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F.A.Q

WHAT IS SAND/SHOT/GRIT/ABRASIVE BLASTING?

THIS PROCESS IS ADOPTED FOR SURFACE PREPARATION PRIOR TO ANY COATING OR PAINTING OR METAL SPRAYS APPLICATION. THE BEST TECHNICAL WORD IS ABRASIVE BLASTING. IN FACT THERE IS SO MANY TYPES OF ABRASIVE AND EVERY ABRASIVE HAS ITS OWN QUALITY AND PERFORMANCE CHARACTERISTICS. SAND IS MOST COMMONLY USED ABRASIVE AND CHEAPER ALSO BUT ITS RECYCLING IS VERY LESS. THIS IS AN EXPANDABLE MEDIA AND BREAKS INTO VERY FINE PARTICLES AFTER STRIKING THE METALLIC SURFACE UNDER COMPRESSED AIR PRESSURE WHICH IS NORMALLY 6 BAR. IT IS GENERALLY BANNED DUE TO SILICOSIS DISEASE. SAND/SHOT/GRIT/COPPER SLAG ALL ARE A TYPE OF ABRASIVE. THERE ARE THREE BASIC PRINCIPLES OF ABRASIVE BLASTING WITH THE HELP OF COMPRESSED AIR. IN THIS PROCESS ANY TYPE OF ABRASIVE CAN BE USED.

1. PRESSURE BLASTING

IN THIS PROCESS ABRASIVE IS STORED IN A PRESSURE VESSEL/TANK. COMPRESSED AIR PUSHES THE ABRASIVE STORED IN TANK AND ANOTHER COMPRESSED AIR LINE IS FED AT BOTTOM OF TANK TO GIVE KINETIC ENREGY TO ABRASIVE PARTICLES. ABRASIVE AND AIR MIXTURE IS PASSED THRU THE BLASTING HOSE UNDER HIGH AIR PRESSURE SAY MAXIMUM 6 TO 6.5 BAR AIR PRESSURE AND FINALLY EJECTS THRU A VENTURI NOZZLE MADE OF TUNGSTEN CARBIDE AND OTHER HARD MATERIAL AND GIVES ACCELERATION TO ABRASIVE AIR MIXTURE. GENERALLY THIS PROCESS IS CARRIED OUT INSIDE AN ABRASIVE BLASTING CABINET OR IN OPEN PLACE SUITABALLY COVERED. OPERATORS PLACE THE NOZZLE OVER THE MATERIAL TO REMOVE ANY RUST / SCALE / DEPOSITS TO CLEAN THE SURFACE. THIS IS CALLED SURFACE PREPARATION. JOB IS FREE OF ANY FOREIGN SUBSTANCE AND VIRGIN METAL IS EXPOSED SUITABLE FOR FURTHER APPLICATION FOR PAINTING/COATING/METALLIZING.

2. SUCTION BLASTING

THIS IS ALMOST SAME PROCESS AS THAT OF PRESSURE BLASTING BUT IN SUCTION BLASTING THERE IS NO COMPRESSED AIR PRESSURE ON THE ABRASIVE. GENERALLY THIS PROCESS IS CARRIED OUT INSIDE A ABRASIVE BLASTING CABINET. ABRASIVE IS CONVEYED TO THE BLASTING GUN BY PARTIAL VACUUM CREATED INSIDE BLASTING GUN. ABRASIVE GETS MIXED WITH AIR INSIDE GUN CHAMBER AND EJECTS THRU THE BLASTING GUN. KINETIC ENERGY OF ABRASIVE PARTICLES ARE GENERALLY LOWER IN THIS PROCESS HNCE MOST COMMONLY USED FOR LIGHT REMOVAL OF SCALE AND CLEANING OTHER SOPHISTICATED PRODUCTS LIKE AUTOMOBILE PISTON, TURBO PARTS, ENGINE VALVES, SURGICAL EQUIPMENTS, STAINLESS STEEL PARTS AND MANY OTHER SIMILAR APPLICATION.

3. WET /VAPOUR BLASTING

THIS PROCESS IS USED FOR VERY FINE SCALE AND SMOOTH FINISH ON JOB. WATER IS USED AS LIQUID MEDIA. GENERALLY THIS PROCESS IS CARRIED OUT INSIDE A ABRASIVE BLASTING CABINET .COMMON ABRASIVE IS ALUMINIUM OXIDE, GLASS BEAD, UREA, MALAMINE. SUITABLE RATIO OF WATER AND ABRASIVE IS STORED IN ABRASIVE STORAGE TANK AND FOR CONTINUOUS AGITATION; COMPRESSED AIR IS INJECTED IN TO THE MIXTURE. ELSE ABRASIVE WILL GET SEDIMENTED AT BOTTOM. THIS MIXTURE IS CALLED ABRASIVE SLURRY. WITH SPECIAL POLYMER PUMP, IT IS BEING PUMPED INTO BLASTING GUN AND THERE IS SEPARATE CONNECTION IN BLASTING GUN FOR COMPRESSED AIR. THIS AIR ACCELERATES THE SLURRY MIXTURE AND AROUND 6 BAR AIR
PRESSURE THE MIXTURE EJECTS THRU BLASTING GUN AND THROWN ON THE JOB TO BE CLEANED. ALL SCALE AND DEPOSITS ARE REMOVED AND GIVES A VERY CLEAN AND SMOOTH SURFACE FINISH.

WHAT IS AIRLESS SHOT BLASTING?

IN THIS PROCESS ABRASIVE IS PROPELLED ON OBJECT BY CENTRIFUGAL FORCE AND NOT BY HELP OF COMPRESSED AIR. THRU FEED FUNNEL THE ABRASIVE MAINLY STEEL SHOTS AND CUT WIRE SHOTS ONLY ARE FED AT CENTER OF BLAST WHEEL AND IT ROTATES AT VERY HIGH SPEED SAY 2880 RPM OR LESS BY VARIABLE AC DRIVE AND SHOTS GETS DISCHARGED RADIALLY. VELOCITY OF SHOTS STRIKING THE JOB SURFACE IS IN THE TUNE OF 70 TO 80 METRES PER SECONDS. AT THIS HIGH IMPACT THE SURFACE OF THE JOB GETS TOTALLY CLEANED AND FREE OF ANY PREVIOUS COATING/PAINT ETC. NEARLY WHITE METAL FINISH IS ACHIEVED WITH SUITABLE ROUGHNESS ON JOB SURFACE. IT IS DESIRED FOR FURTHER APPLICATION AND PROCESS ON THE JOB.MAIN APPLICATION IS FOR CASTINGS, FORGINGS, AUTOMOBILE SECTOR, AVIATION INDUSTRY, ELECTRICAL TRANMISSION LINES FITTINGS ETC AND SIMILAR APPLICATION.

WHAT IS SHOT PEENING?

IT IS SIMILAR TO SHOT BLASTING EXCEPT AIR PRESSURE IS KEPT HIGH AT AROUND 8 TO 9 BAR AND SO AS BLAST WHEEL SPEED AT 2800 RPM. CONSTANT DISTANCE OF NOZZLE/WHEEL IS MAINTAINED, EVEN SHOTS ARE CLASSIFIED AT EVERY RECYCLING SO THAT EQUAL SIZES OF SHOTS ARE USED FOR THIS PURPOSE. FINE AND BROKEN SHOTS ARE REMOVED BY CLASSIFIER AND ONLY USED SHOTS ARE FED INTO THE BLAST WHEEL.
THIS PROCESS INDUCES COMPRESSIVE STRENGTH IN TO THE JOB AND INCREASE THE FLEXIBILITY OF THE JOB, MAINLY USED FOR HELICAL, COIL SPRING, HELICOPTER BLADES, GEARS, AUTOMOBILE AND AVIATION PARTS. SHOT PEENING INTENSITY IS MEASURED BY ALMEN GAUGE IN A, B AND C RANGE. IT CREATS A BOW EFFECT ON THE JOB AND IN COMMON LANGUAGE IT IS BOMBARDMENT OF ROUND STEEL SHOTS ON JOB AT CONSTANT VELOCITY AND CONSTANT DISTANCE DURING PROCESS.

WHAT IS ALUMINIUM OXIDE BLASTING?

THIS IS A TYPE OF ABRASIVE USED FOR BLASTING PURPOSE AND MAINLY USED IN COMPRESSED AIR OPERATED BLASTING ONLY.

WHAT IS GLASS BEAD BLASTING?

THIS IS A TYPE OF ABRASIVE USED FOR BLASTING PURPOSE AND MAINLY USED IN COMPRESSED AIR OPERATED BLASTING ONLY. MAINLY USED FOR ALUMINIUM, STAINLESS STEEL, BRASS COMPONENTS. AUTOMOBILE AND AVIATION APPLICATION IS MOST COMMON FOR THIS ABRASIVE.

WHY Process Control & System?

STRICT QUALITY CONTROL RIGHT FROM RAW MATERIAL STAGE TO FINISH STAGE IS FULLY CONTROLLED AND SUBJECT TO CHECK AT EACH STAGE OF MANUFACTURING. UNLIKE OTHERS WE MAINTAIN THE QUALITY AND THICKNESS OF STEEL SHEET, ABRASION RESISTANT RUBBER AND ITS THICKNESS, BLASTING HOSE QUALITY INTERMS OF ANTISTATIC PROPERTY, FLEXIBILITY, RUBBER HARDNESS, PURITY OF RUBBER, SHORE HARDNESS.
BLASTING NOZZLES ARE LONG VENTURY TYPE MADE OF TUNGSTEN CARBIDE, BORON CARBIDE, SILICON CARBIDE, AND PROPER HARDNESS IN MOHS SCALE.
IN AIRLESS SHOT BLASTING MACHINE THERE ARE SO MANY POINTS TO BE CHECKED WHILE COMPARING PRICE AND QUALITY ASPECTS. SINCE SHOT BLASTING MACHINES ARE SELF DESTRUCTIVE MACHINE HENCE GREAT IMPORTANCE IS GIVEN TO RAW MATERIAL, HARDNESS, THICKNESS, ETC.
ALLOY STEEL, MANGENESE STEEL, NI HARD, HI CARBON HI CHROMIUM PARTS ARE USED IN AIRLESS SHOT BLAST MACHINES. UNLIKE OTHERS WE DO NOT COMPROMISE ON CHEMICAL PROPERTY OF THESE CASTINGS, WEIGHT AND THICKNESS OF THE PARTS TO REDUCE THE COST. IT ULTIMATELY DEPLETES THE QUALITY AND LONGEIVITY OF THE MACHINES. LONGEVITY OF PARTS IS ALMOST DOUBLE IN OUR MACHINE THAN OUR NEAREST COMPETITIOR. THIS SAVES DOWN TIME, MAINTENANCE COST DRASTICALLY WHICH IS EVIDENT ONY AFTER USE OF SEVERAL MONTHS. ALTHOUGH PARTS LIKE CONTROL CAGE, IMPELLERS, BLADE SETS, BLAST WHEEL LINERS ARE COMMON WEAR AND TEAR ITEMS HOWEVER IF RIGHT METALLURGY AND HARDNESS AND ;PROPER THICKNESS IS USED IN MANUFACTURING THESE PARTS LAST LONG. WE IN PCS MADE A POLICY NOT TO COMPROMISE ON PRICE AND DILUTE TECHNICAL SPECIFICATON. IT IS EVIDENT THAT MOSLY ALL OUR CLIENT PLACE THEIR REPEAT ORDER ON US DUE TO TRUST AND QUALITY OF MACHINE BEING MANUFACTURED BY US.

MAINTENANCE TIPS :

EVERY WEEK BLAST HOSE, BLASING NOZZLE, WHEEL BLADE, IMPELLER, CONTROL CAGE SHOULD BE CHECKED. IF ANY VIBRATION AND SOUND IS OBSERVED IN AIRLESS SHOT BLASTING MACHINE, IMMEDIATELY BLADE SET SHOULD BE INSPECTED. CHANGE TOTAL BLADE SET TO MAINTAIN THE DYNAMIC BALANCING OF BLAST WHEELS. GENERALLY USERS DO NOT REPLACE TOTAL SET OF BLADE AND THIS DEVELOPS VIBRATION AND DAMAGE THE DYNAMIC BALANCING. FINALLY BEARINGS AND MOTOR GETS DAMAGED.