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Tips And Tools For Cutting, Grinding, And Finishing Aluminum
Aluminum is used for decades in shipbuilding. But, it is becoming increasingly utilized in metal fabrication due to its superior strength-to-weight ratio as well as corrosion resistance. Since 2005, demand for the material has increased at a higher rate than other metals or alloy primarily because of its increased popularity in additional market segments, such as the manufacturing of trailers, structural framing and repair as well as ladders and service decks, and platforms construction. Ford's most popular truck, F150, switched to aluminum as its body material.

Aluminum has many advantages, but it can also present challenges. Aluminum has a lower melting point than other metals, which makes it difficult to cut, grind, and finish efficiently. asking2expert.com is quickly melted by friction and heat. This results in it sticking to the abrasive and make it higher than the cutting grains. The wheel ceases to function when the material becomes blocked or loaded. Other issues that may be encountered while working with aluminum include contamination as well as the possibility of porosity, oxide inclusions, as well as reaching the desired results.

When abrasive chemicals and contaminants are removed from the wheel, they may cause porosity. This can compromise the structure of the weld. It is critical to remove contaminants on the surface prior to welding, including grease, oil, dirt or paint. Also, only use the highest quality, contaminate-free abrasives for surface preparation and inter-pass grinding.

Oxide inclusions can occur when the aluminum oxide layer is not removed correctly. To ensure that weld strength as well as fatigue resistance and overall weld strength it is crucial to remove the thin transparent layer of aluminum oxide. A stainless steel brush specifically designed for the job works well.

Finish can be a problem when working aluminum because the material is susceptible to being damaged by excessively aggressive methods.

A Better Option To Cut And Grind, Then Finish, Aluminum
The goal when choosing the best product for cutting grinding, and finishing aluminum is to have the right wheel or disc that meets the demands of the post-weld and pre-weld process. Shops can improve quality as well as safety and efficiency by choosing the right product. This can reduce downtime and lower labor costs. A type 27 grinding wheel with no load is an option for cutting and/or grinding aluminum. These wheels feature grain blends designed for consistency in performance, and have a non-contaminant-free bond. These high-quality, aluminum-specific products are designed to cut smoothly and minimize burr creation. They also greatly reduce noise and vibration through the cut, and are therefore more manageable. You can choose to use the wheels for either grinding or cutting or both.

Resin fiber discs (RFDs) designated for aluminum are an excellent choice for grinding, mixing and finishing. RFDs have the backing pad made of rubber. This provides consistent, flat contact with the material making them easy to blend and control. To minimize the buildup of heat when grinding, the most effective discs have been pre-treated or coated in a oil-based lubricant. This stops the aluminum from melting, and will allow for faster cutting speeds. It also prolongs the product's life. Another alternative to discs made from resin fiber to be used for grinding, blending and finishing are treated or top-coated flap discs. They are available in a range of grain types but they aren't as well-known in the industry since they are more pliable and require a more skilled set to gain the desired surface finish. They can be used to finish and grind in one go, which means there are no switching between the Type 27 or resin fiber wheel.

Aluminum can be damaged easily, so some welders use non-woven handpads and 0000 steel wool. This lets them finish the job by hand and minimize any potential damage. Wheels and discs made of non-woven material will cut down on time spent the manual process of finishing. Non-woven discs and wheels are ideal for decorative finishing such as antique, satin, finals sanding and removal of fine burrs. Brushes for cleaning power can aid in completing the task quickly , without putting too much pressure that could damage the aluminum.

Final Thoughts
Aluminum can be a hassle when working with high pressure and temperatures. It is essential to choose high quality, contaminate-free products and let the wheel perform the job. The use of pressure to boost performance is only going to cause further frustration and can compromise the quality. A properly prepared surface is crucial for a solid and reliable weld. The better the condition of the seam welded, the more efficient the weld penetration. Use aluminum-specific products for optimal results.
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