and work flow.

As it is applied to preparation of surfaces prior to finishing, abrasive blasting is generally used to replace sanding, wire brushing and pickling. Ordinarily, no other cleaning is necessary because the blasted surface is chemically and mechanically cleaned.

Abrasive blasting can save from 25% to 75% of the time normally required by hand cleaning. Blasting is considered economical. The abrasives are relatively inexpensive and reusable. The general economical advantages of abrasive blasting lie in the reduction of man-hours required to clean and finish parts and needing only minimally trained personnel, yet still having high productivity per hour per dollar of equipment.

Abrasive blasting can make a good finish better and cleaner. It also produces a better tooth for bonding. It is estimated that the surface area of metal increases as much as ten times as a result of the abrasive impact action. This increases the surface to which paint, coating or plating can adhere.

Pressure

Direct pressure machines require less pressure. Whereas a siphon machine is normally operated at 60-90 PSI, the direct pressure machines can function at 15-80 PSI. Operating at lower pressure reduces the work hardening of the surface and reduces warping of thin parts.

Most people sandblast at an air pressure that is too high. When you blast at pressures above 90 PSI, there is an excessive breakdown of the media and very little improvement of the cutting rate.

The Sandblast Gun

Abrasive blasting is supposed to be a scrubbing action, not a peening process. Therefore, the gun should always be aimed at a 60° to 45° angle to the surface being cleaned. When the gun is aimed at 90°, peening occurs and, due to the abrasive particles colliding with the abrasive bouncing off the surface, a very high rate of media wear occurs.

The gun in a siphon machine should be kept at least six inches from the surface being blasted. This allows the spray to spread out and cover a larger area. Blasting a larger circle allows for better overlap of the pattern and yields a more even and appealing finish. The direct pressure units can effectively operate at distances of one foot or more.

The Gun Nozzle

Nozzles made of tungsten carbide are the best choice. Settling for a less expensive, lower quality nozzle ultimately increases operational costs. If your compressor cannot keep up with the blaster, chose a smaller nozzle for the gun. If you have plenty of pressure at the gauge, but don’t seem to feel it at the gun, look for an obstruction in the abrasive pickup line or something stuck in the nozzle.

In a siphon machine, remember to change the air jet (behind the nozzle) every few nozzle changes. A worn air jet will deflect the flow in the gun and cause the abrasive to wear a hole in the side of the gun. If you have enough pressure at the gun, but very poor flow of abrasive, your nozzle is worn, there is a hole in the siphon tube pick-up hose, or the abrasive is so fine that it won’t flow down to the pickup area.

The Hose

Replace the siphon hose on a regular basis. When the walls get too thin the hose will collapse and obstruct the flow.

Media

Many types of finish may be obtained by the selection of abrasive and by the adjustment of air pressure in the blasting unit. The more commonly used abrasives are:

• Aluminum Oxide Grit (Standard)

• White Aluminum Oxide Grit

• Plastic Abrasive Grit (Urea, Melamine, Acrylic)

• Corn Cob Grit

• Walnut Shell Grit

• Glass Beads

• Pumice Grit

• Kramblast Crushed Glass Grit

• Silicon Carbide Grit

• Steel Grit

• Steel Shot

• And More

For the most efficient performance, when the abrasive in the machine has broken down too much, the entire load should be replaced. Adding new material to the old load greatly reduces the performance of the abrasive and increases the amount of dust.

If you are getting a sporadic flow of abrasive, it is being caused by fine material not flowing down to the pick-up area or too much pressure. Banging on the side of the cabinet hopper can test this. If the flow is good after this, your material is too fine or may be moist.

Media Hints

• Glass Beads can be used to texturize, descale, or remove light burrs and die-cast flash leaving a smooth bright satin finish. Used at 40 to 80 PSI.

• Abrasive Grits can be used for more aggressive work leaving a dull satin finish and are useful for creating a good surface for bonding. Use up to 120 PSI.

• Walnut Shell Grit can be used for deflashing thermoset plastics without destroying the original polish. Use 30 to 80 PSI.

Grounding

Blasting machines occasionally cause shocks from static electricity. If the operator stands on a mat grounded to the machine and the gun is grounded to the cabinet, this will be eliminated. The cabinet can also be grounded to any conduit for insurance.

The Window

Try not to hold a part up to the window. This will cause frosting of the window and make it difficult to see inside.

Kramer industries is a leading abrasive finishing company since 1911. With a knowledgeable and dedicated service team and a large inventory of media in stock, we can be on the road to get you up and running immediately.

Blasting Media Selection Guide

It is important to know the differences in blasting media, since different abrasive blasting media are required for different applications. Blasting media can be used for purposes such as cleaning, stripping, etching, strengthening and polishing. In addition to the media type, grit or mesh size is another factor to consider for your application. The final choice of media depends on the nature of the work required and on the blasting equipment that is employed. The blasting media selection guide below contains a list of the common blasting media and the differences in blasting media.

Aluminum Oxide Grit (Standard)

Aluminum Oxide Grit (Standard) is the most widely used abrasive in blast finishing and surface preparation Aluminum Oxide Grit is an extremely sharp, long-lasting blasting abrasive that can be recycled many times. In addition to the standard brown, Aluminum Oxide Grit (Standard) is available in 99.5% pure white grade. Hardness 8-9; Grit size range 8-1200; Angular shape. Compare

Kramblast Crushed Glass Grit

The angular nature of Kramblast Crushed Glass Grit allows for aggressive surface profiling and removal of coatings and surface contamination. Kramblast Crushed Glass Grit contains no free silica, is non-toxic and inert and contains no heavy metals typically found in coal and copper slags. Since Kramblast Crushed Glass Grit is lighter than many slags up to 50% less media can be used. Hardness 5-6; Grit size range Coarse to Fine; Angular shape; Consumable. Compare

Glass Beads

Manufactured from lead-free, soda lime-type glass, containing no free silica, Glass Beads are manufactured into preformed ball shapes. Glass Beads produce a much smoother and brighter finish than angular abrasives. Glass Beads can be recycled approximately 30 times. Hardness 5-6; Mesh size range 50-325; Round shape. Compare

Silicon Carbide Grit

As the hardest blasting media available, Silicon Carbide Grit is has a very fast cutting speed. Manufactured to a blocky grain shape that splinters, Silicon Carbide Grit can be recycled many more times that other blasting media. The hardness of Silicon Carbide Grit is ideal for etching of glass and stone. Hardness 9-9.5; Grit size range 8-1200; Angular shape. Compare

Plastic Abrasive Grit

Plastic Abrasive Grits are available in a variety of types that deliver quick stripping rates and consistent performance. This media is ideal for stripping coatings and paint from substrates, including aluminum and other delicate metals, composites and plastics. The relative softness of Plastic Abrasive Grit media makes it ideal for automotive and aerospace blasting applications. Hardness 3-4; Grit size range 12-80; Soft, angular shape; Urea, Melamine, Acrylic compositions. Compare

Pumice Grit

Pumice Grit is a light, natural mineral that is used chiefly as a mild abrasive. Pumice Grit is ideal for less aggressive operations where protection of the surface is of supreme importance. Hardness 6-7; Grit size range 14-325+ Compare

Steel Shot

Blasting with Steel Shot is a popular method for cleaning, stripping and improving a metal surface. Steel Shot is manufactured into a round ball shape that results in a smooth and polished surface. The peening action of the Steel Shot produces improved compressive strength to metal surfaces. Hardness 40-51 HRC; Grit size range S-110 to S-780; Spherical shape. Compare

Steel Grit

High-demand, aggressive applications are ideal for Steel Grit. Steel Grit offers a very fast stripping action for many types of surface contaminants from steel and other foundry metals. Softer than Aluminum Oxide Grit (Standard) but still angular in shape, steel grit will not fracture as easily making it perfect for creating an etched surface on metal. Hardness 40-65 HRC; Grit size range G-12 to G-80; Angular shape. Compare

Corn Cob Grit

Corn Cob Grit is an organic, soft blasting grit that is safe for delicate parts and soft substrates. As the preferred blasting media for log homes and other wood surfaces, Corn Cob Grit offers excellent cleaning and stripping properties without damage to the substrate. Hardness 4-4.5; Grit size range Extra Coarse to Extra Fine; Ground, Angular shape. Compare

Walnut Shell Grit

Walnut Shell Grit is used for applications that require aggressive stripping or cleaning without damage or effect on the underlying substrate. Organic and biodegradable, Walnut Shell Grit is extremely durable, angular in shape but is considered a soft abrasive. Walnut Shell Grit sees utility in applications such as cleaning hard woods and aircraft and automotive stripping. Hardness 4.5-5; Grit size range Extra Coarse to Extra Fine; Angular shape. Compare

Nu-Soft Steel Shot

Nu-Soft Steel Shot is a unique blasting media engineered specifically for blasting soft or delicate surface. The high density and extreme durability make this an efficient and cost effective media for many applications. Nu-Soft Steel Shot is supplied in round ball shape that results in a smooth and polished surface. Hardness <20 HRC (3-3.5 MOHS); Grit size range NS-70 to NS-330; Spherical shape. Compare

Copper Slag / Iron Silicate

Copper Slag / Iron Silicate is ideal when a quick and efficient paint stripping process is required. It produces a heavy to medium etch depending on the grade and leaves the surface to primed and painted. Copper Slag is ideal for large commercial projects like bridge repainting, pipeline re-coating, and ship and boat stripping. Copper Slag is a consumable, silica-free premium alternative to silica sand. Hardness 7.5 MOHS; Grit size from Coarse to Fine; Angular

Surface Finishing Questions

How do I pick a system to finish or deburr my parts?

Each type of deburring system has special characteristics. If you know the strong points of a system, you can select the most suitable system for a job. The most common options are:

Sandblasting Systems

Sandblasting propels abrasives at the part via a high-pressure air stream. It can abrade into the minutest details and produce a very even finish. The finish can range from a dull satin using abrasives or a bright satin using glass beads. Sandblasting removes small burrs but not heavy burrs (burrs which are too thick to bend or break off using a fingernail or pencil). Inexpensive manual systems as well as automated systems are available. Use sandblasting for light deburring or scale removal and to provide an even finish for painting or plating.

Barrel Tumbling Systems

Parts can be self-tumbled or tumbled with media. Tumbling is an aggressive system for heavy cutting with abrasives or for producing a shine with polishing media. Tumbling tends to attack edges and round corners more than other surfaces and does not penetrate into recesses well. Tumble parts to remove heavy burrs, round edges or create quick “safe edges” on stampings.

Vibratory Finishing Systems

Vibratory finishers shake parts and media at high speeds, causing the media to scrub the surface of the parts in an action similar to lapping. Since the parts and the media are moving at small increments on each stroke, the parts are not subject to severe stress or damage. Vibratory finishers produce very smooth surfaces, are safe for delicate parts, and have very good action inside recesses and holes. Vibratory finishing is the preferred choice for general deburring/finishing, deburring/finishing delicate parts and for precision deburring/finishing. Vibratory finishing is also safer for threaded parts, though it is not as good as barrel tumbling for rounding edges or removing tough, heavy burrs.

Which compound should I use?

The compound determines how the media will perform. Kramer’s 700 series powder compounds for barrel finishing systems and 1000 series of liquid compounds for vibratory finishing systems work best to protect metal from corrosion. To produce more shine and brightness, Kramer’s 900 series of powdered compounds for barrel finishing equipment or 2000 series liquid compounds for vibratory finishing equipment work best. Consult our compound selector guide for details.

Should I use ceramic or plastic media?

General burr removal can be performed using ceramic media. Ceramic media ranges from very hard for light deburring or polishing to softer media with more abrasive content for fast cutting. Plastic media is used when a part needs a good smooth surface finish, for delicate parts or when harder ceramic media would gouge a soft metal. Plastic media is considerably lighter than ceramic media so it will not distort a delicate part. Consult our Tumbling Media Selection Guide.

Why is my media wearing out so fast?

Ceramic burnishing media can lose 1% of its weight every eight operating hours. An aggressive cutting media can lose 1-2% of its weight every four operating hours. Plastic media will generally lose more than ceramic media due to its softer bond. Aggressive cutting media will wear out more rapidly than burnishing media due to the amount of abrasive added to the composition.

A compromise must be made between long life and fast cutting. Too little load in the machine causes a pounding action that greatly accelerates media wear; adding more media will smooth out the flow.

Why are my parts getting damaged?

Usually most damage is from one part hitting another. Generally, using too little media for the load damages parts. Try to maintain three parts media to one part of parts (by volume), which surrounds the parts in a matrix of media to prevent one part from hitting another.

Increasing the total load height will also help. A barrel tumbler should be run 50% full and a vibratory finisher 80-90% full for optimum cutting and a good finish. In a wet system, adding water will also soften the action.

Why do my parts get dark?

When parts are getting dark, it is usually a case of improper choice of compound or too little compound. Most Kramer compounds are formulated for use at a rate of 1-2 ounces per gallon of water. The ratio should be raised to 2-3 ounces per gallon if the solution is being re-circulated, providing extra chemicals to neutralize the higher load of residue. If the solution is being re-circulated, at some point it must be replaced so protection is not lost.

How do I handle waste products?

The wastewater from a deburring system is comprised of cleaning agents, solid residue from the media and particles abraded from the parts. Modern cleaning agents are biodegradable; however, the solids can harm the environment and clog pipes. The solids can be separated out using a gravity settling tank, a filter or a centrifuge. The gravity-settling tank is the least expensive option, but consumes the most space. Filter units and centrifuges take up much less space. Most small systems require only a settling tank and a pump to remove the usable water from the top of the tank.

Why are my parts warping?

Thin parts are sensitive to the compression stress load of glass beads. When blasting only one side, the parts will be unequally stressed and, therefore, warp. This can be avoided by blasting both sides of the part or by switching to an abrasive such as aluminum oxide that will scrub without imparting a compressive stress. It is also possible to minimize the effect by reducing the pressure.

Why is my barrel tumbler taking so long to process the parts?

It could be mechanical. The motor could be running slow due to age or a belt could be slipping. Loading the barrel past the 50% level also slows down the action. Adding too much compound can produce foam that will slow down the process. Adding more water can soften the action. Burrs may have increased due to worn tooling. Media may have worn down and no longer has the weight to do the cutting anymore. Using fresh media will speed up the cutting process.

Why is my vibratory finisher taking so long to process the parts?

The same rules apply as with barrel tumblers above. In addition, vibratory finishers are particularly sensitive to the water flow through the tub. Reducing the water flow will speed up the action.

Why is my sandblaster not producing finished parts as fast as it used to?

A worn nozzle will reduce the velocity of the abrasive, thus requiring more time to do the job. Replacing the nozzle will speed up the process.

The hose of nozzle may be clogged with a foreign object. Try passing a wire through the hose or nozzle to check.

Working too close to the part reduces the size of the blast pattern and pulverizes the abrasive, reducing its life. Blasting should be done at least six to eight inches from the part if using a suction blasting system and ten to fourteen inches away when using a direct pressure blasting system. Adding fresh abrasive to the machine without removing the old spent abrasive will make the operation very dusty and slow down the action of the fresh abrasive. When adding fresh abrasive, always remove the old material from the machine first. In a suction system there is an air jet behind the nozzle. If this is not replaced regularly, it will cause the air to deflect to one side and not accurately enter the center of the nozzle. This will eventually blast a hole through the side of the gun as well as slow the abrasive pick-up. Replace the air jet every two nozzles.

Operators often tend to hold the blast gun at a 90° angle to the work surface in hope that it will be more aggressive. However, this actually slows down the performance and pulverizes the abrasive. The gun should be held at a 30-45° angle to the work surface. This allows the abrasive to scrub the surface with the least abrasive wear.

If a visible stream of abrasive cannot be seen, one of the above conditions may apply or there may be a hole worn in the abrasive pick-up tube. Check the tube. The wrong blast material might be being used for the job. To remove material or scale, aluminum oxide is fastest. To remove scale and leave a shiny satin finish, glass beads are recommended, but it will take 40% longer than using aluminum oxide.

For additional information on finishing your parts, we’re just a phone call away.

Write your text here...Where Do I Start? Deburring or Surface Finishing? Barrel or Vibratory Finishing: Choosing the Right System for the Job

Many parts need deburring or surface finishing work. In order to keep costs down, manufacturers look to mass finishing. The tumbling barrel and the vibratory tumbler are as versatile as a Boy Scout knife, but to use them properly one must understand how they work.

The Barrel Tumbler

Barrel tumblers have an action similar to that of a rock tumbling and skidding down the slope of a hill. The barrel tumbler’s corners lift the load as the barrel rotates until it reaches a point where it slides down the side of the barrel. The parts are abraded and deburred as they bump and scrape against the media and the other parts.

The Vibratory Tumbler

Vibratory tumblers have an action that is similar to filing. The cutting media surrounds the parts. The eccentric, rotating weight shakes the tub in a circular path during which the entire load is lifted up at an angle and then dropped. As the load is falling (but not actually airborne) the tub returns to an upward position, applying an upward and angular force that causes a shearing action where the parts and media rub against each other.

Cutting Action

While the barrel tumbler is grinding at an applied force, the vibratory tumbler is moving faster than a free fall. The barrel tumbler’s applied force is normally 5 to 10 times the vibratory tumbler’s free fall force. In the barrel tumbler, the entire cutting action is restricted to the slide area or 20 to 30% of the total load. In the vibratory tumbler, the entire load is being cut with each pulse, about 1800 times a minute, explaining why the vibratory tumbler has such short cycle times compared to the barrel tumbler.

The parts in a vibratory finishing system are actually moving only about1/16” in relation to each other. The parts in a barrel finishing system move across the entire diameter of the barrel. These movements cause large radii to form in a barrel tumbler, but relatively small radii to form in a vibratory tumbler. The tumbling barrel can form a one-eighth radius on a part, while removing very little material from the flat sections. The vibratory tumbler must be set for violent action with large blocky media to produce a sizable radius, but due to its scrubbing action, it will remove an appreciable amount of material from the flats.

Generally speaking, vibratory finishing systems tend to produce a very smooth flat finish because it really laps the parts. The vibratory tumbler will also cut inside a tube or cup shaped piece, deburring any spot the stone can reach. Since the load is moving as a unit, very fragile parts are quite safe in a vibrator. There is no tearing action or unequal forces that tend to bend and distort parts. The larger the parts or media are, the faster the cutting action. However, the weight of either does not seem to have as much effect as size, since plastic media, 50% lighter than ceramic media, can provide a good cut.

Barrel finishing systems produce a more uneven surface and generally round off corners before deburring much material from surfaces. There are times when this is desirable. For brute stock removal, the barrel tumbler excels. Foundry castings and parts with heavy radii are usually run in a barrel tumbler. The barrel tumbler’s peening action can be used to work tougher parts and stress relief machined parts. Hardened and polished steel shot is used extensively in a barrel tumbler for producing a quick luster on parts. While this media may be used in a vibratory machine, the barrel tumbler yields a denser surface and more luster.

Speed and Amplitude

The speed and amplitude of vibration is variable on most machines. High speeds (1800 cycles per minute) and small amplitudes are used for fine finishes or delicate parts. Large amplitudes are used for heavier cutting, varying the speed according to the finish requirement. High speeds with large amplitudes can roll burrs in and even peen metal into holes and mushroom edges. The circulation of parts is best at higher speeds; therefore, heavy pieces are run best at higher speeds with moderate amplitudes of 1/8” to 3/32“.

Cost

Cost is one factor that may decide the choice in some cases. Vibratory systems, due to their massive construction, are much more expensive pieces of equipment. Barrel tumbling systems wear out tumbling media at half the pace of vibratory systems, but have to run longer to do the same job.

Media

The tendency is to use ceramic preformed media or plastic preformed media in a vibratory finishing system. Ceramic tumbling media is made with abrasive filler, much as a grinding wheel is made. For plastic tumbling media, plastic is mixed with abrasive and cast to shape. Ceramic media uses aluminum oxide as filler and plastic media uses quartz or silica for cleaner results.

Randomly shaped media, either man-made or natural, are rarely used for precision work, because they tend to jam in the holes and do not deburr into corners or recessed areas. When using ceramic media, care should be taken to avoid glazing or loading of the surface. It is a good practice to run the media with an abrasive grain occasionally to roughen the surface and clean the pores.

Plastic tumbling media is self-cleaning due to its relatively soft bond. Since adding an abrasive to plastic media materially reduces its life, this media should only be used for mild cutting jobs that do not require adding an abrasive to the run. Plastic tumbling media produces large amounts of foam and residue, making it unsuitable for use in an enclosed tumbling barrel. Plastic tumbling media is mainly used for fragile parts or soft metals. Since this media is less than half the weight of stone or ceramic tumbling media, it is safer to use in such cases.

Water

In both systems, water is added to the load to absorb soils and lubricate the media. To help the water keep the parts clean, chemical compounds are added. An abrasive is sometimes added to enhance the cutting and deburring ability of the tumbling media. Most people assume it is the abrasive that does the cutting, and deburring, but this is not so. The abrasive is used mainly to keep the stone rough enough to do the cutting and deburring.

Much of the finesse of using finishing equipment effectively can only be gained by actually working with the equipment. It is important to keep careful records of each run to learn its effect and also to allow the results to be duplicated later.

Thus, there is no easy answer to the question, “Which system is best?” We have found through many years of experience that to arrive at the proper choice, the particular requirement of the job must be studied and the characteristics of the performance of each system must be known.

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Parts Finishing Comparison Chart

System Type

Action

Characteristic Results

Special
Comments

Tumbling EquipmentRotates loads to cascade downhill.Large radii. Poor in recesses. Good for large exposed burrs.Requires good handling equipment. Long cycles.Vibratory EquipmentVibrations cause a scrubbing action of media against parts.Usually small radius (0.010″ to 0.020″). Very smooth surface. Very effective in recessed areas. Twice the speed of a barrel tumbler.Can process very large parts. Lends itself to feed-through automation. Best system for delicate and close tolerance work.Centrifugal EquipmentAction same as a barrel tumbler, but augmented by centrifugal force.Results similar to a barrel tumbler, but much faster. High pressure can roll over burrs.Multiple small barrels require a high degree of handling, but with very fast cutting cycle. Best used for small parts and with small media.Tumble
Blasting EquipmentParts are tumbled slowly to provide random exposure to a sandblasting gun using an abrasive.Removes light burrs or texturizes for an attractive finish. Penetrates the smallest crevices and goes through holes to get cross drill burrs.Performs best with parts around two inches or less. Large heavy parts can be dented. Low labor factor.

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Sand Blasting Basics

Source Wikipedia “Sandblasting”

Types

Sandblasting

Sand blasting is also known as abrasive blasting, which is a generic term for the process of smoothing, shaping and cleaning a hard surface by forcing solid particles across that surface at high speeds; the effect is similar to that of using sandpaper, but provides a more even finish with no problems at corners or crannies. Sandblasting can occur naturally, usually as a result of particles blown by wind causing aeolian erosion, or artificially, using compressed air. An artificial sandblasting process was patented by Benjamin Chew Tilghman on 18 October 1870.[1][2] Thomas Wesley Pangborn perfected the idea and added compressed air in 1904.[4]

Sandblasting equipment typically consists of a chamber in which sand and air are mixed. The mixture travels through a hand-held nozzle to direct the particles toward the surface or work piece. Nozzles come in a variety of shapes, sizes, and materials. Boron carbide is a popular material for nozzles because it resists abrasive wear well.

Wet abrasive blasting

Wet abrasive blasting uses water as the fluid moving the abrasives. The advantages are that the water traps the dust produced, and lubricates the surface. The water cushions the impact on the surface, reducing the removal of sound material.

One of the original pioneers of the wet abrasive process was Norman Ashworth who found the advantages of using a wet process as a strong alternative to dry blasting. The process is available in all conventional formats including hand cabinets, walk-in booths, automated production machinery and total loss portable blasting units. Advantages include the ability to use extremely fine or coarse media with densities ranging from plastic to steel and the ability to use hot water and soap to allow simultaneous degreasing and blasting. The reduction in dust also makes it safer to use siliceous materials for blasting, or to remove hazardous material such as asbestos, radioactive or poisonous products.

Process speeds are generally not as fast as conventional dry abrasive blasting when using the equivalent size and type of media, in part because the presence of water between the media and the substrate being processed creates a lubricating cushion that can protect both the surface and the media, reducing breakdown rates. Reduced impregnation of blasting material into the surface, dust reduction and the elimination of static cling can result in a very clean surface.

Wet blasting of mild steel will result in immediate or 'flash' corrosion of the blasted steel substrate due to the presence of water. The lack of surface recontamination also allows the use of single equipment for multiple blasting operations—e.g., stainless steel and mild steel items can be processed in the same equipment with the same media without problems.

Vapor blasting

A variant of wet blasting is vapor blasting (or vapour blasting; U.K.). In this process pressurized air is added to the water in the nozzle producing a high-speed mist, called "vapor". This process is even milder than wet blasting, allowing mating surfaces to be cleaned while retaining their ability to mate.

Bead blasting

Bead blasting paint from a concrete curb by a worker wearing hearing protection. Mixing particles with water substantially reduces dust.

Bead blasting is the process of removing surface deposits by applying fine glass beads at a high pressure without damaging the surface. It is used to clean calcium deposits from pool tiles or any other surfaces, remove embedded fungus, and brighten grout color. It is also used in auto body work to remove paint. In removing paint for auto body work, bead blasting is preferred over sand blasting, as sand blasting tends to create a greater surface profile than bead blasting. Bead blasting is often used in creating a uniform surface finish on machined parts.[5] It is additionally used in cleaning mineral specimens, most of which have a Mohs hardness of 7 or less and would thus be damaged by sand.

Wheel blasting

In wheel blasting, a spinning wheel propels the abrasive against an object. It is typically categorized as an airless blasting operation because there is no propellant (gas or liquid) used. A wheel machine is a high-power, high-efficiency blasting operation with recyclable abrasive (typically steel or stainless-steel shot, cut wire, grit, or similarly sized pellets). Specialized wheel blast machines propel plastic abrasive in a cryogenic chamber and is usually used for deflashing plastic and rubber components. The size of the wheel blast machine, and the number and power of the wheels vary considerably depending on the parts to be blasted as well as on the expected result and efficiency. The first blast wheel was patented by Wheelabrator in 1932.[6][7] In China, the first blast wheel was built around the 1950s,[8] Qinggong Machinery is one of the earliest manufacturers of blast wheel.[9]

Micro-abrasive blasting

Main article: Abrasive jet machining

Micro-abrasive blasting is dry abrasive blasting process that uses small nozzles (typically 0.25 mm to 1.5 mm diameter) to deliver a fine stream of abrasive accurately to a small part or a small area on a larger part. Generally the area to be blasted is from about 1 mm2 to only a few cm2 at most. Also known as pencil blasting, the fine jet of abrasive is accurate enough to write directly on glass and delicate enough to cut a pattern in an eggshell.[10] The abrasive media particle sizes range from 10 micrometres up to about 150 micrometres. Higher pressures are often required.

The most common micro-abrasive blasting systems are commercial bench-mounted units consisting of a power supply and mixer, exhaust hood, nozzle, and gas supply. The nozzle can be hand-held or fixture mounted for automatic operation. Either the nozzle or part can be moved in automatic operation.

Automated blasting

Automated blasting is simply the automation of the abrasive blasting process. Automated blasting is frequently just a step in a larger automated procedure, usually involving other surface treatments such as preparation and coating applications. Care is often needed to isolate the blasting chamber from mechanical components that may be subject to dust fouling.

Dry-ice blasting

Main article: Dry-ice blasting

In this type of blasting, air and dry ice are used. Surface contaminants are dislodged by the force of frozen carbon dioxide particles hitting at high velocity, and by slight shrinkage due to freezing which disrupts adhesion bonds. The dry ice sublimates, leaving no residue to clean up other than the removed material. Dry ice is a relatively soft material, so is less destructive to the underlying material than sandblasting.

Bristle blasting

Main article: Bristle blasting

Bristle blasting, unlike other blasting methods, does not require a separate blast medium. The surface is treated by a brush-like rotary tool made of dynamically tuned high-carbon steel wire bristles. Repeated contact with the sharp, rotating bristle tips results in localized impact, rebound, and crater formation, which simultaneously cleans and coarsens the surface.

Vacuum blasting

Main article: Vacuum blasting

Vacuum blasting is a method that generates very little dust and spill, as the blast tool does dry abrasive blasting and collects used blast media and loosened particles from the surface to be treated, simultaneously. Blast media consumption is relatively low with this method, as the used blast media is automatically separated from dust and loosened particles, and reused several times.

Equipment

Device used for adding sand to the compressed air (top of which is a sieve for adding the sand)

Portable blast equipment

Mobile dry abrasive blast systems are typically powered by a diesel air compressor. The air compressor provides a large volume of high pressure air to a single or multiple "blast pots". Blast pots are pressurized, tank-like containers, filled with abrasive material, used to allow an adjustable amount of blasting grit into the main blasting line. The number of blast pots is dictated by the volume of air the compressor can provide. Fully equipped blast systems are often found mounted on semi-tractor trailers, offering high mobility and easy transport from site to site. Others are hopper-fed types making them lightweight and more mobile.

In wet blasting, the abrasive is introduced into a pressurized stream of water or other liquid, creating a slurry. Wet blasting is often used in applications where the minimal dust generation is desired. Portable applications may or may not recycle the abrasive.

Blast cabinet

A sand-blasting cabinet

A blast cabinet is essentially a closed loop system that allows the operator to blast the part and recycle the abrasive.[11] It usually consists of four components; the containment (cabinet), the abrasive blasting system, the abrasive recycling system and the dust collection. The operator blasts the parts from the outside of the cabinet by placing his arms in gloves attached to glove holes on the cabinet, viewing the part through a view window, turning the blast on and off using a foot pedal or treadle. Automated blast cabinets are also used to process large quantities of the same component and may incorporate multiple blast nozzles and a part conveyance system.

There are three systems typically used in a blast cabinet. Two, siphon and pressure, are dry and one is wet:

A siphon blast system (suction blast system) uses the compressed air to create vacuum in a chamber (known as the blast gun). The negative pressure pulls abrasive into the blast gun where the compressed air directs the abrasive through a blast nozzle. The abrasive mixture travels through a nozzle that directs the particles toward the surface or workpiece. Nozzles come in a variety of shapes, sizes, and materials. Tungsten carbide is the liner material most often used for mineral abrasives. Silicon carbide and boron carbide nozzles are more wear resistant and are often used with harder abrasives such as aluminium oxide. Inexpensive abrasive blasting systems and smaller cabinets use ceramic nozzles.

In a pressure blast system, the abrasive is stored in the pressure vessel then sealed. The vessel is pressurized to the same pressure as the blast hose attached to the bottom of the pressure vessel. The abrasive is metered into the blast hose and conveyed by the compressed gas through the blast nozzle.

Wet blast cabinets use a system that injects the abrasive/liquid slurry into a compressed gas stream. Wet blasting is typically used when the heat produced by friction in dry blasting would damage the part.

Blast room

A blast room is a much larger version of a blast cabinet. Blast operators work inside the room to roughen, smooth, or clean surfaces of an item depending on the needs of the finished product. Blast rooms and blast facilities come in many sizes, some of which are big enough to accommodate very large or uniquely shaped objects like rail cars, commercial and military vehicles, construction equipment, and aircraft.[12]

Each application may require the use of many different pieces of equipment, however, there are several key components that can be found in a typical blast room:

An enclosure or containment system, usually the room itself, designed to remain sealed to prevent blast media from escaping

A blasting system; wheel blasting and air blasting systems are commonly used

A blast pot – a pressurized container filled with abrasive blasting media[13]

A dust collection system which filters the air in the room and prevents particulate matter from escaping

A material recycling or media reclamation system to collect abrasive blasting media so it can be used again; these can be automated mechanical or pneumatic systems installed in the floor of the blast room, or the blast media can be collected manually by sweeping or shoveling the material back into the blast pot

Additional equipment can be added for convenience and improved usability, such as overhead cranes for maneuvering the workpiece, wall-mounted units with multiple axes that allow the operator to reach all sides of the workpiece, and sound-dampening materials used to reduce noise levels.[14]

Media

In the early 1900s, it was assumed that sharp-edged grains provided the best performance, but this was later shown to be incorrect.[15]

Mineral

Silica sand can be used as a type of mineral abrasive. It tends to break up quickly, creating large quantities of dust, exposing the operator to the potential development of silicosis, a debilitating lung disease. To counter this hazard, silica sand for blasting is often coated with resins to control the dust. Using silica as an abrasive is not allowed in Germany, Belgium, Russia, Sweden and United Kingdom for this reason.[16] Silica is a common abrasive in countries where it is not banned.[17]

Garnet

Garnet is more expensive than silica sand, but if used correctly, will offer equivalent production rates while producing less dust and no safety hazards from inhaling the dust. Magnesium sulphate, or kieserite.

Agricultural

Typically, crushed nut shells or fruit kernels. These soft abrasives are used to avoid damaging the underlying material such when cleaning brick or stone, removing graffiti, or the removal of coatings from printed circuit boards being repaired.

Synthetic

This category includes corn starch, wheat starch, sodium bicarbonate, and dry ice. These "soft" abrasives are also used to avoid damaging the underlying material such when cleaning brick or stone, removing graffiti, or the removal of coatings from printed circuit boards being repaired. Soda blasting uses baking soda (sodium bicarbonate) which is extremely friable, the micro fragmentation on impact exploding away surface materials without damage to the substrate. Additional synthetic abrasives include process byproducts (e.g., copper slag, nickel slag, and coal slag), engineered abrasives (e.g., aluminium oxide, silicon carbide or carborundum, glass beads, ceramic shot/grit), and recycled products (e.g., plastic abrasive, glass grit).

Metallic

Steel shot, steel grit, stainless steel shot, cut wire, copper shot, aluminium shot, zinc shot.

Many coarser media used in sandblasting often result in energy being given off as sparks or light on impact. The colours and size of the spark or glow varies significantly, with heavy bright orange sparks from steel shot blasting, to a faint blue glow (often invisible in sunlight or brightly lit work areas) from garnet abrasive.

Safety

Worker sandblasting without the use of proper personal protective equipment. The worker's face is covered with a bandana instead of a replaceable particulate filter respirator.

Worker sandblasting wearing full coverage protective gear.

Cleaning operations using abrasive blasting can present risks for workers' health and safety, specifically in portable air blasting or blast room (booth) applications. There is a large amount of dust created through abrasive blasting from the substrate and abrasive.[17] Although many abrasives used in blasting rooms are not hazardous in themselves, (steel shot and grit, cast iron, aluminum oxide, garnet, plastic abrasive and glass bead), other abrasives (silica sand, copper slag, nickel slag, and staurolite) have varying degrees of hazard (typically free silica or heavy metals). However, in all cases their use can present serious danger to operators, such as burns due to projections (with skin or eye lesions), falls due to walking on round shot scattered on the ground, exposure to hazardous dusts, heat exhaustion, creation of an explosive atmosphere, and exposure to excessive noise. Blasting rooms and portable blaster's equipment have been adapted to these dangers. Blasting lead-based paint can fill the air with lead particles which can be harmful to the nervous system.[18]

In the US the Occupational Safety and Health Administration (OSHA) mandates engineered solutions to potential hazards, however silica sand continues to be allowed even though most commonly used blast helmets are not sufficiently effective at protecting the blast operator if ambient levels of dust exceed allowable limits. Adequate levels of respiratory protection for blast operations in the United States is approved by the National Institute for Occupational Safety and Health (NIOSH).

Typical safety equipment for operators includes:

Positive pressure blast hood or helmet – The hood or helmet includes a head suspension system to allow the device to move with the operator's head, a view window with replaceable lens or lens protection and an air-feed hose.

Grade‑D air supply (or self-contained oil-less air pump) – The air feed hose is typically attached to a grade‑D pressurized air supply. Grade‑D air is mandated by OSHA to protect the worker from hazardous gases. It includes a pressure regulator, air filtration and a carbon monoxide monitor/alarm. An alternative method is a self-contained, oil-less air pump to feed pressurized air to the blast hood/helmet. An oil-less air pump does not require an air filter or carbon monoxide monitor/alarm, because the pressurized air is coming from a source that cannot generate carbon monoxide.

Hearing protection – ear muffs or ear plugs

Body protection – Body protection varies by application but usually consists of gloves and overalls or a leather coat and chaps. Professionals would wear a cordura/canvas blast suit (unless blasting with steel abrasives, in which case they would use a leather suit).

In the past, when sandblasting was performed as an open-air job, the worker was exposed to risk of injury from the flying material and lung damage from inhaling the dust. The silica dust produced in the sandblasting process would cause silicosis after sustained inhalation of the dust. In 1918, the first sandblasting enclosure was built, which protected the worker with a viewing screen, revolved around the workpiece, and used an exhaust fan to draw dust away from the worker's face.[19] Silicosis is still a risk when the operator is not completely isolated from the sandblasting apparatus.[17]

Sandblasting also may present secondary risks, such as falls from scaffolding or confinement in a small space.[17] Carbon monoxide poisoning is another potential risk, from the use of small gasoline-powered engines in abrasive blasting.[20]

Several countries and territories now regulate sandblasting such that it may only be performed in a controlled environment using ventilation, protective clothing and breathing air supply.

Worn-look jeans

Many consumers are willing to pay extra for jeans that have the appearance of being used. To give the fabrics the right worn look sandblasting is used. Sandblasting has the risk of causing silicosis to the workers, and in Turkey, more than 5,000 workers in the textile industry suffer from silicosis, and 46 people are known to have died from it. Silicosis was shown to be very common among former denim sandblasters in Turkey in 2007.[21] A 2015 study confirmed that silicosis is almost inevitable among former sandblasters.[22] Sweden's Fair Trade Center conducted a survey among 17 textile companies that showed very few were aware of the dangers caused by manually sandblasting jeans. Several companies said they would abolish this technique from their own production.[23]

In 2013, research claimed that in China some factories producing worn-look jeans are involved in varied non-compliance with health and safety regulations.[24]

Applications

The lettering and engraving on most modern cemetery monuments and markers is created by abrasive blasting.

Sandblasting can also be used to produce three-dimensional signage. This type of signage is considered to be a higher-end product as compared to flat signs. These signs often incorporate gold leaf overlay and sometimes crushed glass backgrounds which is called smalts. When sandblasting wood signage it allows the wood grains to show and the growth rings to be raised, and is a popular way to give a sign a traditional carved look. Sandblasting can also be done on clear acrylic glass and glazing as part of a store front or interior design.

Sandblasting can be used to refurbish buildings or create works of art (carved or frosted glass). Modern masks and resists facilitate this process, producing accurate results.

Sandblasting techniques are used for cleaning boat hulls, as well as brick, stone, and concrete work. Sandblasting is used for cleaning industrial as well as commercial structures, but is rarely used for non-metallic workpieces.

See also

Abrasion (mechanical)

Abrasive machining

Air abrasion

High-frequency impact treatment

Laser ablation, for laser blasting surface ablation instead of abrasive medium surface ablation

Shot peening

References

Smil, Vaclav (2005). Creating the twentieth century: technical innovations of 1867–1914 and their lasting impact. Oxford University Press US. p. 211. ISBN 978-0-19-516874-7.

US 108408, Tilghman, Benjamin C., "Improvement in cutting and engraving stone, metal, glass, &c.", published 1870-10-18

Travis McEwan, "Edmonton worker allergic to walnuts dies after inhaling particles at worksite," CBC News, 23 October 2017. (Retrieved 2017-10-25)

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General and cited references

Manufacturing Processes Reference Guide, 1st ed., by Robert H. Todd, Dell K. Allen, and Leo Alting

Tool and Manufacturing Engineers Handbook, Vol. 1: Machining, 4th Edition, 1983. Society of Manufacturing Engineers

External links

Media related to Sandblasting at Wikimedia Commons

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