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Mill Scale Removal & Descaling – Efficient Surface Treatment

DESCALING Removing Scale: Efficient processes for steel and iron surfaces Oxygen and heat cause scale to form When steel or iron is heated, scale forms through contact with oxygen. This oxide layer must be removed to ensure effective further processing of the product. Scale forms mainly during forming processes such as hot rolling or forging in the blast furnace, but also during heat treatment processes intended to improve the durability of metal / steel surfaces. To avoid surface defects during subsequent processing (painting / mechanical machining), all scale must be removed beforehand. To achieve this level of surface cleanliness and surface quality, mechanical descaling, chemical descaling, and electrochemical methods (electrochemical descaling) are available. A special form is weld scale, which is a by-product of welding. This must also be completely removed before any coating. Descaling processes: mechanical and chemical methods Descaling by shot blasting: Special requirements for the equipment Scale can be removed particularly effectively by shot blasting using wheel blast or turbine blast systems. Since oxide scales typically have high hardness, they require strong impact energy of individual steel shot particles to obtain a clean metal surface after blasting. In large rolling mills, steel plates, stainless steels, or raw steel are often descaled directly after production using shot blasting equipment and then provided with corrosion protection. These metal parts are then delivered to end customers. Beyond rolling mills, typical users include the steel production sector, forging operations, or heat-treating facilities. Depending on the classification, scale adheres with varying strength to different materials. Dry scale — which forms on carbon steels — can be removed relatively easily. To remove adhesive scale, which forms a thin, closed, and very strongly bonded surface layer, shot blasting must be performed for a long time and at very high abrasive velocities. This residue also places high demands on the blasting equipment. If blasted-off scale enters the abrasive cycle, it acts like sandpaper. This leads to extreme wear of turbine blades and (in the worst case) can damage the components. Therefore, shot blasting systems for descaling must feature extremely reliable abrasive cleaning with effective air-wash separation. A special form of descaling is wet blasting for stainless steel components, known as "Pure Finish." This process is particularly used to prepare surfaces for the food industry where high surface cleanliness and corrosion resistance are required. Descaling by mass finishing (vibratory finishing): The most efficient option for small and medium-sized parts in large quantities Beyond large rolling mills and foundries with massive workpieces, mass finishing can also be the first choice for removing scale from raw steel. Workpieces after heat treatment — especially in larger quantities — can be descaled or simply cleaned of discoloration (oxides) very economically in mass finishing equipment . These finishing processes are especially suitable when surface impurities (oxides, oxide layers, contamination) do not adhere too strongly to the metal surface. Another advantage of mass finishing is the possibility of fully automated, program-controlled multi-step processing. In specially modified mass finishing systems, parts can be cleaned, descaled, and polished in a single run. Deburring, grinding, smoothing, and polishing can also be combined as required. In many industrial applications, even part-to-part processing without media is highly effective. Cleaning and pickling inside tubular or sleeve-shaped internal geometries is also possible. Another important consideration is the desired surface finish: Mass finishing can achieve relatively smooth surfaces, while shot blasting typically produces a rough but very uniform surface structure. It is also crucial how well the system integrates into the production line and how the workpiece is to be processed after descaling, for example through subsequent coating or additional finishing processes. Chemical and electrochemical descaling In addition to mechanical descaling methods — which include shot blasting, mass finishing, manual descaling (often using ceramic flap tools), and processing in a scale washer — chemical methods are also available. In chemical descaling, usually by pickling, the component is immersed in a bath where the scale layer is dissolved using acidic solutions such as hydrochloric or sulfuric acid. The acid reacts with the iron oxides and removes the hard, brittle oxide scales from the metal surface. This chemical process can be intensified by applying electrical current. This type of scale removal is particularly effective for complex geometries and hard-to-reach areas. A disadvantage is that acid residues must be thoroughly removed to prevent corrosion. The process also generates harmful fumes and wastewater that is environmentally damaging, and improper treatment can attack the base material. What you should know about descaling: Frequently asked questions What is scale and how does it form? Chemically, scale is an oxide or mixture of oxides that forms on the surface of iron or steel when the metal reacts with oxygen at high temperatures. It consists mainly of a mixture of various iron oxides, including wüstite (FeO), magnetite (Fe₃O₄), and hematite (Fe₂O₃). These oxide layers form at high temperatures, adhere strongly to the metal surface, and create a dense, hard outer layer that is difficult to remove using mechanical methods. What is the difference between scale and rust? Scale and rust are both oxidation products of iron, but they differ significantly in formation and properties. Rust forms at normal temperatures in the presence of water and oxygen. Scale forms mainly at high temperatures — usually without the presence of water. Scale adheres tightly to the metal surface and forms a dense, hard layer, while rust forms loosely on the surface, makes the material porous, and continuously promotes corrosion. What is the difference between scale and burn-off? Scale refers to the oxide layer that forms on the metal surface at high temperatures, while burn-off refers to the material loss caused by oxidation, burning, or slag formation. In steel manufacturing, such losses can reach up to 4% of the initial weight. Depending on the formation process, scale may also be referred to as mill scale, forging scale, or scale from heat treatment. Use the Solution Finder to find the right system for your processing method. Solution finder

Vibratory finishing is the most economical solution to round off the edges

EDGE ROUNDING Sharp edges, short service life: How edge rounding protects metal part Gentle edge processing through advanced surface finishing Workpieces with high quality requirements can be processed economically, reproducibly, and precisely on their cutting edges and surfaces using mass finishing (vibratory finishing). Complex sheet metal parts with multiple edges, produced by punching or fine blanking, are frequently deburred and rounded in flexible mass finishing systems. Rounding is essential for smooth further processing, for example to ensure proper feeding in automated operations. Edge rounding plays a particularly important role in the manufacture of cutting tools where defined edges with a precise edge radius are required. It is also crucial as a preparation step before coating or painting sheet metal. We offer one of the world’s most comprehensive portfolio of process media, along with a wide range of mass finishing systems for the diverse challenges of edge rounding. Edges – more than just deburred Technically, edge rounding is an extension of the deburring process. At a certain point, depending on factors such as the type of grinding media or the machine used, deburring transitions into edge rounding. While traditional deburring often only removes a small burr or creates minimal edge breaking — because the parts are supposed to remain “burr-free but sharp-edged,” — edge rounding aims for a uniform, defined radius. Overview: Types of Edges? Sharp edge: A workpiece edge that has not been post-processed. Broken edge: An edge where burrs have been removed, often by manual grinding (edge breaking). Chamfered edge: An edge beveled, often at 45°, usually in preparation for welding. Rounded edge: An edge rounded with a defined radius, for example by mass finishing (vibratory finishing) or blasting processes. What do you need to know about edge rounding? Frequently asked questions Why are rounded edges more than just a “nice-to-have”? Sharp sheet metal edges or workpiece edges can disrupt functionality, cause injury during assembly, damage components, or create problems during coating of the metal parts—for example, because powder coating does not adhere properly. Careful deburring and edge rounding are therefore essential. With modern machines, edges can be precisely rounded with a defined edge radius of up to 0.2 mm. This reproducible deburring process significantly improves the quality, functionality, and durability of metal parts. Why is edge rounding indispensable in sheet metal processing? In the metalworking industry, edge rounding is a standard step in sheet metal production. After punching, laser cutting, or other separation processes, parts often have sharp, burred cutting edges that must be rounded—especially before powder coating. This applies to many metals, including steel, stainless steel, and aluminium. The requirements for edge rounding vary by application: in decorative elements, aesthetics matter most, while in functional components, safety and corrosion resistance are crucial. Why must sheet metal edges be carefully rounded before coating? If a sheet metal edge is sharp, especially with burrs, the coating thickness (e.g., powder coating) is often reduced because the coating does not adhere properly. This leads to higher corrosion risk—the most common cause of flaking and premature rust. Defined edge rounding increases the surface area, allowing the coating to flow more evenly around the edge, resulting in uniform layer thickness, mechanical stability, and durable corrosion protection. Rounded edges also improve handling safety and ensure a longer service life. How does edge rounding extend the service life of a workpiece? There are numerous reasons why metal edge rounding increases the service life of sheet metal and other metal parts. Sharp edges are more prone to corrosion because they provide a larger attack surface for moisture and contaminants. Rounded edges are less susceptible and therefore more resistant. In addition, mechanical wear, tool wear, and edge chipping occur much faster in everyday use when sharp edges remain. By rounding to a defined edge radius, loads are distributed more evenly, reducing the risk of cracks or fractures. Can inner edges also be rounded? Yes. Inner edges can — and must — also be rounded to a defined edge radius, while remaining burr-free. This step is vital for product safety: rounded inner edges prevent sharp edges from damaging pneumatic hoses or cables. Mass finishing technology offers the optimal solution here as well. The patented Multishape media is especially effective for processing internal edges. Why is edge rounding of cutting tools so important? For cutting tools such as drills and milling cutters, edge rounding is crucial. By rounding cutting edges to a defined radius, mechanical stability is increased, reducing the risk of microchipping. This significantly extends tool life and reduced tool wear. What are the benefits of edge rounding for carbide tools? For carbide tools, edge rounding is a proven method to prevent microchipping. Rounded edges also improve the surface quality of the machined parts, reducing burrs and uneven cutting marks. Particularly demanding machining tasks can be performed effecively in DLyte machines . When is blasting technology the best solution for edge rounding? For large or complex workpieces, blasting processes are often the best option. Both dry and wet blasting methods are available. A typical example is a fully automated line in which deburring, edge rounding, surface cleaning, and coating are integrated—such as in a preservation line for steel components. Use the Solution Finder to find the right system for your processing method. Solution finder

Industrial decoating: safe and efficient coating removal

DECOATING Effective decoating: The key technique in surface finishing Components and specific requirements Decoating is a cleaning process and one of the most common types of surface finishing. It involves removing contaminants or unwanted materials down to the base material. Often, decoating also removes previously applied foreign coatings, such as paints and protective layers. In industrial settings, mechanical decoating is primarily achieved using shot blasting, often referred to as sandblasting. Decoating, like paint stripping, serves various purposes: recycling raw materials, helping meet aesthetic standards, cleaning components of dirt or rust, improving adhesion, or removing temporary corrosion protection. In the aerospace industry, decoatin (also called stripping) serves a specialized purpose: components such as landing gear parts, turbine blades, brake and turbine housings, or combustion chamber surfaces must be decoated before safety inspections to detect even minimal surface defects. The base material or component must not be damaged in the process. An optimal decoating process does not attack the substrate, ensuring its (repeated) reuse. With the right equipment and tailored processing methods, mineral building materials like concrete, sandstone, glass, or wood can be decoated, as well as plastics and metals. It is crucial to precisely adapt the equipment to the components being processed. Choosing the right decoating technique is also essential for process efficiency. What are the most common shot blasting methods for decoating? Wheel blasting (turbine blasting) Wheel blasting is the most effective method for quickly, intensively, and cost-efficiently processing large, flat components. It is the most important industrial decoating technique, ensuring uniform treatment of parts with low energy consumption and a high degree of automation. By recycling and reusing the blasting media, wheel blasting is not only effective but it is also sustainable, even for large quantities, such as in multi-tumbler or trough belt blasting systems . Compressed air blasting This method allows for precise, localized blasting using injector guns, which can be operated manually or robotically. It is highly controllable, and effectively reaches complex geometries like interior spaces, undercuts, or corners. However, media consumption per treated area is significantly higher than with wheel blasting, and energy consumption is substantial due to the compressed air . High-pressure water jetting When decoating with high-pressure technology, water is applied under high pressure to the surface layer using a nozzle. In most cases, no blasting media is required, which helps preserve the substrate. This method is often a preferred alternative to chemical decoating, offering significantly better environmental compatibility. More information on high-pressure water jetting can be found here . What do you need to know about decoating? Frequently asked questions What Is the difference between decoating and paint stripping? Decoating is a process used to remove coatings and layers from surfaces. Paint stripping is a special kind of of decoating, specifically referring to the removal of paint layers. Decoating is the broader term and also includes the removal of: Mill scale and oxide layers Scale from forged parts Casting skin and molding sand Rust and corrosion products General contaminants and foreign substances What alternative decoating methods are available? Surface finishing includes various decoating methods beyond just mechanical processes. The most significant are chemical and thermal decoating, the latter also being known as pyrolysis. Thermal decoating removes coatings using high temperatures, making it unsuitable for some materials. When it can be used, it delivers fast and thorough results without damaging the substrate. Chemical decoating removes surface coatings without harming the base material, enabling uniform material removal even on complex geometries. However, it poses a high environmental burden due to the use of chemicals, and incurs high disposal costs for contaminated wastewater. Is selective decoating of substrates possible using shot blasting? Within certain technical limits, yes. Selective decoating is particularly feasible when the layer to be removed differs significantly from the base material, such as in hardness or adhesion strength. In such cases, targeted removal can be controlled by selecting the appropriate blasting media . Selective decoating via shot blasting reaches its limits when the coating and substrate have similar mechanical properties or very high adhesion. In these cases, chemical or thermal decoating methods are often preferred. What are the benefits of decoating using shot blasting? Decoating is a crucial step in surface finishing to ensure the quality and longevity of components. It is used to clean and prepare surfaces for further processing, and can also remove dirt and corrosion. Thus, decoating is essential for maintaining the quality and durability of components. Use the Solution Finder to find the right system for your processing method. Solution finder

ISF® stands for Isotropic Superfinishing

ISF ® -PROCESS For superfine surfaces Isotropic Superfinishing, ISF® for short, is also known as the “REM process” and stands for chemically accelerated surface finishing. The patented ISF ® process is the ideal combination of chemical and mechanical surface finishing. It is used when high-quality parts need to be finished as gently as possible. By using compounds, usually in the acidic pH range, a thin conversion layer forms on the parts being processed. This is then removed by the special grinding media used in the process. This ensures the permanent removal of the material. The subsequent neutralization phase produces super-smooth, shiny and decorative surfaces. Another benefit of this surface finishing technique is that the achieved surface profile reduces the rolling and running noises of components, while also increasing their service life. Let’s work together to discover the opportunities that the ISF ® process can offer you. Use the Solution Finder to find the right system for your processing method. Solution finder

Why is it necessary to grind a surface?

GRINDING Why is it necessary to grind a surface? Almost every product requires an optimal finish Machining marks from milling, surface defects, parting lines, or general roughness on parts from all areas of manufacturing—whether from conventional methods or additive manufacturing (3D printing)—often need to be evened out before further processing of the surface can take place. This is done through grinding, one of the most important metal finishing methods in modern industry. Grinding helps improve surface quality and control roughness levels. Surfaces need to be ground for both functional and aesthetic reasons to enhance performance—for instance, when grinding bearing rollers, door handles, or aluminum wheels, where the surface is first ground before being polished to a high-gloss finish. What happens during grinding? Grinding is a cutting process in which material is removed with an abrasive tool to improve the form, dimension, and surface of a workpiece. Grinding media are used that perform very fine cutting operations. Primarily metals such as steel, aluminum, brass, or titanium are ground, but wood, plastics, glass, ceramics, and stone can also be handled. The grinding method varies depending on material properties and the desired outcome. The fundamental technique of grinding is ancient and has always been used for refining surfaces. Nature’s example can be seen in pebbles smoothed by stream processing in riverbeds. Conventional grinding or mass finishing? When complex-shaped parts need to be deburred, smoothed, or surface-finished, the question arises: which grinding method should be used? The choice depends on factors such as the desired surface appearance, material, geometry, size, and batch size. Manual or machine grinding is well suited for “simple” shapes, mostly flat parts, or when partial areas must be selectively processed. It delivers high precision but often requires considerable human intervention, which increases processing time and computing resources. Mass finishing, by contrast, is an automated batch processing system that offers considerable cost efficiency and time savings for larger quantities. It achieves uniform results even on complex geometries, making it ideal for edge rounding, burr removal, or producing homogeneous surfaces. Modern batch processing systems work with high efficiency and can process large volumes of data-like work units with a hands-off approach, minimizing manual intervention. Drag finishing and surffinishing – mass finishing for high-end requirements Drag finishing Drag finishing was developed in the 1980s to make mass finishing viable for high-tech industries such as aerospace and medical device production. Here, parts are mounted on spindles and dragged through stationary media. This allows targeted, reproducible processing of delicate individual parts without part-to-part contact. Drag finishing has largely replaced manual intervention, saving computer time and ensuring reliable results. Compared to conventional mass finishing, drag finishing is around 40 times more effective. Surffinishing Surffinishing takes this a step further. Parts are clamped and immersed in grinding media, rotated at various angles, while the media rotates with the work bowl at up to 80 RPM. This creates a highly intensive interaction between workpiece and media, achieving reproducible results with very short processing time. Surf-finishing enables rough grinding, fine grinding, and even polishing of hard-to-process materials such as ceramics or specialty metals. This high-volume processing method ensures mirror-smooth, scratch-free surfaces. Surf finishing is the most intensive form of vibratory finishing. Its efficiency is around 80 times higher than that of a classic mass finishing machine. What you should know about grinding Frequently asked Questions Are deburring, rounding, and similar processes subcategories of grinding? Not exactly. While the terms often overlap in practice, technically speaking, deburring, rounding, smoothing, and polishing are not merely subcategories but independent processes or objectives. They sometimes employ the same technologies—in our case, mass finishing (vibratory finishing). However, these goals can also be achieved with other methods. For example, burrs can be removed using brushes, thermal techniques, or shot blasting technology. To remove scratches in small-scale projects, polishing with a soft cloth may suffice—or, when preparing surfaces for painting, coarse/fine sandpaper is used. How does mass finishing (vibratory finishing) work? Mass finishing (wet finishing) is a special form of grinding primarily used for the industrial conditioning of metal surfaces. Workpieces are usually processed in batches together with application-specific grinding media, water (99% of all mass finishing jobs are wet processes), and compounds (active cleaning additives) inside a mass finishing system. Contact pressure from the media and the relative movement of the finishing machines work together to create a consistent surface pattern across the complete batch of parts. When is mass finishing the best choice? If you want to grind larger workpiece batches of mass-produced parts that are relatively robust, then mass finishing machines are the most cost-effective solution. With the right grinding media and compounds, such systems enable the most efficient and economical results. In addition, mass finishing offers the unique advantage that multiple processes can run batch jobs within the same system—like degreasing, grinding, cleaning, deburring, rounding, corrosion protection, or rust removal. Such systems can easily be integrated into complex production lines. In highly automated workflows, parts only need to be loaded once at the beginning of the batch window. They then pass through the entire batch job cycle without further human intervention. This approach exemplifies modern batch processing applications for repetitive tasks and high volume processing, providing significant cost saving. Why is grinding an important step before painting? To achieve optimal coating results, many surfaces must first be ground. Grinding creates a homogeneous, grippy surface that improves adhesion of coatings. Specially equipped mass finishing systems can reliably and cost-effectively process large batches of small or micro parts for this purpose. Possible outcomes – what can be achieved through metal grinding? Depending on the method, abrasive grain, and processing stage, industrial grinding can yield a wide variety of surface results. Generally, grinding produces a uniform surface, though roughness may vary considerably—from coarse and visible to extremely smooth. Rough grinding results in distinctly rough surfaces with visible grinding structures and medium roughness values (Ra) between about 6 and 1 µm. Such surfaces are ideal for subsequent processing steps. Fine grinding produces much smoother surface results, often with roughness values between Ra 1 and Ra 0.2 µm. The surface appears uniformly matte to slightly shiny, with barely visible grinding marks. Ultra-fine or polishing grind achieves surfaces with very low roughness below Ra 0.2 µm. These areas appear smooth or even glossy and are ideally suited for high-gloss polishing. In total, grinding—particularly metal grinding—offers a wide spectrum of possible outcomes, ranging from functional roughness to decorative smoothness. Even finely ground surfaces remain microscopically rough but, free of abrasive particles, can already be considered “finished” for many applications. What about grinding and mass finishing of wood and plastics? Wood finishing Wood: Traditional grinding with sandpaper smooths surfaces mechanically, removing uneven fibers and preparing the material for oiling, staining, or painting. Depending on grit size, rough pre-grinding or fine finishing is possible. Mass finishing is less common but effective for sawn or turned parts with complex geometries, e.g., in toy making or instrument building. Dry finishing with dust extraction and specially designed media ensures process efficiency. Plastics: Many plastic surfaces can also be processed by mass finishing. This is ideal for deburring injection-molded parts, removing parting lines, or smoothing surfaces before painting. Soft grinding media and short cycle times prevent damage. Suitable plastics include ABS, POM, PA, glass-fiber reinforced materials, and 3D-printed polymers. Flexible or thin-walled parts require careful handling. Dry mass finishing as a specialized method Water is not always required for mass finishing. If the material demands it (e.g., wood, certain plastics) or if disposal reasons favor it, dry finishing is used. Dry processes are usually less aggressive and remove less material than wet processes, but this lower performance can be compensated for with more intensive systems such as drag finishing, surf-finishing, or centrifugal systems. Dry processing methods are also employed for high-value workpieces in aerospace and medical technology. These hybrid systems process large amounts of data-like tasks without user interaction, providing flexibility on an as-needed basis. Grinding media – the key element of the mass finishing process In grinding—and especially in mass finishing—it’s not just about the machines. The successful processing of different materials requires perfectly matched grinding media and process components. As a market leader in mass finishing, we offer the world’s largest range of media developed and produced in-house. Plastic-bonded media with fine abrasive grains are used for gentle workpiece processing, especially aluminum parts, and create conditions for later polishing. Ceramic media with higher pressure provide intensive grinding performance. Wet grinding pastes in various grit sizes support processes from coarse grinding to fine grinding. Combined with compounds, some equipped with corrosion protection, our product portfolio includes more than 15,000 different process materials, ensuring that all processing challenges and workpiece geometries can be handled efficiently. Use the Solution Finder to find the right system for your processing method. Solution finder

Shot peening – increases the service life of workpieces

SHOT PEENING Shot Peening Explained: Targeted Surface Hardening for Improved Component Properties Shot peening, also known as shot blasting for surface strengthening, enhances the durability and strength of metallic components. This shot peening process offers many advantages: it increases the fatigue life of a component, improves load capacity while reducing overall weight, closes microcracks, reduces the tendency to stress corrosion cracking and corrosion fatigue, and enhances both reliability and fatigue resistance (for example in springs, connecting rods, and crankshafts). This cold working process is suitable for any metal surface and is considered one of the most important surface treatments in the industry. Especially in sectors where maximum requirements for fatigue resistance and durability are demanded, and where components are constantly exposed to stress, the peening process has become indispensable. Additionally, due to the continuous impact of the shot stream during shot blasting, components are also deburred, descaled, and derusted, achieving a comprehensive surface finishing. Typical parts treated by shot peening include small mass parts such as gears, shafts, transmission components, springs, axles, valves, connecting rods, and crankshafts, but also suspension parts and large structural components. What Makes Rösler’s Shot Peening Technology Special? Rösler’s shot blasting and shot peening work stand out through intelligent process monitoring, innovative details, and durable components, including: Monitoring of the shot stream during air blast systems via magnetic measurement or Coriolis dosing systems – depending on whether metallic or non-metallic peening media are used. Use of the Rösler Power Line Valve for regulation in centrifugal blast wheel operations. Automatic acquisition, evaluation, and storage of process data through the HMI system “PC Supervisor” for maximum process safety in air blast systems. Efficient shot circulation using advanced classification systems, such as flow-optimized air separation, sieving for shot size classification, and media entrance location optimization. Workpiece transport monitoring for continuous reliability. High-performance RUTTEN Gamma turbines with reversible blades, delivering up to 16 times longer service life and ensuring a stable blast stream with minimal adjustment needs. What You Should Know About Shot Peening Frequently Asked Questions How Does Shot Peening Work? – Residual stress creates increased part strength Strength is forged under pressure: In the shot peening process, carefully selected round metallic media are accelerated at high velocity and consistently directed onto the metal surface of gears, connecting rods, crankshafts, and similar parts. Upon impact, they induce compressive residual stress in the surface layer and down to a maximum penetration depth. This effect significantly increases the fatigue resistance of highly stressed components such as gear teeth, turbine blades, and connecting rods. The principle behind this cold working process is similar to forging metal – but instead of a hammer, the material is compacted by the high-energy shot flow. Each individual shot particle produces microscopic plastic deformation, and in total, these overlapping passes result in a continuous layer of beneficial compressive stresses. What Are the Advantages of Shot Peening? After shot peening, the metal surface is stronger, less prone to stress corrosion, and more resistant to corrosion fatigue. It shows improved mechanical properties, longer fatigue life, and increased fatigue resistance (e.g., in springs, crankshafts, and connecting rods). Particularly in aerospace, the process development of shot peening since the 1950s has been advanced rapidly. Today, the advantages of shot peening are indispensable in numerous industries. Whether used for turbine blades, engine blocks, suspension parts, or structural components – shot peening protects against fatigue cracks, optimizes weight, and increases durability under continuous stress. In aerospace, where all parts are exposed to extreme tensile stresses and operating loads, shot peening has become a standard method to introduce compression stresses into the surface. It is now used Which Peening Media Are Used in the Shot Peening Process? As the German term “Kugelstrahlen” suggests, cut wire shot or cast shot in a round metallic shape is typically used. The objective is to transfer impulse energy and induce residual compressive stress in the surface zone of the workpiece. The size of the peening media plays a critical role: larger media can penetrate deeper and introduce compressive stresses at greater depth, but may also cause excessive cold working and unwanted plastic deformation on the metal surface, reducing the beneficial effect. Another critical factor is shot quality. Shot breakage can generate sharp-edged shot fragments that roughen or damage the surface, causing local weakening. To avoid this, high-quality peening media with narrow size distribution, high hardness, and low fracture tendency must be used. Cut wire shot, produced from rounded wire sections, is particularly effective, as it ensures a consistent and stable desired surface effect during shot blasting. For Which Industries Is Shot Peening Essential? In aerospace, shot peening is used to strengthen turbine blades, structural components, stringers, fan blades, and even complete aircraft cabins. It prevents stress corrosion cracking, delays fatigue cracks, and helps components withstand extreme operating conditions. In e-mobility, where lower component weight means higher performance, reduced resource use, and longer range, shot peening enables the production of form-optimized, lightweight parts that are stronger and more durable. Use the Solution Finder to find the right system for your processing method. Solution finder

Wet blasting

WET BLASTING Wet blasting or slurry blasting – gentle on the surface When water and blasting media work together Wet blasting, also referred to as slurry blasting, is a particularly gentle technique for surface finishing. In this process, compressed air, water, and blasting media are applied in combination to the workpieces and parts being processed. The process removes contamination and produces defined surface conditions without damaging the base material. Water serves several functions in this process: it combines the blasting process (conventional "sand blasting" or dry blasting) with a cleaning effect, promotes more uniform distribution of the blasting media, penetrates even the smallest crevices, and simultaneously cushions the blasting media like a buffer. As a result, material removal is minimal, since the water absorbs the impact energy — allowing the tightest workpiece tolerances to be maintained. The process is particularly well suited for producing easily cleanable surfaces, for the gentle cleaning of workpieces, and for achieving a visually appealing surface finish. What is wet blasting especially suited for? Wet blasting is ideally suited for sensitive and precision-manufactured metal workpieces. The flow of water across the workpiece surface produces a grinding-like effect. However, this method is not only gentle but also cost-effective: the cushioning water layer between the workpiece and the blasting media reduces blasting media consumption. Because dust generation — and the associated contamination — is prevented, very fine blasting media can also be used. To achieve a particularly uniform blasting result and surface finish, blast nozzle control in Rösler wet blasting systems is typically handled by an industrial robot or a CNC system. Feeding and discharge are also individually adapted to your production requirements — and can be automated in a variety of ways upon request. Frequently asked questions – What you need to know about wet blasting How does wet blasting work? Compressed air is generated by a compressor and applied to the workpiece in combination with water and blasting media. The blasting media used is continuously reconditioned to ensure a clean and resource-efficient blasting process. The captured contamination and the spent blasting media must be separated after use and disposed of properly. What distinguishes wet blasting from dry blasting? In wet blasting, water is added to the blasting media. This mixture cushions the impact energy of the blasting media, reduces material removal, and prevents dust generation. The result is particularly uniform surfaces that are treated with minimal stress. What advantages does wet blasting offer over other processes? Gentle processing of sensitive workpieces Dust-free and clean working environment Reduced blasting media consumption Combination of cleaning and surface refinement Ability to use fine blasting media as well For which materials or components is wet blasting suitable? The process is particularly suited for sensitive or precision-manufactured workpieces such as implants, turbine and engine components, jewelry, tools, and parts from the medical technology, aerospace, and precision engineering sectors. Stainless steel in particular can be effectively processed using the wet blasting method, producing surfaces that meet the stringent cleaning and disinfection requirements of the medical and food processing industries. Which blasting media can be used in wet blasting? Depending on the desired result, blasting media such as glass beads, ceramic beads, or fine grades of aluminum oxide are used, among others. The water-based process allows very fine blasting media to be handled that would be difficult to manage in dry blasting. The key principle applies: the effectiveness of wet blasting depends on the correct combination of blasting media, its concentration, water, and air pressure. How does wet blasting affect surface quality? The water ensures uniform distribution of the blasting media and produces a defined surface with a slightly glossy effect. In addition, blasting media embedment in the surface is minimized, and the workpiece is freed from residues and contamination. How did the wet blasting process originate? The first wet blast machines were developed in the 1960s for the processing of highly sensitive components in the aerospace industry. Where is the process most commonly used today? Today, the process is used, among other applications, for producing precision surfaces on implants, jewelry, engine components, cutting tools, and machining tools in the aerospace, medical technology, and tooling manufacturing sectors. Is wet blasting environmentally friendly? Yes. Since no dust is generated during the process and the water binds the removed particles, the impact on the working environment is significantly reduced. In addition, blasting media consumption is lowered, contributing to more efficient use of resources. Wet blasting for surface compaction (shot peening) The wet blasting process can also be used for surface compaction and work hardening when surfaces are highly sensitive and conventional shot peening processes would be too aggressive. Use the Solution Finder to find the right system for your processing method. Solution finder

Rösler has the perfect solution for your finishing process otherwise we create a solution for you.

SPECIAL APPLICATIONS The perfect solution for every application Cutlery cleaning and drying Cleaning cutlery so that it is residue-free and spotless is a labor-intensive process that takes up your staff’s time. However, with our tried-and-tested, modular system for cutlery cleaning and drying we can help you save valuable time. Our range of machines includes compact individual machines for efficient cutlery cleaning, drying and final polishing. We also offer combination systems that clean, dry and polish your cutlery to a high shine in a fully-automated machine. All our machines guarantee a hygienic clean and brilliant shine in a very short time. All the consumables needed for processing the cutlery have been tested and approved for use in the food sector. In addition, we offer our special RÖSLER Keramo-Finish® process for refinishing cutlery and removing heavy signs of wear. High gloss wheel polishing Until you can see your reflection: our compact wheel finishing machine is ideally suited for pre-grinding, fine-grinding and polishing small batches and special wheels up to 24 inches. Forged or cast, new or used: our machines polish your wheels quickly and are extremely user-friendly thanks to dual motor technology with integrated lifting system. With variable speed control, the wheel finishing machine can be adapted to any surface finishing task – without any manual labor. This type of machine is also suitable for other motor components as well as reconditioning parts from classic cars. Stone finishing Even natural products are given the finishing touch with our machines. For example, with stone finishing, we use mass finishing systems to enhance the characteristic features of the stone, following nature’s example. We can achieve different finishes, including antique surface effects, ragged edges and smooth marble surfaces. Even extremely large and heavy workpieces weighing more than 100 kilograms can be processed with our stone finishing machines. Our portfolio includes fully linked system solutions with automatic handling as well as individual machines. Wood finishing Deburring, smoothing and varnishing are also everyday challenges in the woodworking industry. With our mass finishing systems, we offer numerous flexible solutions that have proven themselves to be well suited to hardwoods. Our customers in the woodworking industry include manufacturers of toys, musical instruments and decorative items. The mass finishing process can also be used for the reliable antiquing of wood. In the woodworking industry, our customers also benefit from the largest range of consumables worldwide with around 15,000 finishing media and compounds as well as our decades of experience in dealing with all conceivable types of surface finishing. Coin finishing For decades, we have had many of our finishing systems in use worldwide in the coin industry, and many major mints rely on our expertise and Rösler product quality. Whether for cleaning circulation coin blanks following the annealing process or the pre- and post-treatment of galvanized coin blanks, our fully automatic, stainless steel centrifugal disc finishing machine, MPA 37.1A/2, delivers perfect results and guarantees you the highest processing capacity on the market with a throughput of up to 1,800 kg per hour. For the next step of drying the coins, we offer linear hot air dryers with textile linings, hot air dryers without drying agents as well as classic drying systems. Our newly developed and patent-pending drying technology offers significant energy savings, especially for users with high production volumes – and therefore also a reduction in CO 2 of up to 45% for the drying process. Mass finishing without media Part-on-part finishing is another common option for small or bulk parts. The benefits are clear – no grinding media is required for this special process, making the process cheaper and significantly reducing the cost per piece. Centrifugal disc finishing machines or rotary vibrators from our WTA range can be used for mass finishing without media. These are actually washing and drying systems. However, the rounding, smoothing, polishing, cleaning or de-oiling of miniature components and small parts is also possible in these part-on-part machines. Both machine types allow the complete unloading of the finished workpieces either by tilting the work bowl or via an unload gate in the bottom of the work bowl. Use the Solution Finder to find the right system for your processing method. Solution finder

Rösler the perfect solution for your surface finishing treatment .

PRODUCTS Discover the diverse world of surface finishing The largest range of products and services worldwide – precisely tailored to your needs At Rösler, solutions are only solutions when they are perfect. Why can we say that? Because with our extensive range of machines, we have almost endless possibilities for surface finishing – and in our Customer Experience Center we have the expertise to find the ideal finishing processes for you. So, take a look through our options – then challenge us. We look forward to learning about your products. Roughening Deburring Paint stripping Rust removal De-sanding Decoating Descaling High-pressure water jet blasting ISF ® -Process Edge rounding Wet blasting Polishing and smoothing Cleaning, de-oiling or degreasing Grinding Shot Peening Dry Electropolishing (DryLyte) Special Applications We have the right solution for your individual challenge! send Inquiry

Technically high-quality, long-term and economical solutions from

PRODUCTS Innovative blasting solutions with maximum efficiency for your perfect surfaces product overview Solution Finder Unlimited applications – no matter what your requirements Our shot blasting machines offer you almost unlimited options for surface finishing: from deburring, descaling, de-sanding and rust removal to roughening, cosmetic blasting, smoothing and edge rounding all the way to shot peening. After all, the functionality and aesthetics of surfaces are not only an important sign of quality for technical products, they also contribute significantly to their success on the market. Surface finishing is therefore nearly always essential and has to be integrated into existing production processes as an additional, value-added step. Not many technical procedures have such a variety of uses as shot blasting, especially when it comes to metal surfaces. However, other materials, such as concrete, sandstone, glass, textiles, wood and plastics, can also be processed with machines from Rösler. Intelligent, flexible, individual – our offer to you The range of machines from Rösler includes systems for precise compressed air blasting, wet blasting, as well as turbine blasting with highly efficient turbines, also known as blast wheels. Turbine shot blasting machines, or wheel blasters, are particularly well known for their low energy consumption, large blast coverage area, the so-called “hot spot” and achieving uniform surfaces. Injector and pressure blasting systems are especially suited to small area applications and precision tasks, both automated and manual. They also allow the use of highly abrasive media, which cannot usually be used in turbine blasting machines, such as corundum, silicon carbides, glass beads and fine plastic granulate. Turbine blasting machines Compressed air blasting machines Wet blasting machines Plastic deflashing machines That’s not all Choosing a machine from Rösler isn’t the end of your journey with us. As your partner, we offer a unique product range that covers everything you need for your surface finishing applications: Optimal customer support from our worldwide industry experts together with our sites around the globe Use of state-of-the-art simulation tools to simulate and optimize challenging blasting processes Digital process monitoring for even more reliable and cost-effective processes Expert advice and testing in our worldwide Customer Experience Centers State-of-the-art manufacturing sites with a unique in-house production range After sales service for shot blasting machines, including individual service contracts and retrofitting advice Worldwide support from our own service and application engineers on site Training and professional development opportunities for your employees in our Rösler Academy We offer you a complete, stress-free package. That makes us unique and you successful! Professional & individual – we develop your custom process Thanks to our technical process knowledge developed over many years, our ability to quickly understand complex systems and the large number of tests and simulations carried out in our worldwide Customer Experience Centers , we are in the position to reliably find the best solutions for your requirements. We offer our customers the best possible quality and cost-effectiveness and therefore provide decisive competitive advantages. 90 percent of the shot blasting machines that leave our factory are customer-specific individual solutions. We feel at home in almost every sector. Our branch in France is also a top specialist for the aerospace and automotive industries. Did you know that we also develop customized shot peening solutions? In surface finishing, the design of the machine and the process used determine the effectiveness and cost – that’s why we use the latest multiphysics simulation software to optimize and design the blasting processes and the machine technology. You benefit from significant advantages: more effective and quicker processes, less waste, reduced costs and optimized dust extraction for shot blasting. Voice of Costumers Turbine blasting machines Compressed air blasting machines Wet blasting machines Plastic deflashing machines Innovative, durable, efficient – maximum power for you Our shot blasting machines boast a long service life, low maintenance requirements and innovative features. These are not just nice words; they translate into real added value for you. For example, 10mm blast room wear liners instead of the market-standard 8mm, spinner hanger blast machines with manganese plates that are usable on both sides and individually replaceable and highly efficient and effective blast media processing thanks to flow-optimized air separator equipment. We also focus on user-friendly ergonomics with lower working heights for our continuous belt blasting machines as well as easy operation through state-of-the-art controls. The heart of any shot blasting machine is its turbines (blast wheels). Over the last few years, we have put a lot of effort into further developing these key system components and our patented Rösler turbine technology gives you a decisive competitive edge. Our Gamma turbines enable you to increase performance by up to 20 percent for the same energy input. In addition, using both sides of the throwing blades can reduce operating costs by up to 30 percent. Digitalization and process monitoring also play an increasingly important role in the field of shot blasting. With Rösler Smart Solutions , we offer our customers a digital solution for all areas of process monitoring. From the quality of the components, to analyzing the operating parameters and even predictive maintenance. Finally, you are able to respond quicker to problems and faults, use active monitoring, reduce your processing costs and lots more. Turbine blasting machines Roller conveyor blast machines A roller conveyor blast machine is perfectly designed for processing long workpieces in a continuous process. Discover product Preservation lines Highly complex giants for the processing of steel sheets or profiles. The heart is a roller blast machine with up to eight high-performance turbines. Discover product Wire mesh belt blast machines With up to eight turbines, this powerhouse is a multi-talent for machining long, flat or voluminous parts - economically and reliably. Discover product Spinner hanger blast machines Heavy, large-volume and massive parts are suspended from cross beams in these systems and processed in batches or in a continuous process. Discover product Multi-Tumbler Thanks to specially shaped ribs, pyramid-shaped drum base and gap-free design, the Multi-Tumbler blasts innovatively, quickly and thoroughly. Discover product Tumble belt blast machines Derusting, descaling or roughening in a continuous or batch process: Troughed belt shot blast machines are suitable for all robust, drum-type workpieces. Discover product Turning chamber blast machines The best solution for machining larger workpieces with sometimes complex geometries - largely based on the principle of single-part machining. Discover product previous next Compressed air blasting machines RSK Blasting cabinet Flexible and compact: We offer our blast cabinets in injector or nozzle blasting versions and with many expansion modules. Discover product VB-Systems Robust and variable plant system, ideal for manual blasting operation and expandable with many features for comfortable and ergonomic working. Discover product AST-Systems Compact robotic blast machine with motorized, swing-out turntable for external and internal machining with various tools. Discover product ARD-Systems Automated swing door system for satellites or workpiece holders for precise machining processes. Discover product ALS-Systems Robotic shot blast machine for the processing of very large and heavy parts with motorized main door. Robot controlled and operator friendly. Discover product ATT-Systems Proven system for effortless handling of heavy workpieces in CNC or robot operation with motorized loading carriage. Discover product ATV-Systems Continuous blast machine for the processing of large structural components with vertical part transport, highly precise thanks to dual blast robot. Discover product Vacjet S or P Mobile manual blasting system for processing very large, immobile parts - such as in aerospace, energy or shipbuilding. Discover product previous next Wet blasting machines ALS UHPW-Systems Ultra-high pressure water jetting system for removing the toughest coatings at up to 4,000 bar, especially for the aerospace industry. Discover product VB H-Systems Manual or automated stainless steel wet blast cabinet with high efficiency pumps for perfect product/water mixture and repeatable results. Discover product ABR Pure Finish-Systems Wet blast room for machining particularly large parts and achieving low roughness Ra < 0.8 µm on stainless steel surfaces. Discover product ARD-Systems Automated swing door system for satellites or workpiece holders for precise machining processes. Discover product previous next Plastic deflashing machines Tumble belt blast machine The compact solution for the all-round and effective processing of drum-compatible thermoset and highly filled thermoplastic workpieces. Discover product Multi-Tumbler The blast media in this system uniformly and reliably captures even the smallest bulk material parts - thanks to the unique "Multi-Tumble" effect. Discover product Wire mesh belt blast machine High-performance system for non-contact blasting in continuous operation with up to four turbines for the continuous processing of plastic workpieces. Discover product Blast cabinet From manual blasting to fully automatic process - proven system with many additional options for a wide range of applications. Discover product Satellite machines Particularly suitable for deburring sensitive workpieces with complex geometries - can be operated as an injector or turbine blast machine. Discover product previous next What are the key points about shot blasting? A look at frequently asked questions. What is shot blasting? Shot blasting is an essential technology for surface treatment or surface finishing. As such it offers numerous methods for the mechanical refinement of surfaces. There are dry shot blasting processes as well as wet systems, utilizing a mix of blast media and water or pure water. Dry shot blasting is generally used for surface texturing, deburring, striping of paint and other coatings, de-rusting, de-sanding, descaling and, last but not least, shot peening. Wet blasting is by and large a particularly gentle surface finishing process. Typical applications are the gentle surface cleaning of delicate components, light edge radiusing of, for example, tools and the creation of decorative surface finishes. In shot blasting processes the abrasive is thrown at the work piece surface with speeds of up to 170 m/s. The kinetic energy required for accelerating the blast media in dry blast systems is generated by blast turbines (blast wheels) and compressed air, whereas in wet blast systems high-pressure pumps are utilized. The blast results generally depend on the machine type, the process parameters and, above all, on the type and size of blast media used for specific shot blasting operations. What shot blasting systems are available? In the turbine shot blasting technology the high rotational speed of the so-called blast wheels, also known as turbines, is used for accelerating and throwing the abrasive onto the work piece surface. The most common applications for turbine blast machines are de-rusting, deburring, descaling, de-sanding and surface texturing (making a surface rougher). Compressed air blasting is ideal for targeted blasting of relatively small surface areas. It also allows the use of particularly abrasive mineral blast media. Compressed air blasting is also the preferred technology for shot peening. In wet blasting systems a mix of blast media and water (a so-called “slurry”) is pumped to a wet blasting gun and is finally accelerated by pressurized air. In high pressure water jet blasting systems pure water is used to blast parts but with a very high pressure. The water jet is generated with a pressure of up to 4.000 bar (58.000 psi) and can remove even the hardest coatings by use of only pure water. Wet blasting as well as high-pressure water jet blasting are frequently employed in the aerospace industry. “Shot peening” , a special shot blasting method, is primarily utilized in the automobile and aerospace industry for components exposed to dynamic operating loads. “Hammering” the work pieces with blast media generates a residual compressive stress in the top surface layers. This increases their resistance against bending and tensile stress and significantly extends their service life. Plastic deflashing , another special shot blasting method, is used for de-flashing and deburring of plastic components like duroplastic and some thermoplastic materials. Generally, plastic de-flashing systems demand considerably less energy, and they utilize specialized, rather soft blast media. What are the most common blast media types Selection of the most suitable blast media for a given shot blast operation is one of the most important decisions in the process development. The users can choose from a broad range of blast media, some of which can fulfill the same shot blasting tasks. Important selection criteria are the desired blast results, the expected wear rate of the equipment and the cost efficiency of the blast media. The most common blast media can be classified as metallic, natural or synthetic mineral materials and natural or synthetic organic materials. The most common media at a glance: Metallic media made from iron and steel: Steel shot (round), steel grit and chilled iron grit are ideal for aggressive surface cleaning, de-rusting, de-scaling, de-sanding, deburring, surface texturing, creating a mat finish and shot peening (only spherical media). They can be used in turbine blast machines as well as in compressed air suction (injection) or pressure blast systems. Cut wire blast media in different shapes (cylindrical, rounded edges, nearly round or completely round) are used for general cleaning, de-rusting, de-scaling, de-sanding, deburring/slight edge radiusing and, frequently, shot peening. Cut wire media are suitable for turbine as well as compressed air suction (injection) and pressure blast systems. Stainless steel blast media: Cast stainless steel shot (perfectly or partially round) and grit are suitable for surface cleaning, de-scaling, de-sanding, deburring/slight edge radiusing, surface texturing, creating a mat finish and shot peening (only spherical media). They can be used in turbine as well as compressed air suction (injection) and pressure blast systems. Cut wire stainless steel media (cylindrical, rounded edges, nearly round or completely round) are used for de-scaling and, frequently, shot peening. They can be used in turbine as well as compressed air suction (injection) and pressure blast systems. Mineral blast media: Glass beads, glass grit, ceramic beads, ceramic grit, Corundum, Silicium carbide are used for surface cleaning, roughening, creating a mat finish and deburring. They can be used in compressed air blast systems only. Mineral – non-ferrous blast media: Brass swarf, small brass pellets, brass cut wire, aluminum granules, aluminum cut wire, zinc granules and zinc cut wire are used for surface cleaning and deburring. They can be used in turbine as well as compressed air suction (injection) and pressure blast systems. Natural mineral blast media: Garnet sand, Soda and quartz sand are suitable for paint stripping, de-scaling, de-rusting, surface cleaning, creating a mat finish and deburring. They can be used in compressed air suction (injection) and pressure blast machines only. However, in case of quartz sand this is only partially true: In many countries, also in Germany, the blasting with quartz sand is prohibited, because it represents a serious health hazard in the form of silicosis lung disease. In wet blasting processes quartz can still be used as no dust is created. The most common shot blast machines Which shot blast machine is most suitable for treating certain work pieces must be determined individually for every application. But the shot blast system as such is only one factor of many. The user must also decide between processing of complete batches of small to very small, mass-produced parts or single piece processing. Typical batch systems are tumble belt blast machines, multi-tumblers and hand blasting cabinets with rotating baskets. Spinner hanger blast machines can be used for single piece as well as batch processing of somewhat larger work pieces. Most common are roller conveyor and wire mesh belt shot blast machines, which can be used for a wide variety of shot blast applications and robotic blasting machines for special tasks and sensitive work pieces. 90 out of 100 blast machines leaving our factories are custom engineered to precisely meet the customer requirements. Rösler sells mostly wheel, respectively, turbine blast machines due to their power and low treatment time but also delivers several robotic machines every year to customers all over the world where challenging tasks must be solved. Whenever large surface areas must be treated, turbine blasting machines represent the most cost-efficient solution. Moreover, with turbine blast machines the capital expenditures and operating costs in relation to the achievable throughput are relatively small. Turbine blasting machines Compressed air blasting machines Wet blasting machines Plastic deflashing machines You want only the best for your surface? We will gladly help you! send Inquiry Phone Downloads Airblast EN 273.pdf PDF Foundries and forge shops EN 270.pdf PDF Plastics Deflashing EN 274.pdf PDF Retrofit EN 262.pdf PDF Shot Peening EN 272.pdf PDF Steel fabrication-Steel trader EN 271.pdf PDF