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Abstract
The coatings industry is very familiar with shot/grit blasting as a mechanical
means of surface preparation. Over the years, operators have worked with manual and
automatic blast equipment with its associated dust collection arrangements. As with every
manufacturing process, operating costs are very critical in this highly competitive
industry. Therefore, coaters are always on the lookout for ways to tune their process and
increase productivity.
Fortunately, blast industry professionals are also exposed to an allied process
called shot peening which promises to elevate blast cleaning to a more productive level.
Shot peening is a technique to strengthen production parts that relies on process
control. Application of these controls can greatly benefit the blast cleaning process.
Proper media selection and effective equipment operation and maintenance within
identified parameters can reduce costs and increase productivity. Though the pace of
process development and standardization has been relatively slower than more
sophisticated, computer controlled production machinery the future in this industry is
exciting and encouraging.
This discussion will also include green manufacturing and how it is more than just
a social cause for this mechanical surface preparation technique.
diameter wheel, 20 HP motor). Centrifugal wheels are generally limited to ferrous blast
media, whereas blast nozzles can propel both ferrous and non-ferrous media. Centrifugal
blast wheels are either direct driven or belt driven through a bearing system. The
resulting line speed of the associated blast machine is directly proportional to the total
connected wheel horsepower.
SSPC: The Society for Protective Coatings identifies five initial rust conditions
before surface preparation. This covers the range from plain mill scale to rust and pitted
conditions. These are identified as Condition A, B, C, D and G (images available in the
SSPC-VIS 1)
The most common initial conditions of steel are Condition A and B. The resultant
expectation of surface finish is traditionally SSPC-SP 10 / Sa 2-1/2 / NACE 2 or NearWhite Blast Cleaning.
Cleaning Process Parameters
The purpose of cleaning is to remove rust, scale, sand or any such contaminant
from the surface of a metallic part. Blast cleaning may also impart a profile on the surface
to facilitate a downstream coating process such as painting or galvanizing. Given its
reach, its not uncommon for a metallic component to have been processed in a blast
machine atleast once during its manufacturing process.
The above described methods to evaluate cleaning quality and cleaning results are
largely visual. If a particular anchor profile or etch is desired on a part, the roughness
becomes a parameter to check using a profilometer. In certain cases, in order to remove
the element of subjectivity, a copper sulphate test is performed to determine whether a
part is properly descaled or not.
Blast cleaning doesnt involve monitoring of media velocity, size or shape. In
fact, for certain cleaning applications, it is advantageous to have an operating mix of blast
media in the machine. This might also include a mixture of spherical shot and angular
grit. Lets discuss peening and compare it to cleaning with relation to process variables
and determine if we can benefit from the quality of results.
Shot Peening:
Peening is a process that induces
compressive stress into the surface of the component.
Induced compressive stresses counter the tensile or
working stresses during the components work life,
neutralizing the detrimental effect and preventing
failure.
2
When peening, the shot peener is required to achieve a particular Almen intensity
(measured by deflection on a representative strip of spring steel), based on demonstrating
saturation and 100% or higher visual coverage. This intensity directly translates to a
particular value of compressive stress that the component designer has specified to be a
requirement. In all cases, the size of blast media, i.e. steel shot, conditioned cut wire,
glass bead and ceramic is also dictated by the specification.
Both centrifugal wheels and compressed air nozzles are used for shot peening.
Consider the following to determine your choice:
Peening
Media velocity
No monitoring, as long as
equal to or greater than a
critical value (usually 240
feet per second)
Measurement and
monitoring critical as it
affects part quality / life
Media size
Consistency critical
Media shape
Semi-critical
Measurement of results
Visual only
Mix
Waste
To
hopper
Stand-off
Distance
Arc
height
Ra Micro
inches
Arc
height
Ra Micro
inches
Arc
height
Ra Micro
inches
0.011
85
0.0146
122.7
0.0153
135.5
0.0088
57.2
0.01205
109.1
0.0127
112.4
0.00755
57
0.01165
105.3
0.0111
88
0.0064
56.1
0.0116
102
0.0107
84.5
0.0064
54.1
0.0109
99.3
0.01065
11
Effect of stand-off distance on impact energy / peening intensity
85
As seen in the tabulated data above, particularly at results at 40 PSI, the exponential drop
in intensity at the start, when stand-off distance is gradually increased. It continues to be
steady following that, until the part is almost 11 from the nozzle. This information is
useful in determining the capacity of a particular abrasive to impart energy, at different
distances from the part. This information helps in positioning the blast nozzles in an
automated blast machine and optimizing coverage with the distance from the part.