BLASTING TECHNICAL INFORMATION

BLAST FINISHING Blasting is the process where small angular or spherical particles are propelled at a part by compressed air, or mechanical high speed rotating wheels or water pumps . The blast media type, shape, size, density, and hardness, along with media acceleration and volume of media, combined with blasting distance from the workpiece, angle of impact and time cycles are important factors in the blast process capabilities. The blasting equipment is produced to deliver, reclaim and contain the media, contain the part to be blasted and collect the dust from the blasting process. Parts can be processed individually as a batch process or can be automated thru the system. Surface affects from the blasting process are: VISUAL Bright Matte nish Dull Matte Finish Satin nish Satin luster nish Blending of tool marks Removal of weld discoloration Surface cleaning Glass frosting and etching Pre plate and anodize nishes MECHANICAL Deburring De-ashing Paint and coating removal Peening Pre paint and coating adhesion Heat treat, mill scale removal Weld splatter removal Thermal metal spray prep. Rust removal Mold cleaning

BLASTING TECHNICAL INFORMATION

FACTORS THAT AFFECT BLAST FINISHING ARE: 1. Media delivery systems 2. Blast containment enclosures, media recovery and dust collection systems. 3. Media used in industrial blasting systems

1. MEDIA DELIVERY SYSTEMS There are three media delivery systems that propel and deliver media for high speed impact to the part being processed. A. Air Blasting ( Pneumatic) B. Mechanical Wheel (airless blasting) C. Hydro blasting (pumped water)

A. AIR BLASTING utilizes an air compressors energy to deliver air/media mix at speeds and volumes to impact the parts being processed. The air speed or pressure of an air compressor is controlled by a pressure regulator. The regulator can increase or decrease the speed of the media delivery. Air pressure is measured by pounds per square inch (psi), industrial blasting is effectively done between 20 and 90 PSI. The higher the PSI the higher the air speed. The volume delivered of the air/media mix is determined by the orice or opening diameter of the nozzle with pressure blast systems or air jet diameter of the suction blast gun body. Air volumes are measured by surface cubic feet per minute (scfm). The larger the orice ID opening the larger volume of air/media. Other factors that affect volume of air into the blast system is media and air hose diameter. Increased air pressure (PSI) also increases the SCFM with a given size orice. . Industrial blasting gun bodies of suction cabinet blast systems range between 12 to 38 SCFM. The pressure blast cabinet systems range between 12 to 68 scfm and the pressure blast room systems use up to 254 scfm. Industrial air compressors produce approximately 4.5 SCFM per horse power (hp). Blasting cabinets require 3 to15 hp compressors per nozzle and blast rooms can use up to 53 h.p. per man or nozzle.

BLASTING TECHNICAL INFORMATION

THERE ARE TWO TYPES OF AIR BLAST DELIVERY SYSTEMS

Suction Pressure

( used in blast cabinets) ( used in blast cabinets, blast rooms, and outdoor blasting)

SUCTION blasting uses the venture principle sucking media from a hopper. The air jet is 1/2 the ID of the nozzle and as the air stream is passed through both, it creates a low pressure which sucks the media from the hopper into the air stream. The media acceleration distance is very short ( from the nozzle to the workpiece-approximately 4 to 14). The suction systems work ne and can be continuously blasted as long as there is blasting media in the hopper. Suction systems do not deliver media well at very low air pressures (5 to 25 psi) and they have limits on how long the suction feed hose can be. Very heavy blasting ( larger steel media) cannot be conveyed into the air stream with suction blasting. Most industrial blast cabinets are suction systems and work well with most medias.

PRESSURE blasting utilizes various sizes of ASME approved pressure vessels called pressure pots. The pressure pot contains the media, and as it is energized with compressed air, it pressurizes the pot. When the air/media mix is released from the pot it accelerates from the pot through at least 5-10 feet of hose and then even faster as it travels thru the ventura of the nozzle. The acceleration rates of air/media mix are much higher in pressure blasting than suction blasting. When the pressure pot empties of the media and air, the pressure pot has to be depressurized to rell the pot with media. The pressure blasting systems are much more productive when blasting than suction systems. Pressure systems can blast all medias regardless of weight or size and can also deliver medias at very low psi.

BLASTING TECHNICAL INFORMATION

AIR BLAST SYSTEMS - AIR CONSUMPTION RATES Below are charts of air volume (SCFM) used in blasting with pressure and suction systems utilizing various pressures (PSI) and orice sizes. CABINET BLAST SYSTEMS - AIR REQUIREMENTS Suction Systems Suction-Blast Air Requirements (scfm) Pressure (psi) 30 40 50 60 70 80 90 100
1/4 nozzle 3/32 jet 6 7 8 1/4 nozzle 1/8 jet 10 12 15 5/16 nozz 5/32jet 15 19 23 7/16 nozz 7/32 jet 31 38 45 10 17 27 52 11 12 13 15 19 21 23 26 31 37 38 42 59 66 73 80

Pressure Systems Pressure-Blast air requirements (scfm) Pressure (psi) 20 30 40 50 60 80 100 120
1/8 nozzle 3/16 nozzle 1/4 nozzle 5/16 nozzle 3/8 nozzle 6 15 27 42 55 8 18 32 50 73 10 22 41 64 91 13 14 26 30 49 55 78 88 109 126 17 48 68 113 161 20 25 45 55 81 97 137 152 196 220

BLAST ROOMS AND OUTDOOR SYSTEMS - AIR REQUIREMENTS Air consumption and media delivery rates are much higher on blast rooms and outdoor blasting systems than in pressure blast cabinets. The air supply hose ID, the media blast hose ID, the nozzle ID, the pressure pot and pot piping are all much larger on the blast rooms than cabinet systems. The increase in production is also due to the further distance that the nozzle is from the work piece in blast rooms creating a larger blast pattern. Pressure- blast requirements (blast rooms) Nozzle ID
3/16 #3

Pressure
AIR (CFM) Air compressor horse power Lbs Sand hour Air (CFM) Air compressor horse power Lbs Sand hour Air (CFM) Air compressor horse power

60
30 7 171

70
33 7.5 196

80
38 8 216 68 15 406

90
41 9.5 238 74 16.5 448 126 28.0

100
45 10 264 81 18 494 137 30.5

120

1/4 #4

54 61 12 13.5 312 354

97 21.5 582 152 34.0

5/16 #5

89 101 113 20.0 22.5 25.5

BLASTING TECHNICAL INFORMATION

Lbs Sand hour 3/8 #6 Air (CFM) Air compressor horse power Lbs Sand hour 534 604 672 740 173 38.5 1,052 812 912

126 143 161 28.0 32.0 36.0 754 864 960

196 220 44.0 49.0 1,152 1,320

Nozzle ID
7/16 #7

Pressure
Air (CFM) Air compressor horse power Lbs Sand hour Air (CFM) Air compressor horse power Lbs Sand hour

60

70

80

90

100

120
300 67.0 1,800 392 87.5 2,352

170 194 217 240 254 38.0 43.5 48.5 53.5 56.5 1,032 1,176 1,312 1,448 1,584 224 252 280 390 338 50.0 56.0 62.5 69.0 75.0 1,336 1,512 1,680 1,856 2,024

1/2 #8

AIR BLAST PRODUCTION RATES Blast nozzle spray patterns are affected by orice size, air pressure, and distance from the workpiece. The total diameter of the blast pattern increases as the distance from the workpiece is increased. The hot spot (where work speed is maximized) can be obtained at larger distances from the workpiece with pressure air blast systems. CABINET SUCTION BLASTING CABINET PRESSURE BLASTING

BLASTING TECHNICAL INFORMATION

CABINET BLAST PRODUCTION RATES Below is an estimate of abrasive delivery rates per hour and sq. ft. of blast area in sq. ft. per minute with various orice I.D.!s and 80 p.s.i. I.D.
3/32 1/8 5/32 3/16 1/4

CFM
7 15 25 40 80

PSI
80 80 80 80 80

Blast Area Sq.Ft./Minute

1/2 1 to 1-1/2 1 to 2-1/2 3 to 3-1/2 4 to 4-1/2

Abrasive Unit Hr.

80 lbs 120 lbs 160 lbs 216 lbs 400 lbs

BLAST ROOM AND OUTDOOR BLAST PRODUCTION RATES

BLAST SPECIFICATIONS
NO 1 WHITE METAL BLAST
Approx. Sq. Ft. Cleaning Per Hour at 90 PSI

ESTIMATED BLAST CLEANING RATES SSPC-SP5

Loose Mill Scale Pitted Paint 170 Sq. Ft 85 Sq. Ft. Tight Mill Scale Layered Paint

#7 NOZZLE
140 Sq. Ft. 70 Sq. Ft.

NO 2 NEAR WHITE BLAST

Approx. Sq. Ft. Cleaning Per Hour at 90 PSI

SSPC-SP10
Loose Mill Scale Pitted Paint 180 Sq. Ft. 90 Sq. Ft. Tight Mill Scale Layered Paint

#7 NOZZLE
146 Sq. Ft. 72 Sq. Ft.

NO 3 COMMERCIAL BLAST
Approx. Sq. Ft. Cleaning Per Hour at 90 PSI

SSPC-SP6
Loose Mill Scale Pitted Paint 420 Sq. Ft. 200 Sq. Ft. Tight Mill Scale Layered Paint

#7 NOZZLE
270 Sq. Ft. 140 Sq. Ft.

NO 4 BRUSH - OFF
Approx. Sq. Ft. Cleaning Per Hour at 90 PSI

SSPC-SP7
Loose Mill Scale Pitted Paint 840 Sq.Ft. 830 Sq.Ft. Tight Mill Scale Layered Paint

#7 NOZZLE
835 Sq.Ft. 825 Sq.Ft.

For more information on blast specications contact SSPC.org

B. MECHANICAL WHEEL BLASTING Wheel blast system utilizes a high speed rotation wheel using centrifugal force to propel the media. The wheel size design and rotation speed affect the velocity and pattern of the media.

BLASTING TECHNICAL INFORMATION

The abrasive is fed into the rotating wheel. The impact on the media by the hard rotating wheel usually restricts media selection to a very tough steel or stainless steel shot or grit. Machines can be built with multiple wheels for automation. Automated systems include basket, table, spinner hangers and continuous conveyor processing. Wheel blast systems are a less expensive way to blast (due to higher media recycleability and automation) than air blasting by a factor of 10. Their disadvantage are restrictions to very few media

C. HYDRO BLASTING This blasting system uses a pressurized water stream generated by pumps that are capable of pumping an abrasive charged water supply at high rates of speed. The Hydro Systems are good for conveying very ne abrasives. They are also used in cleaning gunky, greasy parts, and containing toxic materials. The wet blast systems are very good at blasting surfaces without damage and blasting internal surfaces.

ALL INDUSTRIAL BLAST SYSTEMS HAVE THE FOLLOWING COMPONENTS: Delivery Systems (Air or Wheel Blasting) Containment Systems (Hand cabinets, Automated enclosures, and Blast rooms) Reclaim Systems Dust Collection

Containment Systems Hand cabinets, automated enclosures and blast rooms are built to handle various size and shapes of parts. The containment systems are built to control and contain the blast media and parts within the enclosures.The enclosure systems use gravity for the blasted media to drop down to a collection area so the media can be conveyed to the reclaim system. Blast systems can have inexpensive or premium containment systems. Matching the right containment system to the application is very important.

BLASTING TECHNICAL INFORMATION

Media Reclaim Systems Recoverable medias used in industrial blast systems will run from 5 to 100 times through the blast system. These recoverable medias need to be cleaned, sized and returned to the blast system after being blasted. The media reclaim system accomplishes this. The reclaimer keeps nish and production rates consistent. Media reclaim systems can be Air Cyclones or Mechanical Systems. Dust Collection All Industrial blast systems utilize dust collectors to allow blast systems to be indoors. The dust collector removes the ne blasting dust keeping the media clean and operators safe through visibility and breathable air. Dust collectors remove 99% of 1 micron or larger material. Hepa lters can be added to remove dust particles down to 1/2 micron.Dust collectors are sized to the cabinet size, media type, and amount of blast nozzles or wheels being used. BLAST MEDIAS Recoverable blasting medias are used in industrial blasting. Indoor blasting systems require medias with extended life. Blast media, type, shape, size and hardness affect the process and materials they!re capable of blasting. Spherical medias are used for peening and produce smoother surface nishes. Angular medias chip at a parts surface; removing paint, rust and scale quicker, with better results than round medias. Angular medias produce a rougher surface nish and produce superior anchor patterns for paint and coating adhesions. Higher blast pressures increase production but reduce media life. Blasting harder workpieces also reduces media life. Recoverable blasting medias have two basic shapes. Round (spherical) and angular. The most common recoverable industrial blast medias are: Spherical shaped media Ceramic beads Glass beads Stainless shot Angular shaped media Aluminum oxide Ceramic grit Crushed glass Silicon carbide Stainless grit Steel grit

Aluminum Oxide (AL2O3) is a man made fused alumina that is very tough; angular blocky shaped, medium density, with a hardness of 9 on the Mohs scale. This

BLASTING TECHNICAL INFORMATION

abrasive is designed for high blasting pressures up to 90 PSI. Aluminum oxide is very good for light deburring and surface prep (bonding strength) prior to painting and coating. AO creates a dull matte nish.Aluminum oxide has media life of approximately10-12 times through the blast system. Typical Aluminum Oxide blasting applications: cleaning of investment castings Scale removal Thermal spray coating prep Rust removal Hard oxide removal Heat treat and mill scale removal Glass frosting and etching Monument lettering and carving Air craft engine overhaul Matte nishing surface prep durability up to 20 passes No free silicas
Grit Size Conversion for AO and SIC
Grit Size 16 20 24 30 36 46 54 60 70 80 90 100 120 150 180 220 Inches (average) Micronts(average) 0.043 0.037 0.027 0.022 0.019 0.014 0.012 0.010 0.008 0.0065 0.0057 0.0048 0.0048 0.0035 0.0030 0.0025 1092 942 686 559 443 356 305 254 203 165 145 122 102 89 76 63

Silicon Carbide (SIC) is a man made abrasive that is very sharp and friable. SC is very hard at 9.5 on the mohs scale. It is used to blast very hard materials such as tool steels, glass and ceramics. SC creates a dull matte nish. The grit sizes available are the same sizes as aluminum oxide. SC blasts at pressures up to 90 psi and has an approximate life of 9-12 times thru the blast system. Typical Silicon Carbide blasting applications Sizing same as aluminum oxide

Blasting hard metals Glass etching Ceramic recast removal Very tough scale removal Heavy prole and metal preparation Before brazing and weld applications requiring no aluminum oxide contamination

BLASTING TECHNICAL INFORMATION

Glass Beads and Glass Grit Glass bead is a round glass used in peening and surface nishing on tight tolerance machined surfaces. Glass Beads create a bright matte surface nish with no surface contamination or damage. As a round particle beads are very slow on removal of paint, rust, or scale. Glass grit is the angular counterpart of glass beads. Glass grit is very aggressive on a blasted surface. Glass beads are blasted at pressures between 40-80 psi. Glass bead media life cycles are 9 - 12 times thru the blast system. Typical Glass Bead blasting applications: Light deburring Grit Size Conversion Chart for Glass Beads surface cleaning Mil-G-9954A Average Inches Average Micron US Screen Size Peening #3 .0283 725 20-30 mesh Blending machine marks #4 .0187 512 30-40 mesh Removal of welding discolor #5 .0139 363 40-50 mesh Blasting tight tolerance parts #6 .0105 256 50-70 mesh Produces a bright matte nish #7 .0084 215 60-80 mesh Pre Anodize nishing. #8 .0071 181 70-100 mesh #9 .0060 153 80-120 mesh #10 .0047 120 100-170 mesh # 11 .0039 100 120-200 mesh # 12 .0033 85 140-230 mesh # 13 .0026 68 170-325 mesh

Ceramic Blast Media Ceramic Beads are spherical shaped media with high mechanical strength and high wear rates. Ceramic is impact resistance creating very little dust. The ceramic beads keeps its round consistency and is chemically inert. Ceramic blast processes produce a smooth bright satin nish. The ceramic beads density creates higher impact speed making it a good choice for deburring and peening. Blast pressure recommendations are between 40-65 psi with media cycle lives between 70-90 times thru the blast system. Ceramic blast media is very versatile and can be blasted with all delivery systems,( air, wheel and water) Ceramic beads is a standard peening material for titanium parts. Ceramic grit is angular and is excellent for etching parts with extended media life.

BLASTING TECHNICAL INFORMATION

Typical Ceramic Media blasting applications Peening Titanium Non contamination High impact for deburring Long media life applications Bright surface nish requirements Aircraft and medical parts

Stainless Steel Blast Media is available in both shot (cut wire conditioned and casted) and grit. Stainless media is available in 302-304 and 316 alloys. Stainless is a softer but heavier media that is a good choice for short blasting times, deburring, and rust free surfaces. It produces a brighter nish with reduced blast machine wear rates. Stainless shot obtains some the highest media recovery rates of up to 150-200 cycles through the blast system. Blasting pressure can be as high as 90 PSI. Typical Stainless Steel blasting applications: Blast cleaning, de-burring, surface renement, surface nishing All types of aluminum castings and forgings Zinc pressure die castings Non-ferrous metals and special alloys Stainless steel castings and forgings Stainless steel equipment fabrication Granite and stone industry

Steel Shot and Grit Media Steel blast media is produced in round/spherical shape (conditioned cut wire and cast shot) and angular steel grit. Steel abrasives are very durable making it the rst choice in blast rooms and automated wheel applications. The hardness ranges between 40 to 65 Rockwell. Conditioned cut wire (rounded) is the primary choice for shot peening over cast shot that produces an unfavorable angular breakdown while blasting. Steel shot and grit is very often mixed to achieve both anchor patterns with good nishes. Steel shot can be blasted with very high pressures of up to 110 PSI. Media cycle lives are between 80-100 times through the blast cycle.

BLASTING TECHNICAL INFORMATION

Steel shot and grit blasting applications: Blast Rooms for long media life Wheel blasting for long media life Paint prep on steel parts Deburring Scale and rust removal Aluminum Casting and weldment blasting Pipe blasting (ID & OD)

SHOT & GRIT SIZING

Steel Shot
S390 All Pass No. 12 Screen 5% Max on #14 Screen 85% Min on #18 Screen 96% Min on #20 Screen S330 All Pass No. 12 Screen 5% Max on #14 Screen 85% Min on #18 Screen 96% Min on #20 Screen S280 All Pass No. 16 Screen 5% Max on #18 Screen 85% Min on #25 Screen 96% Min on #30 Screen S230 All Pass on #18 Screen 10% Max on #20 Screen 85% Min on #30 Screen 97% Min on #35 Screen S170 All Pass on #20 Screen 10% Max on #25 Screen 85% Min on #40 Screen 97% Min on #45 Screen S110 All Pass on #30 Screen 10% Max on #35 Screen 80% Min on #50 Screen 90% Min on #80 Screen .0661 - 1.70 .0555 - 1.40 .0394 - 1.00 .0331 - 0.850 .0555 - 1.40 .0469 - 1.18 .0331 - 0.85 .0278 - 0.710 .0469 - 1.18 .0394 - 1.00 .0278 - 0.710 .0234 - 0.600 .0394 - 1.00 .0331 - 0.850 .0234 - 0.600 .0197 - 0.500 .0331 - 0.850 .0278 - 0.710 .0165 - 0.425 .0139 - 0.355 .0234 - 0.600 .0197 - 0.500 .0117 - 0.300 .0070 - 0.180

Steel Grit
G25 All Pass on # 16 Screen .0469 - 1.18 70% Max on # 25 screen .0278 - 0.710 80% Min on # 40 screen .0165 - 0.425

G40 All Pass on # 18 Screen .0394 - 1.00 70% Max on # 25 Screen .0165 - 0.425 80% Min on # 40 screen .0117 - 0.300

G50 All Pass on # 25 Screen .0278 - 0.710 65% Max on # 50 Screen .0017 - 0.300 70% Max on # 80 Screen .0070 - 0.180

G80

All Pass on # 50 Screen .0165 0.0425 60% Max on # 80 Screen .0070 - 0.180 75% Min on # 120 Screen .0049 - 0.125

G120 All Pass on # 50 Screen .01117 - 0.300 60% Max on # 120 Screen .0049 - 0.125 70% Min on # 200 Screen .0029 - 0.075

BLASTING TECHNICAL INFORMATION

MEDIA OVERVIEW:

BLASTING TECHNICAL INFORMATION

RECOVERABLE MEDIA LIFE CYCLES

Media Life Cycles Silica sand Garnet Plastic Media Glass Bead Silicon carbide Aluminum oxide Ceramic media Steel shot, grit Stainless shot, grit 1 3-5 7-9 9-12 9-10 10-12 70-90 80-100 150-225

% Breakdown 100% 25% 13% 10% 11% 9% 1.2% 1% 0.5%

RECOVERABLE MEDIA COSTING Costing

Media Cost Per Hour Hourly Delivery Rate x % Breakdown x Cost per Lb Media Cost to Blast a part Hourly Delivery Rate x % Breakdown x Cost per Lb x Part cycle time (% of Hour)

Other factors in total blasting cost include; air compressors, labor, blast system costs and media disposal fee. If blasting heavy metals use a highly recyclable media.

BLASTING TECHNICAL INFORMATION

OVERVIEW: OF BLAST FINISHING EQUIPMENT AND ABRASIVE MEDIAS

EQUIPMENT Air Blasting" " Blast cabinets" " " " " " " " " " " " " " " " " " " " " " " " "

ABRASIVE MEDIAS Spherical Glass beads Ceramic beads Steel shot Stainless shot Angular Aluminum oxide Ceramic grit Glass grit Plastic stripping media

Automated cabinets" Blast rooms" "

Portable pressure pots" " ID-OD pipe blasters" Basket blasters" " " " " " "

In line conveyors" " Wheel Blasters" "

Spinner hangers " "

BLASTING TECHNICAL INFORMATION

OVERVIEW OF BLAST FINISHING EQUIPMENT AND MEDIA CONTINUED EQUIPMENT Wheel blasters Table blasters Conveyor blasters Basket blasters Wet Blasting Cabinets Automated systems Basket blasters Specialty equipment Soda blasting Dry ice blasters ABRASIVE MEDIAS Angular Steel grit Stainless steel grit Silicon carbide