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Bead blasting impact of surface roughness

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M
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Hi, I am looking for a method of removing machining marks from aluminium parts while also improving the parts’ durability. After reading another post on this forum, it seems as if bead blasting would be best suited for this. However I would like to know more about the different types of bead blasting finishes that are available, and will the bead blasting process negatively affect the material properties?

Solved by JeanTech75

Adding to Dan’s response, bead blasting can actually improve material properties and has been shown to increase fatigue resistance. This is because it flattens and smoothes out microscopic cracks in the surface, making it harder for cracks to initiate in the first place.

    • M

      Hi, I am looking for a method of removing machining marks from aluminium parts while also improving the parts’ durability. After reading another post on this forum, it seems as if bead blasting would be best suited for this. However I would like to know more about the different types of bead blasting finishes that are available, and will the bead blasting process negatively affect the material properties?

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    • D

      Hello Mike, bead blasting is an excellent choice for removing machining marks from soft materials like aluminium. Bead blasting will not negatively affect the material as it is generally a gentle process, especially when compared to the far more aggressive abrasive grit blasting. Bead blasting does not remove material but rather very slightly deforms the surface as the beads impact it creating small indentations. Larger glass beads create a rougher but still uniform finish whereas smaller beads create a satin, sometimes shiny finish.

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      • M
        DanML

        Thank you, how would I specify the grade of bead blasting? For example, I want a smooth satin finish but it must not be shiny.

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      • D
        Mike Henderson

        It really depends on the supplier, usually the beads are defined by grit size, the higher the grit number, the finer the glass beads. Some suppliers will also classify the beads by course, medium, fine, and very fine.

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      • J
        Technical Writer
        Mike Henderson

        Hello Mike, to add to Dan’s comments here, specifying coarseness and desired finish in drawings or notes is usually enough for most suppliers to understand what you are going after. For instance, you could add a note such as :  “Media blast with fine glass bead for a satin finish.” 

        This does leave some room for interpretation, so if you are concerned with repeatability and consistency for a product line, you can also specify grit range and pressure. For example, I asked for the following for the stand parts seen below : “Media blast with #70-100 glass bead at 50-60psi. Surface to be free of dirt, oils, debris, and blemishes.” 

        Bead Blasted Xometry Stand

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      • J
        DanML

        Adding to Dan’s response, bead blasting can actually improve material properties and has been shown to increase fatigue resistance. This is because it flattens and smoothes out microscopic cracks in the surface, making it harder for cracks to initiate in the first place.

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      • M
        JeanTech75

        Thank you, so bead blasting just improves the surface toughness of the part, but are there methods for improving the crack resistance of the alloy past just the surface? I have read that annealing will prevent the material from cracking when formed.

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      • J
        Mike Henderson

        If you want to increase an aluminium part’s resistance to cracking during cold work then you can anneal it. It is also a good idea to anneal aluminium after machining as the machining process will impart mechanical stress to the material which can increase the likelihood of cracks forming once the part is exposed to regular loading. Just two things to keep in mind, do not anneal prior to machining as the material can become too soft to machine, i.e. it could stick to the cutting tools. Secondly, not all grades of aluminium can be annealed.

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Bead blasting impact of surface roughness
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