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Selecting Abrasives for Welding and Metal Fabrication
Selecting abrasives that make the grade
It is important to realize that abrasive products come in various grades, which some manufacturers designate as good, better and best. Metal fabricators who measure total grinding results and want to achieve the lowest overall grinding cost for an application will seriously consider the “best” abrasive products available and reserve the use of “better” abrasives for high productivity applications, where only abrasive costs are important. End users wanting the lowest initial abrasive costs are likely to select “good” abrasives, but should understand that such a choice may not be as economical in the long run.
Metalworking companies that want to measure total grinding results can work with their abrasive supplier to test and compare abrasives of various grades, or alternative products from different manufacturers. Such tests, performed in a metalworker’s own shop, will reveal relative abrasive cost based on initial cost and wear rate, and can even measure overall worker productivity in terms of worker’s wages. Then, relative abrasive cost can be added to the operator cost to determine the total grinding cost. What such tests typically show is that the most advanced (“best”) abrasive products usually last longer, work faster and may be the most cost-effective choice.
Abrasives Selection Guide
The following are abrasive selection guidelines for typical welding and metal fabrication operations. Products are listed in descending order of 1) best, 2) better and 3) good for the applications referenced:
|
APPLICATION |
ABRASIVE PRODUCTS |
FORMULATIONS |
|
Grinding down metals: |
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|
Cut-off applications: · Cutting sheet metal · Cutting, notching pipe |
Cut-off wheels |
1. Ceramic alumina and zirconia alumina blend for Stainless and carbon steels, other ferrous and exotic metals 2. Zirconia alumina for stainless and carbon steel sand other non-ferrous metals 3. Aluminum oxide blend for carbon steels |
|
Grinding: · All weld grinding · Pipe notching, beveling · Heavy stock removal |
Depressed center grinding wheels (24 or 36grit) |
1. Ceramic alumina and zirconia alumina blend for Stainless steel and other ferrous metals 2. Mix of zirconia alumina and premium aluminum oxide grains for metals ranging from alloys and stainless steel to gray iron and non-ferrous metals 3. Aluminum oxide for ferrous metals, aluminum and other soft metals |
|
APPLICATION |
ABRASIVE PRODUCTS |
FORMULATIONS |
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Grinding down metals (continued): |
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|
Blending: · Blending welds · Medium to light stock removal |
Coated abrasive flap discs (36 or 40 to 80grit) |
a) Ceramic alumina for stainless steel and other ferrous metals b) Ceramic alumina and zirconia blend for low pressure grinding of ferrous metals 2. Zirconia alumina for ferrous and non-ferrous metals 3. Aluminum oxide for ferrous metals |
|
· Blending welds · Metal fabrication |
Fiber discs (24or36to80grit) |
1a) ceramic alumina for difficult-to-grind materials, Including super alloy sand hardened steel 1b) Zirconia alumina for fast stock removal and rough cutting applications 2. Aluminum oxide blending disc fora consistent finish 3. Aluminum oxide for general purpose applications |
|
· Dimensioning and shaping · Heavy stock removal |
Coated abrasive cloth belts (for bench stand grinders) |
1) Ceramic alumina for hard-to-grind alloys 2) Zirconia alumina blend for exotic and heat-sensitive metals 2b) Zirconia alumina for stainless steel 3)Aluminum oxide for general use and maintenance / repair operations. |
|
Blending the surfaces: |
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· Deburring welds |
Coated abrasive flap discs (60 or 80grit) |
1. Ceramic alumina 2. Zirconia alumina blend 3. Aluminum oxide |
|
· Light deburring and finishing |
Resin fiber discs (80 to 120grit) |
1a) Ceramic alumina 1b) Zirconia alumina blend 2. Ceramic alumina and zirconia alumina blend 3. Aluminum oxide |
|
· Blending and leveling (contoursor flat surfaces) |
Non-woven deburring discs |
1. 1) Engineered alumina oxide 2. Aluminum oxide |
|
· Blending · Finishing · Polishing |
Non-woven deburring and finishing discs |
3. 1) Engineered alumina oxide 4. 2) Aluminum oxide |
|
· Blending welds · Deburring |
Fiber discs (60 to 120 grit for light deburring) |
1. Ceramic alumina for difficult-to-grind materials 2. Aluminum oxide disc fora consistent finish 3. Aluminum oxide for general purpose applications |
|
· Surface preparation · Blending welds
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