Category Archives: Shot Blasting

Automotive Crankshafts, Part 1 – Cost-Effective Surface Improvement for Key Engine Components

Crankshafts are a key component of internal combustion engines, be it mass-produced engines for motorcycles and automobiles, engines for heavy trucks, off-high highway equipment, and even large ships.

Crankshafts convert the reciprocating (up/down) movement of the pistons/connecting rods into a rotational movement that drives the wheels and allows a vehicle to move forward.

Rosler Metal Finishing understands the vital importance of these engine components and has developed specific shot blasting and mass finishing machines to process these pieces to perfection.

A crankshaft with connected rods and pistons
A crankshaft with connected rods and pistons

Materials & Production Methods

Considering that automotive crankshafts weigh around 40-60 pounds and rotate approximately 100 times per second, these parts are exposed to tremendous tensile, compressive, and shear stresses. In addition, combustion forces and piston acceleration in an engine can also cause significant vibration.

Therefore, crankshafts must be made from tough, wear-resistant materials, usually high alloy carbon steel. Typical alloying elements are manganese, chromium, molybdenum, nickel, cobalt, or vanadium.

Continue reading Automotive Crankshafts, Part 1 – Cost-Effective Surface Improvement for Key Engine Components

Spinal Implants, Part 3 – Mass Finishing Versus Shot Blasting Methods

implanted spinal rods
Implanted spinal rods

With worldwide sales at nearly $10 billion annually, there is a high demand for spinal implants. These implants are subject to very specific and strict surface finishing requirements to ensure longevity and fixation to bone.

Mass finishing and shot blasting play key roles in creating the right finish for spinal implants, not only for intermediate surface treatment after forging, casting, machining, additive manufacturing, etc., but also for placing the final surface finish before implantation.

Let’s examine the capabilities of mass finishing and shot blasting for spinal implants and how Rosler Metal Finishing can develop a precise and repeatable finishing process to meet your unique challenges and goals.

Continue reading Spinal Implants, Part 3 – Mass Finishing Versus Shot Blasting Methods

Forge & Foundry, Part 7 – Selecting a Shot Blasting Machine for Forgings, Non-Sand Castings, and Powdered Metal Components

This installment of Rosler Metal Finishing’s Forge and Foundry Series continues with shot blasting machine selection considerations for forgings, non-sand castings, and powdered metal components.

While none of these work pieces contain sand, their surfaces may show oxidization or – in the case of ferrous metals – heavy scale/rust caused by iron oxide.

All forms of oxidization must be removed to ensure that subsequent manufacturing operations such as machining, coating, and painting are economical and efficient. Poorly cleaned work pieces may cause additional processing, premature wear on milling tools and drill bits, excessive pollution within coolant systems, and inefficient adhesion of coatings and paint.

Traces of oxidation may also impact the work piece’s functionality.

Continue reading Forge & Foundry, Part 7 – Selecting a Shot Blasting Machine for Forgings, Non-Sand Castings, and Powdered Metal Components

Joint Reconstruction, Part 4 – Comparing Surface Finishing Methods

Shot blasting and mass finishing have become indispensable technologies for surface preparation and finishing of joint reconstruction implants. Their applications range from surface cleaning, deburring, edge radiusing after forging, casting, additive manufacturing, and machining to surface preparation for different kinds of coatings, shot peening for increasing the longevity of an implant, and placing an extremely smooth, high-gloss finish on the implants before they are inserted into the body.

Rosler Metal Finishing leverages its extensive experience in the medical industry to create customized solutions and equipment for the treatment of joint reconstruction implants.

This installment of the Joint Reconstruction Series will compare the working principles and features of utilizing shot blasting and mass finishing technologies for endoprosthetic implants.

Continue reading Joint Reconstruction, Part 4 – Comparing Surface Finishing Methods

Forge & Foundry, Part 6 – Selecting a Shot Blasting Machine for Die Castings

Our Forge and Foundry Series continues with tips for selecting a shot blasting machine for die castings.

Considerations for machine selection include:

  • Are the work pieces sturdy enough to allow for somewhat more aggressive processing or must they be handled gently without any part-on-part contact?
  • Is batch processing possible or must it be continuous?
  • Which work piece handling system is best: rotary drum, troughed belt, wire mesh belt, or overhead monorail system?
  • Can the work pieces be handled by robot, etc.?

Rosler Metal Finishing builds shot blasting machines that are designed to expertly prepare the surface of delicate and sturdy die castings and everything in between. We can design a machine that is perfectly matched to your work piece and process.

Continue reading Forge & Foundry, Part 6 – Selecting a Shot Blasting Machine for Die Castings

Forge & Foundry, Part 5 – Cleaning Features & Dust Precautions for Sand Castings

Our Forge and Foundry Series continues with a look at the cleaning required for sand castings and the collection of removed contaminants.  

Rosler Metal Finishing builds shot blasting machines that are equipped to prepare the surface of sand castings as well as collect removed contaminants for a consistent workpiece finish and the health of the utilized machine and personnel.

What design features must be considered in blast turbines used for the cleaning of sand castings?

Baked-on molding sand, sand cores, and scale/rust on the sand castings are difficult to remove and require turbines with a lot of fire power. Turbines with curved throwing blades, such as Rosler’s Gamma G series, have proven to be exceptionally effective since, compared to straight-bladed turbines, the curvature of the blades generates up to 25 percent higher throwing speeds!

Continue reading Forge & Foundry, Part 5 – Cleaning Features & Dust Precautions for Sand Castings

Joint Reconstruction, Part 2 – Material Standards

Joint reconstruction implants allow millions of individuals to regain mobility and reduce pain. Just as surgical skill is required to implant these artificial joints, so is skillful construction and finish of the joint components themselves.

A leader in surface finishing for medical technology, Rosler Metal Finishing has extensive experience in shot blasting and mass finishing a wide range of medical devices from instruments to implants used specifically for joint replacement.

Our Joint Reconstruction Series continues with an overview of the most common materials used for these endoprosthetic implants.

Material Standards

The most common materials used for joint reconstruction implants are currently titanium and titanium alloys and cobalt-chromium alloys. Both materials are very tough, corrosion-resistant, highly biocompatible, and have proven themselves to be absolutely reliable.

Continue reading Joint Reconstruction, Part 2 – Material Standards

Forge & Foundry, Part 4 – Selecting a Shot Blast Machine for Sand Castings

Building upon the information shared in our last Forge and Foundry Series post about sand casting, we now turn to the process of selecting and designing machines to specific sand casting operations.

Selecting the right shot blasting machine for your process and work piece means understanding how the work pieces and machine will interact. Here are common questions Rosler Metal Finishing receives when developing perfectly specified solutions for sand casting.

How do work piece delicacy, size, and weight influence the machine choice?

Before choosing a machine, the following questions must be asked:

  • Are the parts sturdy, allowing for aggressive processing, or must they be handled gently, without any part-on-part contact?
  • Is batch processing possible or must it be continuous?
  • Which work piece handling system is best: rotary drum, troughed belt, wire mesh belt, overhead monorail system, or heavy-duty crane or trolley on rails for extremely heavy work pieces weighing several tons?
  • Can the work pieces be handled by robot or is a custom-engineered shot blast system the best solution?

It is extremely important to find a supplier that can offer a machine that is perfectly matched to the work piece characteristics.

Continue reading Forge & Foundry, Part 4 – Selecting a Shot Blast Machine for Sand Castings

Forge & Foundry, Part 1 – Shot Blasting Systems

Getting castings and forgings ready for the subsequent processing steps presents some of the toughest surface finishing challenges. Shot blasting machines can handle all of these tasks from removing residual sand, casting shells, flashing, die marks, or scale. Whether cast iron, steel, stainless steel, super alloys, titanium, aluminum, zinc, or magnesium, the comprehensive portfolio of Rosler Metal Finishing blasting systems for the foundry industry enables the optimal process for any requirement.

Shot blasting is an essential part of most forge and foundry operations and has been used since the late 1800s. This specialized surface finishing process throws small metal (or mineral) pellets, called blast media, onto the surface of a work piece at incredibly high speeds, ranging from 200-800 feet per second. The impact on the work pieces from this process is what blasts the contaminants from the parts and produces the desired surface finishing effect.

When properly applied prior to finishing, blasting achieves three key aspects of the finishing process:

  1. Cleans and descales surfaces
  2. Creates a uniform texture on the part and blends the surface
  3. Enhances paint adhesion
Continue reading Forge & Foundry, Part 1 – Shot Blasting Systems

Structural Steel FAQ, Part 10 – Blast Rooms for Touch-Ups

When it comes to shot blasting complex weldments like the chassis for construction equipment, excavator booms, and wind power components, sometimes even the best turbine placement may not clean all the nooks and crannies of the work piece’s surface.

Surface finishing experts such as Rosler Metal Finishing have solved this issue with the addition of manual blast rooms to automatic shot blast systems.

This installment of our Structural Steel FAQ series will answer When are blast rooms behind turbine blast machines required for manual touch-up?

Continue reading Structural Steel FAQ, Part 10 – Blast Rooms for Touch-Ups