INDUSTRIAL CLEANING

Almost all workpieces must be cleaned one or more times during their manufacturing sequence. Processes used
to clean the work surfaces include:
 Chemical cleaning methods - use chemicals to remove unwanted contaminants from the work surface
 Mechanical cleaning methods - involves removal of contaminants by various mechanical operations

Reasons Why Parts Must be cleaned

 Prepare surface for subsequent processing, such as a coating application or adhesive bonding
 Improve hygienic conditions for workers and customers
 Remove contaminants that might chemically react with the surface
 Enhance appearance and performance of the product

Chemical Cleaning methods

 Alkaline cleaning
 Emulsion cleaning
 Solvent cleaning
 Acid cleaning
 Ultrasonic cleaning etc.

Mechanical Cleaning methods

This involves physical removal of soils, scales or films from the work surface by abrasives or similar mechanical
action. Often it serves other functions also, such as deburring, improving surface finish, and surface hardening.
Mechanical cleaning methods include:
 Blast finishing
 Shot peening
 Mass finishing processes etc.

BLAST FINISHING,
Blast finishing/Abrasive blasting also known as grit blasting or sandblasting can be defined as a process of
cleaning and finishing of surfaces of materials by forcefully directing an abrasive media applied either dry or wet
(suspended in a liquid medium) against the surface of a workpiece. In this method of finishing, high velocity
impact of particulate media is used to clean and finish a surface where media is propelled at the target surface
using pressurized air or centrifugal force. Most well-known method of blast finishing is the sand blasting, which
uses grits of sand as blasting media. Other blasting media include hard abrasives such as Aluminum oxide (Al2O3)
and Silicon carbide (SiC) and soft media such as nylon beads etc.
The process of abrasive blasting began in 1904. Blasting is used for finishing, cleaning, coating removal, surface
preparation, and surface treatment. It is faster than competitive processes of pickling, electrochemical cleaning or
hand finishing and thus reduces time required. Some common applications of this versatile process are:
 As finishing process: It can be used to add matte or satin finish, frost, decorate, remove glare, blend tooling
marks and imperfections, hone and burnish and mark identifications.
 As cleaning and removal process: It can be used to remove/clean rust/oxidation, coatings, paint,
sealants/adhesives, carbon deposits, excess brazing, casting medium, flash and burrs.
 As surface preparation process: It can be used to etch for bonding and adhesion of subsequent coatings,
expose flaws for inspection, and remove hard cast surfaces for subsequent machining.
 As surface treatment process: It can be used to shot peen for increased fatigue resistance, strengthen,
increase wear properties, improve lubrication, reduce design weights, reduce susceptibility to corrosion,
seal porous surfaces, and correct distortion.

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Industries using abrasive blasting
Abrasive blasting is utilized for many different purposes by foundries, shipyards, steel fabrication plants, special
purpose job and machine shops, gas transmission stations, steel mills, structural steel supply yards, building
cleaners, wineries, breweries, canneries, rubber manufacturers, painting contractors, plastic manufacturers,
welders, wood shops and furniture manufacturers, plating and anodizing shops, aircraft manufacturers, electronic
manufacturers, petrochemical companies, memorial monument markers and many others.

METHODS OF BLASTING
Methods of applying abrasive materials can be segregated into two distinct types:
 Dry blasting and
 Wet blasting (slurry blasting)

DRY BLASTING
There are two methods used for dry-blast cleaning. The most popular is compressed air.
 Air pressure blasting.
 Mechanical blasting

Air Pressure Blasting

Air pressure blasting uses compressed air to apply abrasive to a surface. Air pressure blasting uses either a direct
pressure or a suction (siphon) method that may use either the siphon or gravity method.

o Direct Pressure Method: In direct air pressure blasting, the abrasive is fed from a pressurized container
(pressure vessel) into a blast hose, as shown in Figure 1. The compressed air line is piped to both the blast
hose and upper portion of the pressure vessel. Air pressure (usually 80 to 90 psi) to both the hose and
pressure vessel are equal thus permitting the free fall of the abrasive through an aperture (feed point) at
the bottom of the pressure vessel. As the abrasive falls through it is picked up by the compressed air and
conveyed to the point of operation. In order to maintain air pressure, a valve is fitted at the filling point of
the machine and held tightly closed by the air pressure. Direct air pressure blast cleaning machines can be
used separately as portable units for site work or they can be built into cabinets or blast rooms.

o Suction (Siphon) Method: Suction (siphon) systems shown in Figure 1work on the principle that air
passing over an orifice will create a vacuum. This action takes place in the hand-held suction gun, with a
media hose connected from the vacuum area to a media storage hopper. Compressed air is piped into the
back of the gun and causes the lifted media to be blown out of a nozzle on the front of the gun. Energy is
expended indirectly to lift the media and then mix it with the compressed air, making suction less efficient
than a pressure system. These systems are selected for light to medium amounts of production and
moderate budgets. Suction is not as efficient as pressure, so the range of applications is more limited, but
it often yields comparable results. Suction systems have the ability to blast continuously without stopping
for media refills. They are also simpler to use and have fewer wear parts, making them inexpensive and
easy to maintain.

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 Figure 1: Suction (siphon) and pressure blasting systems

Mechanical Blasting:
In this method, the abrasive flows from a hopper by gravity to a feed funnel. A valve meters the abrasive flow to
an impeller. The impeller imparts centrifugal velocity to the abrasive which is the directed onto the workpiece
surface. Abrasive velocity of approximately 250 feet per second are used and volume of abrasive are such that
mechanical systems provide a high level of work capacity per unit time. Mechanical (centrifugal) blasting
equipment are used for medium to high production applications. The equipment often are used to descale cast
products, debur transmission parts and to clean automotive crankshafts, axle shafts, engine blocks and rear axle
housings. Mechanical blasting mostly uses cabinet-type blasting equipment. It is available in either in batch, semi-
automatic or automatic versions. Typically, the cabinet houses one or more blast wheels which directs the abrasive
on the workpiece surface by centrifugal force.

Figure 2: Mechanical (Centrifugal) Blasting system

Figure 2 shows a mechanical (centrifugal type) blasting system. Abrasive (A) is fed through opening onto an
impeller (B) and then passes through a stationery control cage (C) which immediately makes the abrasive to be
picked up by a rotary blade (D). The rotary blade/ wheel (D) is the abrasive throwing device which propels the
abrasive (blast) onto the workpiece surface.

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WET BLASTING
Wet blasting involves the propulsion of a slurry onto a workpiece surface. The slurry normally consists of fine
abrasive suspended in chemically treated water. It is kept usually in continuous agitation to prevent settling of the
abrasive. The slurry can be propelled against the workpiece surface by anyone of following three methods:
1. By a stream of compressed air which raises the slurry through a siphoning action and then projects it
through a suitably designed nozzle.
2. By means of compressed air which propels a gravity-fed slurry to a gun.
3. By use of a high-pressure centrifugal pump which produces the required speed of projection for the slurry.
Most wet blast equipment are of the cabinet-mounted type which are modified with auxiliary strippers, take-off
conveyors and wash-rinse dry stations.
Industries use several variations of wet abrasive methods for special purposes. Some of the methods have resulted
in new wet blasting process such as:
o Hydro-blast process: Sand is mixed with water and propelled by water pressure.
o Vapor-blast process: Abrasive is suspended in a liquid projected at high velocity by a jet of compressed
air.

Figure 3: Wet abrasive blasting system

Figure 4: Typical water-injected wet abrasive blasting nozzle

BLASTING EQUIPMENT
There are five types of abrasive blast cleaning systems commonly used, they are:
o Portable blast cleaning machines
o Hand-operated units in blast cleaning rooms
o Hand-operated cabinet-type blast cleaning machines
o Automatic blast cleaning machines and
o Wet-blast cleaning machines.
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Portable Blast Cleaning Machines
Portable blast cleaning machines generally consist of a high-volume air supply (usually in the 90 to 100 psi range),
a container or pressure vessel to contain the abrasive, a metering device to control air-to -abrasive ratio and flow,
a flexible hose to deliver the abrasive and a hand-held nozzle to aim the abrasive onto the workpiece surface.
Some of the portable units may have hopper-fed storage tanks which enable multiple blasting operations from a
single source of supply. Portable units can be operated either manually or automatically. Manual types generally
require a "pot" attendant who manually controls abrasive flow per instructions of the nozzle operator. Automatic
machines have controls which start and stop operations by use of a flow control valve or a "deadman" switch on
the nozzle. When the operator closes the valve, the machine starts and the air and abrasive mixture is ejected from
the nozzle. When the operator releases the flow control valve, the abrasive discharge stops and the machine
depressurizes.

Figure 5: Portable blast cleaning machines

Hand-operated cabinet-type blast cleaning machines

Blast cabinets are self-contained units where the user is isolated from the process for safety. Cabinet enclosures
are used for manual systems where an operator accesses the part through rubber gloves. Example of hand-operated
cabinet-type blast cleaning systems is shown Figure 6:

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 Figure 6: Hand-operated cabinet-type blast cleaning systems

BLASTING MEDIA
The media used in blasting varies greatly in material, size, and shape. Dry blasting employs abrasive and non-
abrasive particles of 12 to 300 gauge mesh while wet blasting particles vary from 60 to 5,000 gauge mesh. When
considering different media, the following factors should be considered:
o Suitability for the purpose-density, shape, hardness
o Working speed
o Reusability, breakdown percentage
o Dust levels generated by broken media
o Probability of surface removal for close tolerance parts
o Possibility and consequences of substrate contamination
o Equipment modifications
o Disposal

Types of media

 Glass bead: is one of the most common medium and is often used as an all-purpose media for general
cleaning and finishing, including contaminant, coating or burr removal; honing, blending and peening.

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 Glass beads are non-contaminating, leave dimensions unchanged and are available in the widest variety
of sizes.
 Steel shot is another commonly used media. It is a solid, round particle that causes a peening action and
produces a dimpled surface. Steel shot has a relatively high mass, which gives this media greater impact
and a hammering action.
 Steel grit is an angular product that acts like thousands of tiny chisels. Steel grit cleans quickly and
efficiently and produces an excellent surface to which almost any new coating can adhere.
 Aluminum oxide is widely used as a cutting media. This substance can produce an anchor pattern in
preparation for a new coating. It can also remove heavy foreign matter, deburr, frost or decorate glass and
letters on stone. Aluminum oxide is economical because it can be used over and over again. It is classified
in various sizes for a wide selection of finishes.
 Silicon carbide is similar to aluminum oxide, but is especially useful for cleaning very hard surfaces, such
as tungsten carbide. Silicon carbide is a sharp media that is extremely fast cutting.
 Garnet is manufactured from the natural mineral. It, too, is hard and fast cutting. It is used to remove
heavy material such as rust and weld scale and leaves a uniform anchor pattern.
 Plastic media are relatively soft and gentle. They are most often used for paint removal from delicate
substrates such as aircraft, fiberglass and automobiles. Plastic media are also used to deflash molded burrs
and for cleaning precision molds, dies, electronic connectors, and circuit boards. They can deburr soft
materials such as aluminum.
 Agricultural media, such as walnut or pecan shells and com cob, are soft enough to remove foreign matter
without etching, scratching, or marring the cleaned areas. They find use cleaning molds, electric motors,
and windings. Two newer media are wheat starch and sodium bicarbonate (baking soda). Wheat starch
can replace plastic for paint removal. Sodium bicarbonate is a water-soluble medium that is convenient
for cleaning contaminated surfaces as well as for stripping paint. Sodium bicarbonate requires a flow agent
to work reliably, and the large volume of dust generated must be suppressed. Both are soft, low-aggression
media that are unlikely to damage parts.
 Sand has lost favour to longer life, less dusty, and more versatile media. Silica sand dust has also been
found to cause health problems such as silicosis. Alternative media should be explored for anyone still
using sand abrasive.

Blast Media Shapes

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Variables (Blasting Parameters) affecting blasting process
Important blasting parameters are
 Blast media type
 Size of media
 Nozzle and hose size
 Blast pressure
 Distance the nozzle is held from the work piece
 Angle of blast stream in relation to the work piece
 Operator experience

Each blasting operation requires careful calibration of these parameters to ensure maximum efficiency without
damaging surfaces or parts. Typically, harder surfaces with tougher coatings will use aggressive media at higher
pressure, while more delicate surfaces will require softer media at lower pressure. Nozzle distances vary from 1-
4 feet depending on surface, coating and media.