The Role Of Abrasives in the Shipbuilding Industry

We should be aware that marine abrasive materials are crucial to the advancement of industry, both now and in the future. The space used for human activity is made up of land and water together, with the ocean taking up the majority of the area. For a very long time to come, the growth of the shipbuilding sector will take precedence. This also indicates that the shipbuilding sector is a significant one. In the shipbuilding sector, abrasive materials are mainly used for coatings, painting, and sandblasting, among other processes.

THE USE OF ABRASIVE MATERIALS IN THE SHIPBUILDING SECTOR

Ships have long been sandblasted using powdered abrasive materials, but recently, several shipyards have started looking for alternatives. For instance, the steel plate's oxide scale and rust are removed from its surface using steel shot peening technology. A primer sprayed in the spraying workshop then protects the steel plate against rusting during the shipbuilding process.

The number and size of segments have expanded along with the growth in shipbuilding. Currently, the need for secondary rust removal cannot be met by the sectional brick spraying rooms of different enterprises. As a result, an increasing number of manufacturers have started using the outdoor copper slag spraying method.

COMMON SHIPBUILDING DIFFICULTIES

Because much of the parts' final assembly happens inside the ship, work is frequently done in small, difficult-to-reach areas, frequently with short contract deadlines.

The work location may be hundreds of feet from the power supply, so the operator may need to crawl or walk through the ship's ballast with tools and equipment. Proper cutting and grinding equipment may not always be the ideal choice when work is being done far from the power source.

Air (pneumatic) tools are preferred by many operators over electrical ones. However, if the compressed air line is extended too far, the pressure may be insufficient to operate the tool correctly, necessitating the use of abrasives. If air tools are underpowered, they will bog down more easily than electric right-angle grinders when attempting to maintain surface speed. Using a grinding or cutting wheel with a soft bond can help maximize performance in both situations when an air tool or an electric tool is underpowered.

NEEDS FOR CUTTING AND GRINDING

Handheld tools such as air and electric right-angle grinders and die grinders are commonly used for weld prep, cleaning between weld passes, and post-weld cleaning and finishing in the line fabrication, finishing, or painting sections of a shipyard operation.

There are numerous handheld tools and accessories available. Although operators may sometimes choose the most convenient option, selecting the right tool and accessory for a specific task can improve productivity and save labor. Selecting the best option requires considering a number of key factors.

• CLIENT REQUIREMENTS - Will the finished project be a commercial vessel or part of a military fleet? This significantly affects the final specs as well as any rules or specifications, such as the kinds of coatings that can be added to the ship. Understanding the final specifications is the first step in selecting the appropriate tool and accessories.
• KIND OF MATERIAL - Although carbon steel and aluminum are frequently used for shipbuilding components, operators may also encounter other metals. Make sure you use an abrasive product made specifically for that metal and are aware of the sort of material being worked on. Use materials created exclusively for steel on aluminum or stainless steel to prevent cross-contamination. Furthermore, never use a product intended for use on steel, aluminum, or stainless steel. Instead, use it on steel.
• WORKING CONDITIONS AND SURROUNDINGS - When cutting and grinding in these tight spaces, it's crucial to consider the relative importance of product longevity and speed of completion. If it takes the operator thirty minutes to reach the job site and they need more tools to reach the site, using a fast cutting or grinding product that only lasts fifteen minutes and needs to be replaced is not very efficient. In this situation, using a more durable product like a ceramic disc can save time and money.

Although battery-operated tools are becoming more common in these applications, their battery life needs to be improved for long workdays in production settings. With cordless tools, using an extremely thin cutting or grinding wheel, such as one millimeter thick, helps minimize tool strain and increases battery life.

ABRASIVE PRODUCT SELECTION

A broad range of abrasives, including wire brushes, nonwoven abrasives, and coated and bonded abrasives, is utilized in shipbuilding applications. For instance, resin fiber discs can be used to remove extra material and expose bare metal so that the operator can reapply any necessary coatings. In contrast, wire brushes are commonly used to remove the discoloration that accumulates on aluminum after welding. Pros and drawbacks exist for each product category based on the particular task.

BONDED ABRASIVES

Grinding wheels and other bond-bonded abrasives can be used to grind down materials to give them a uniform appearance or to remove heavy mill scale before welding. Plunge cuts, such as cutting a window in a large piece of metal, can also be made using cutting wheels. They are also often used to penetrate completely and to allow for easier inspection of the cut edges above and below the weld.

COATED ABRASIVES

Flap discs and resin fibre discs are two examples of coated abrasives frequently used as accessories in shipbuilding. They can be used to grind, blend, remove oxidation, and finish welds. Unlike bonded abrasives, coated abrasives cut quickly and don't tend to slow down or load up.

WIRE BRUSHES

Wheel, cup, and end brushes are just a few of the various sizes and configurations available for power wire brushes. These materials are frequently used for post-weld cleaning or to eliminate spatter between weld passes. The task at hand determines which kind of power brush is best. For instance, end brushes work well at cleaning fillet welds and tight areas.

Occasionally, air tool operators will opt for a needle scaler over a wire brush, mainly when dealing with heavy dirt or rust. Although needle scalers are significantly slower than wire brushes to complete a task, they do have a longer lifespan and are effective at removing heavy materials. An operation that uses needle scalers ought to take into account the considerable productivity increases that wire brushes could provide for those kinds of jobs.

TOP 3 SUCCESS PRACTICES

Once the correct product has been chosen for the job, a few simple recommended practices can help improve performance and extend the life of the attachment.

1. On the job site, steer clear of utilizing too-long air hoses or power cords for hand-held electric or air equipment, as this may decrease power and performance. If you have no choice but to use a long power cable or air hose, keep in mind that some abrasive attachments perform better and more effectively with reduced power or air pressure than others. Recognize the pressure at a specific workstation in order to make wise choices.
2. While it could be tempting, particularly in cramped, difficult-to-reach areas, resist the urge to use the same accessory for every task. Additionally, operators could reach for the same product they've always used without thinking about how alternative items might lead to better outcomes. Operator performance, productivity, and safety can all be improved by matching appropriate abrasive products to the task.
3. Always follow the correct procedures when using abrasive products. Using a tool guard and any other required safety equipment falls under this. Appropriate operator training can also help in reducing time spent on cutting and grinding because products often function better when utilized at the specified angle, speed, pressure, and orientation to the material.