Mass Welding & Surface Conditioning

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I'm a little out of what the forums are for, but am having trouble finding a forum for what im looking for. I am an employee at a custom aluminum gate company. I was trying to see if anyone here does mass production? Even if not ill ask my question anyway.I am currently trying to find a cheaper effective way of cleaning up welds on aluminum before the gates go to powder coating. I have my guys currently using this 3M Disc Pad Holder with these Scotch-Brite Surface Conditioning Disc's on a right angle grinder. My problem is the pads are roughly $3 a pop and the holder $20. These guys can go through 50 pads a week easy, and a backing plate in a couple days.
Reply:I use a sandpaper flap disc on an angle grinder, 60-120 grit.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Another tactic that might be more effective is to improve the weld quality.  If you have spatter problems or lumpy welds that need to be dressed it might be more cost effective to improve the welds.  At 150 dollars a week in pads that is 7800 dollars per year.  For that kind of money you should look at pulse current and cleaning/sanding joints before welding.  There are resources at Lincoln and Miller that could diagnose your problem and offer solutions.  One thing that is ignored often is temperature and humidity.  They have an influence in strength and quality of aluminum welds.   Design of the joints can also be a problem.  I once worked on large aluminum truss work.  The braces made a connection at angles less than 30 degrees.  Of course there was porosity and cold lap.  I had suggested a redesign of the joint but was put off.  Sure enough those welds resulted in hours of repairs.
Reply:Both of these guys had good ideas but pictures would help so we know what exactly they have to clean. TIG welds? Mig welds? Not to repeat but are the joints chamferred to get the weld to lay flat?  That could be done on a milling machine if you guys are using .250 wall like on some of the bigger aluminum gates. That would save a lot of abrasives. Do the guys waste them?? I`ve worked in plenty of production places where guys use the edges and throw them out after barely any use.  Do your powdercoaters media blast  before ?  Ask if you don`t know because not all of them do. When grinding are they using wax?  Lubricating abrasives on aluminum is critical as well, both to give a better finish and make the abrasives last longer. WD-40 works as well but is messy.
Reply:I work in production and I've had problems with people not fully using abrasives too. Doesnt sound like you are doing a lot of material removal with the pads you mentioned. Since you are powdercoating anyway why not use a wire wheel they are initially expensive but they will last a long time if you are just using them for removing the cleaning area of tig welds or the smoke and crap from mig welds. If you need material removal I would use an AL specific sand paper flap disk and lubricant.
Reply:These guys recommend reducing the grinder speed:http://www.csunitec.com/sanding_poli...ger-shark.htmlHow about machining the welds instead of grinding? Maybe use a router with a template guide.http://www.cnczone.com/forums/showthread.php?t=3072Lincoln SA200, HH135, Lencospot, HF80 Inverter, Rockwell 11x35 lathe, HF drill mill, Kama 554 tractor w/ FEL & BH, Belarus 250AS, lot's of Chinese tools
Reply:I am just new at he welding game but I agree with previous posts. I commented at work once that I was sick of grinding. The old guys started laughing and said "Get better at welding then!". Kinda made me med. But true. No offense at all but maybe your process could be improved or tweaked?Just another clown trying to be cool
Reply:Where are your pictures? Sounds like a nice production you've got going on!Just another clown trying to be cool
Reply:how about sandblasting?Dynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:Originally Posted by Gate MastersI'm a little out of what the forums are for, but am having trouble finding a forum for what im looking for. I am an employee at a custom aluminum gate company. I was trying to see if anyone here does mass production? Even if not ill ask my question anyway.I am currently trying to find a cheaper effective way of cleaning up welds on aluminum before the gates go to powder coating. I have my guys currently using this 3M Disc Pad Holder with these Scotch-Brite Surface Conditioning Disc's on a right angle grinder. My problem is the pads are roughly $3 a pop and the holder $20. These guys can go through 50 pads a week easy, and a backing plate in a couple days.
Reply:Originally Posted by lotechmanAnother tactic that might be more effective is to improve the weld quality.  If you have spatter problems or lumpy welds that need to be dressed it might be more cost effective to improve the welds.  At 150 dollars a week in pads that is 7800 dollars per year.  For that kind of money you should look at pulse current and cleaning/sanding joints before welding.  There are resources at Lincoln and Miller that could diagnose your problem and offer solutions.  One thing that is ignored often is temperature and humidity.  They have an influence in strength and quality of aluminum welds.   Design of the joints can also be a problem.  I once worked on large aluminum truss work.  The braces made a connection at angles less than 30 degrees.  Of course there was porosity and cold lap.  I had suggested a redesign of the joint but was put off.  Sure enough those welds resulted in hours of repairs.
Reply:Originally Posted by lotechmanAnother tactic that might be more effective is to improve the weld quality.  If you have spatter problems or lumpy welds that need to be dressed it might be more cost effective to improve the welds.  At 150 dollars a week in pads that is 7800 dollars per year.  For that kind of money you should look at pulse current and cleaning/sanding joints before welding.  There are resources at Lincoln and Miller that could diagnose your problem and offer solutions.  One thing that is ignored often is temperature and humidity.  They have an influence in strength and quality of aluminum welds.   Design of the joints can also be a problem.  I once worked on large aluminum truss work.  The braces made a connection at angles less than 30 degrees.  Of course there was porosity and cold lap.  I had suggested a redesign of the joint but was put off.  Sure enough those welds resulted in hours of repairs.
Reply:I agree with those above, improve the welding to solve the problem.