PROCESS EQUIPMENT UPDATE


more than 100,000 of these workers are employed as sandblasters. 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. “Sandblasting is inherently unsafe for operators. Te silica glass used in sandblasting is toxic. An operator must wear a full HEPA suit when sandblasting to avoid breathing in particulates.” Sandblasting also is time-consuming to clean up since the sand essentially scatters everywhere, even though it is usually considered a “fast” cleaning method.


DRY ICE BLASTING 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 significant


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


Laser systems remove corrosion, grease,


residue, and existing coatings from metal surfaces quickly


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traditional methods when preparation and clean-up are considered. “In our experience, laser cleaning is


as fast at removing rust or old coatings as other methods, but without the same amount of clean-up,” 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 3,000-watts (a 4,000-watt version is in development) with chamber sizes from 3in x 3in 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 automotive 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. In another example, Galiardi was asked


to remove rust from over 400 transmissions in a couple of days. Te laser systems are particularly effective when reaching into tight spaces that are hard to reach by hand. By masking the area to protect vulnerable parts, the laser can be applied without affecting the rest of the assembled product. “No other parts [of the transmission] had to be removed and nothing had to be cleaned afterwards,” he says. 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. “Disc grinders basically just chip off [the rust] and it becomes airborne and makes a mess. Grinders can also be dangerous because sparks or debris can shoot off the wheel or catch an article of clothing,” he says. With clean laser technology, there is


now an environmentally friendly alternative to abrasive blasting and chemical stripping for surface pre-treatment. Te approach is safer for operators and highly adaptable to a wide range of manufacturing and industrial applications.


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