Blasting Medium, Process for Its Production, and Use Thereof

This Application claims the benefit of the priority of German Applications P 41 42 893.5, filed Dec. 23, 1994, and P 42 14 988.6, filed May 6, 1992.

The invention pertains to a reusable jet blasting medium consisting of a thermoplastically processable polymer granulate filled with finely divided metal. The invention relates further to a process for the production of this blasting medium and the method of the use of the polymer granulate for deflashing cast metal parts, particularly those which are ground.

Cast or die-cast metal parts made in a foundry have a certain amount of flashing residues which must be removed; for economic reasons, these residues must be removed quickly and easily. Deflashing by particle blasting is at present the best developed and most economical method, it is important, in this context, that the particles must be less hard than the material to be deflashed.

In the prior art, the aftertreatment of surface-ground diecast metal parts, e.g. of aluminum, is carried out with vegetable blasting materials such as ground nutshells and apricot pits, and/or with ground duroplastic wastes, glass balls, scrap metal, glass-filled thermoplastic plastics, and the like. According to the state of the art, the smallest particles should have a diameter not less than 0.5 mm, otherwise the impingement energy is too low.

All blasting media referred to have the disadvantage that, in addition to deflashing, they adversely affect the surfaces of the parts. They lead to undesired matting and roughening, as well as to "shotpeening" when using blasting media of high specific gravity such as iron or steel. Due to breakage, nutshells, apricot pits, and duroplastic plastics cause intensive dust development, which itself requires aftertreatment of the parts. Glass beads break and attack the surfaces. The thermoplastic plastics filled with glass beads last long and allow good deflashing, but cause matting and even roughening of the surfaces.

Unfilled thermoplastic plastics are exceptions. With respect to durability, these blasting media, in particular polyamides and polycarbonates, are probably superior to all other products, but because of their low specific gravity they exhibit insufficient deflashing action.

From German patent DE 960,418, blasting media consisting of a mixture of a plastic with a metallic/mineral material in granular form or containing polyamide or glass fiber are known. However, the plastics recommended there must be hardened by suitable post treatment. Because of their pronounced abrasive action, the recommended granular admixtures such as corundum, quartz, and various metals do not permit extruder processing for intimate mixing with the plastics. The blasting media themselves can be reused only to a very limited extent, as they are decomposed into their components during deflashing as a result of their high impingement energy.

It is, therefore, among the objects of the invention to provide blasting media for the deflashing of cast or ground diecast metal parts which do not have the disadvantages of the prior art and, in particular, do not adversely affect the surface of the parts to be deflashed, yet can be re-used. Further a method for the production of such blasting media is also desirable.

It has now been found that, surprisingly, polymer granulates which are filled with finely divided metal do not adversely alter the surfaces, especially ground or polished surfaces, of cast metal parts during deflashing. To this end thermoplastics are especially suitable, as they have a certain degree of impact toughness and thus do not break up when impinging on the metal parts.

Suitable metals are preferably iron, copper, tin, and, more desirably those alloys thereof which are softer than the processing equipment, e.g. the structural parts of the extruders. Especially preferred is finely divided bronze, which is usable ideally in spherical form and is extrudable with polymers without difficulties or abrasion; indeed, an advantageous lubricating effect occurs in the extruder.

The finely divided metal particles are preferably coated with adhesion promoters of the commercial amino or epoxy silane type. One uses silane in a quantity of 0.1% to 0.4% by weight, preferably 0.2% to 0.25% which can be applied e.g. by a drum mixer, possibly with the use of suitable inert solvents. As the finely divided metals the commercial types in spherical or powder form are satisfactory; their diameter is desirably between 0.01 and 0.5 mm. Especially suitable are particle sizes between 0.05 and 0.1 mm.

The thermoplast granulates are preferably commercial polyamide and polycarbonate types, specifically mentioned are homo- and copolyamides. Especially preferred are PA 6; PA 6,6; PA 11; PA 12; and mixtures thereof. All impact toughness modifiers common in the state of the art can be added to the overly brittle polymers. The proportion of metal in the blasting media according to the invention is 20% to 90% by weight, with 60% to 80% being especially preferred. The advantageous granulate form is cubic with edge lengths between 0.50 and 2.0 mm, with edge lengths between 0.75 and 1.5 mm being especially preferred.

The blasting media according to the invention, consisting of polymer granulate filled with finely divided metal, are produced by selecting as a suitable polymer granulate one consisting of commercial thermoplast which is a polyamide and/or a polycarbonate and, as the metal, iron, copper, tin, or an alloy of stainless steel, brass, and/or bronze. The metal or the alloys are to be present in particle sizes of 0.01 to 0.5 mm diameter; and should contain 0.1% to 0.4%, preferably 0.2% to 0.25% by weight epoxy silane. They are placed in a mixer open to atmospheric moisture, to produce an intimate mixture of polymer melt and metal or alloy, preferably in an extruder. The mixture is then extruded in the conventional manner, preferably as a ribbon; after discharge, it is reduced by cutting to the desired form and size. The blasting medium thus produced is in the form of cubic particles having edge lengths of 0.50 to 2.0 mm. The blasting media according to the invention are suitable for use in all conventional deflashing methods, preferably blasting wheels, pressure jets, or injector systems.

The blasting media according to the invention exhibit, as compared with the prior art, no dust development due to breakage and/or separation of the components, so that subsequent cleaning of the deflashed parts is unnecessary It is even possible, unexpectedly, to re-use the media cost-efficiently. Moreover, the higher specific gravity and the resulting higher kinetic energy of the metal-filled blasting media, make it possible to operate blasting wheels at lower speeds, and pressure jets and injector systems at lower operating pressures.

The use of polymer granulate filled with finely divided metal for the production of blasting media has thus proven to be particularly advantageous, cost-efficient, and quality improving. Commercial thermoplasts, specifically polyamide or polycarbonate types, are filled with finely divided iron, copper, tin or alloys thereof which are present in spherical or powder form, with particle sizes of 0.01 to 0.5 mm. The blasting medium preferably has the form of cubic particles with edge lengths of 0.5 to 2.0 mm. In this connection, polyamide 11 or polyamide 12 which is filled with spherical bronze particles having a diameter of 0.03 to 0.1 mm is particularly well suited, whereby the preferred edge length lies between 0.8 and 1.2 mm.

While only a limited number of specific embodiments of the present invention has been expressly disclosed, it is, nonetheless, to be broadly construed and not to be limited except by the character of the claims appended hereto.