PROCESS EQUIPMENT UPDATE


particles onto a surface, usually with compressed air or steam. Te silica sand used in abrasive blasting typically fractures into fine particles and becomes airborne, which can cause serious or fatal respiratory disease. When workers inhale crystalline silica, the lung tissue reacts by developing fibrotic nodules and scarring around the trapped silica particles, causing a fibrotic lung condition called silicosis. In addition, particles are generated during abrasive blasting that further contribute to respiratory problems and other harmful health effects. “When sand or any other media is used to knock off particles from a substrate, there is always a byproduct that has the potential to become airborne and inhaled,” says Galiardi. “Besides the sand, this could be the particles you’re removing – the coatings, plating, anodising, corrosion and even lead paint. “Industry has needed a cleaner, safer


surface pre-treatment solution for a very long time,” adds Galiardi. With dry ice blasting, dry ice pellets


are used as the abrasive. Te challenge is that dry ice blasting is often not abrasive enough to sufficiently remove paint or corrosion from the surface of metals. Since dry ice is an expensive consumable, the costs can escalate when cleaning metal surfaces in higher volumes.


CHEMICAL STRIPPING With chemical stripping, harsh, even toxic chemicals are used to strip metal- based objects of paint, rust, and other contaminants to bare metal. However, for operators, exposure to corrosive acids and noxious chemical fumes is inherently dangerous. Te process can also be time- consuming to prepare the proper chemical bath, achieve the required level of cleaning, and dispose of the waste. In addition, disposing of toxic chemicals is costly and closely regulated by agencies such as OSHA and the EPA.


Laser-based systems have advantages


over these traditional methods, including ease of use in which an operator simply points and clicks a high-energy laser beam at the surface. Te substrate is not affected by the laser, and the systems do not create any mess or byproducts. Te approach is eco-friendly, energy-efficient and completes the job in half the time of traditional methods when preparation and cleanup are considered.


Laser systems remove corrosion,


grease, residue and existing coatings from metal


surfaces quickly


“In our experience, laser cleaning is


as fast at removing rust or old coatings as other methods, but without the same amount of cleanup,” said Galiardi. “When we treat a surface with lasers, any fumes or dislodged particulate is extracted into a HEPA filter and the job is done. Tere is no media [sand, dry ice, chemicals] to replenish or clean up.” Galiardi Laser Clean uses laser systems


made by Laser Photonics, a leading provider of industrial-grade CleanTech laser systems for cleaning and surface conditioning. Te systems function either as mobile standalone units or can be integrated into production lines. Te laser systems are available in


portable and stationary models ranging from 50 to 3,000W with chamber sizes from 3in x 3in in size to 6in x 12in. Te systems can also be installed in manufacturing lines in cabinets or operated by a robotic arm. Galiardi says that laser pre-treatment of metal surfaces can be used to streamline various manufacturing processes. Corrosion, for example, can begin to accumulate within a very short time on new parts, depending on the material and environmental conditions, and should be removed prior to coating. For one major auto manufacturer,


Galiardi Laser Clean was asked to remove rust from conveying system components used to transport cars through the manufacturing process. Te components were corroded due to being left outside


during a six-month delay in the project. When it was time to install the items, the provider wanted to first treat the surfaces and return the components to a “like new” appearance. Industrial plants that need to recoat existing metal structures also need to remove rust before painting. According to Galiardi, he removed corrosion from a very large storage tank using the CleanTech laser system in about half the time of the alternative being considered, an abrasive disc grinder. With clean laser technology, there


is now an environmentally friendly alternative to abrasive blasting and chemical stripping for surface pretreatment. Te approach is safer for operators and highly adaptable to a wide range of manufacturing and industrial applications. “As people become more aware of laser-based systems and compare them to traditional methods, they need to factor in prep and cleanup time, which can impact project cost. When the improved operator safety, equipment longevity and lower maintenance of laser systems are also considered, the clean laser technology has a much higher ROI,” says Galiardi. Te longevity of low-maintenance laser systems further adds to their value. “CleanTech laser systems can last for 50,000 to 100,000 hours. After purchase, there’s virtually no maintenance necessary,”concludes Galiardi.


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