Solved by SAIT: Weld Seam Grinding - Preventing Scratches Popping Through Paintwork

Material & Tool Profile

Material Being Processed:
Carbon Steel: Weld Seams (av. 2m in length)

Product in Use:
Flap Disc, 125mm x 22.23mm, Zirconia (P80)

SAIT Product: 
POWER MAX-D 9.3 Fibre Disc, 125mm x 22mm, Ceramic, P80+ (with SAITPAD-DQ backing pad)
SAITAC D-VEL Z-F Hook & Loop Disc, ø 150mm Zirconia (P80, P100 & P120)
SAITAC D-VEL ZF-F Hook & Loop Disc, ø 150mm, Al-Ox/Zirconia (P180)

Machine Spec:
125mm 110v Angle Grinder, 150mm Random Orbital Sander

The Challenge

The fabricator was using flap discs to grind and blend weld seams before sending pieces to paint. However, the resulting scratches were popping through the painted finish and there was undulation in the finished surface. This meant that it was impossible to make good with any subsequent processes and parts were routinely being rejected.

Advantage Realised

SAIT identified a combination of products that would succinctly address the stages of grinding, blending and finishing:  

• For the first step, where quick stock removal was a priority, the POWER MAX-D 9.3 fibre disc in P80 grit was paired with the flexible SAITPAD-DQ backing pad.
• As the customer had newly invested in 150mm orbital sanders, SAIT utilised this as a basis for the finishing process. Three grits (P80, P100 & P120) of the SAITAC D-VEL Z-F hook and loop disc were used to gradually work out scratches, rounded off with the SAITAC D-VEL ZF-F hook and loop disc in P180.

The solution put in place meant that the fabricator could send the pieces straight to the paint shop, eliminating a substantial amount of time and money spent on filling and smoothing processes.

SAIT also delivered a toolbox talk to the team of 25 operatives, to ensure comfort and confidence with the new process. 

Watch the Solution in Action

Resources

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