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Solution for burr removal and answer for eliminating powder coating


Dear Sir,

1 Huge manpower is wasted in removing burrs & flashes after aluminium die casting & high overhead is spent on inspection of the parts. We need any best solution available to avoid the process.

2.After finishing the aluminium die cast it is taken for powder coating for improving the weatherability properties .Is there alternate process available to avoid the extra high polluting coating ?

Please acknowledge.


Mani Dhanraj
- Pune, Maharastira, India


I can only answer part 1 question. Even this answer is somewhat general. The size of your part, weight, volume, and existing in house equipment all play a part in the answer. Normally the best way to remove metal flash is either tumblasting equipment or mass finishing equipment. Steel shot is the preferred method for tumblast and very large preform ceramic or alum. star media for mass finishing.

tony kenton
AF Kenton
retired business owner - Hatboro, Pennsylvania


Further reply to your question 1:

The best solution is not to have the flash and burrs in the first place. Either your dies are worn or distorted, or the clamping force of your diecasting machine is not high enough. Fix the tooling, and the problem won't occur at all.

Bill Reynolds
Bill Reynolds [deceased]
consultant metallurgist - Ballarat, Victoria, Australia
We sadly relate the news that Bill passed away on Jan. 29, 2010.


This is first time I have heard that Powder Coating pollution is "extra high". Either your recovery system is konked out or there seems to be some other processes in use, which are not containing the pollutants properly. We in India use a lot of solvent based paints, hence, powder coating should definitely be much less polluting.

Amit Amembal
- Mumbai, Maharashtra, India

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