Aluminum Grinding Problems

Aluminum is a metallic material with a wide range of uses. It is a very flexible material that is easier to fabricate and shape than most other metals. But when grinding aluminum, there are also some problems due to some characteristics of aluminum.

1. Heat resistance/low melting point

Aluminum alloys have a low melting point and are highly sensitive to heat. We all know that heat is generated during the grinding process, and if you use the wrong grinding disc or try to over-grind aluminum, this can quickly raise the temperature to a point where it can destroy the aluminum.

2. Adhesion

The low melting point also easily clogs the porous surface of any abrasive. Grinding aluminum at high temperatures can cause aluminum swarf to become lodged between the abrasive grains and become embedded in the grinding disc. As more and more aluminum is embedded, your disc will have a lot of metal aluminum attached, which will cause the temperature to rise faster, which will damage the aluminum, and if the temperature is too high, it may cause the grinding disc to explode.

3. Aluminum oxidation

Aluminum doesn't rust like iron or steel, but it oxidizes quickly when exposed to oxygen. Aluminum oxide does not develop a flaking rust color, but a white surface. This is a nightmare for welders as it causes the welding arc to stutter and increases porosity in the weld, which is why you should always sand the surface in preparation for welding aluminum.

4. Pollution

Even though aluminum doesn't rust, that doesn't mean it's impossible to get a rusty aluminum finish. Especially using the wrong abrasive can easily damage the surface of the aluminum. Small amounts of abrasive particles from sandpaper, grinding discs or even wire brushes can contaminate aluminum due to its softness and low melting point. If you embed iron or carbon-based materials in it, your aluminum will end up with rust spots on the surface.