Surface preparation

1- Cleaning of surface.

2- Roughness of surface.

Dry abrasive blast cleaning :( open blast -

clean).

Abrasive type: expendable (consumable)

(nonmetallic sand ,garnet, copper slag, coal slag)

Characteristics: 4main

1-Shape: grit or shot

-size: grain size

-Density: when density of abrasive increases the efficiency increases.

-hardness: must be harder than the steel

Abrasive type: metallic, nonmetallic, by product (organic)

Metallic: chilled iron, metallic grit , metallic shot

Standards used to determine the size of abrasive :BS 410 ,BS 7079 PT E

Grit and shot mix percent (70-80% shot ) (20-30 % grit)

Roughness range: 30-75 micron

Profile name: peak to trough , surface profile , roughness , amplitude high, anchor pattern
&key.

Adhesion theory: 2 principles

1-molecular interference (physical) velecro.

2-molecular attraction (chemical) magnet.

Grit blasting problems:

1-hackle: steel stands up like needle (13mm)

2-rougue peaks: roughness higher than the proper roughness than proper roughness (30-75)
causing rash rust (rust spot) when exposed to humidity due to concentrating blasting at this
surface.

3-lamination (sliver): lip cutting in steel needs reporting to Engineer for ultra-sonic check.

-compressor pressure at the nozzle 100 psi (7 bar)

-air capacity: nozzle size 1/4 '' =103 cfm

1/2 ''=413cfm
-100%effeciency when P=100 psi

-each drop in pressure by 1 psi =1.5 % efficiency

- 80 psi = 70% efficiency.

Hoses: carbon impregnated to reduce static shock

Hose size to nozzle size

3-4times: 1time 1.25''=34mm 1/4''=6.5mm

Nozzles: shall be lined with tungsten carbide to avoid abrasion

-velocity of abrasive to venture nozzle: 450mph

- …………………………………straight bore: 200 mph.

Measuring profile and assessment:

Nacked eye - visual aid -tactile.

For measuring profile:

1-replica tape + dial micrometer

-replica tape coarse type : 0.8 mil to 2mil (20 μm-50 μm)

X-coarse : 1.5 mil to 4.5 mil (37 μm -115 μm)

Surface profile needle gauge

1 thou=25.4 inch, 1mm=1000 micron

Surface comparator:

We are using surface comparator to asses surface profile.

Grade of assessment

Fine (seg1 to seg 2) , medium (seg2 to seg 3) , coarse ( seg3 to seg 4)

Finer than fine: below seg 1

Coarser than coarse : higher than seg 4.

Wheelaberator : close blasting unit depend on wheel used metallic shot or mix, the velocity of
abrasive 220 mph.

Make recycling for abrasive (metallic shot) by air stream and centrifugal forces. (air washing system)

Air wash: abrasive recycling in wheelabrator .

Over open blasting: operator safety, recycling abrasive and economic method.
- Good use of abrasive, high production rate, low cost.

- Abrasive can be used till 20 times.

Disadvantage of wheelaberator:

-high price of abrasive

-cannot reach narrow area.

-need flat surface, suitable size with machine.

Knock out pots, vapor traps, humidity and oil filters to absorb H2O, oils from compressed air
–dead man handle : pot remote, in order to stop and open the blasting pot from it from
a distance equal to hose length.

- ISO 8501 OR BS7079 part A or SS 05 5900

- 14 photo for blasting: 3 SA1, 3SA2, 4SA2.5, 4 SA3

- 6 Photo for power tool: 3 ST2, 3ST3.

- 4 ………………..RUST GRADE: A, B, C, and D.

- 4 ……………….FLAME CLEANIING: AFL, BFL , CFL , DFL.

Total photo in standard: 28photo for grit blasting

Sa 1 Light blast cleaning

Sa2 Through blasting cleaning
Sa2.5 Very through blasting cleaning
Sa 3 Clean to visually clean steel

Rust grade A Filled with millscale and little rust

Rust grade B Millscale percent 30-60% and a lot of rust and millscale start to flake
Rust grade C No millscale a lot of rust and pitting start to appear
Rust grade D Completely rust and a lot of pitting

St2: through hand and power tool cleaning

St3: very through hand and power tool cleaning

Water blasting:

1-high pressure water jetting: 30000 psi

2-………………………………………..+ abrasive: 20000psi

3- Low…………………………………………………..:100psi

4-air blasting with water injection

5-steam cleaning

Advantage:

1-remove chemical (hygroscopic salts)

2-environmental friendly

3-low cost

4-used with toxic material removal

5-remove oil and grease

6-no spark

7-no dust or silica.

Disadvantage:

1-operator fatigue

2-no cuuting profile

3-using huge amount of water

4-using inhibitors

5-using surface tolerant paint specially

6 -formation of flash rust.

Flame cleaning:

1-expansion

2-dehydration: removing H2O

3-Heat penetration: opening steel surface and good wetting for paint, no need for thinner.

Pickling: duplex footner process

1-remove oil and grease

2-pickling using H2SO4(Sulphuric acid) 5-10% concentration ,5-25min. ,65-70º c temp.

3-rinsing by warm water.

4-passivation: using chromic or phosphoric acid 2%, 2min, 80 c temp.

5-rinsing with water till PH range 4.5-7.

6- PH indicator strops: 0-7 acid ,(7-14 alkaline), (7neutral).

Power tool:

1-ordinary disc. 2-copper brush.

3-jason hammer 4- needle gun(very rough surface)

Hand tool :

1-emery paper 2-emery clothes

3-hammers 4-brush 5-knifes 6- scrapers 7-wire brush.

-Jason hammer , needle gun: Type of power tools cause high roughness more than 100 micron

If high roughness takes place: grinding shall be done to minimize roughness, or sand abrading.

Burnishing : take place only if we reach till ST3 and it means no roughness.

-not take place with ST2