Aluminum

Common challenges and solutions in grinding aluminum

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Grinding aluminum

Aluminum requires a tailored approach. Due to its soft structure, discs clog more quickly, increasing the risk of surface damage.

Cibo has developed specific solutions for grinding aluminum, from removing welds to creating a uniform finish.

Most common challenges in grinding aluminum

Phase 1

Removing welds

Removing welds on flat workpieces

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Removing welds on round workpieces

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Removing welds in internal or 2D corners

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Phase 2

Finishing and cleaning

Removing scratches

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Deburring sharp edges

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Clogging of a cutting disc on aluminum

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Phase 3

Finishing and uniformity

Leveling the surface

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Phase 1

Removing welds on flat aluminum applications

When grinding aluminum, we always use SPAG in combination with a fiber disc. A correct combination of abrasive disc and anti-clogging solution is essential.

SPAG

SPAG anti-clogging spray: the key to success with aluminum

This specially developed spray prevents grinding dust from accumulating between the grains of the abrasive disc. Using SPAG not only increases the disc’s lifespan but also improves grinding efficiency.

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Recommended fiber discs

Best value for money

Powerful material removal with maximum resistance to clogging.

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KFK

Economical

An economical alternative that still provides reliable performance for less demanding finishes.

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Choose the right back-up pad

The performance of a fiber disc depends heavily on the backing pad used.

Depending on the workpiece, you choose from:

FIH

For maximum aggressiveness and rapid material removal

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FIW

For standard flat work

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FIZ

For slightly curved or uneven surfaces

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Phase 1

Removing welds on round aluminum workpieces

Traditional flap discs grind continuously, without interruption, which causes them to clog quickly. Our flap discs with interruptions and surface conditioning technology ensure constant renewal of the disc.

Recommended products

RCD

Our choice

Grinds and finishes welds in a single step. RCD/UC for heavy welds, RCD/CO and ME for standard weld seams, and RCD/VF for structuring the surface.

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FAC

Economical

Special flap disc with linen and zinc stearate coating; prevents clogging (not for high-quality finishes)

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Phase 1

Removing welds in internal or 2D corners of an aluminum workpiece

Welds in internal corners or 2D joints require a different approach than flat surfaces. Due to limited space and difficult access, precision and adaptability of the abrasive materials are crucial.

TA10

Thanks to its robust grain structure, it removes material efficiently without clogging quickly. In addition, the disc provides a smooth and even finish.

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Phase 2

Removing scratches on aluminum

Removing scratches without damaging the shape of the workpiece requires a smart choice of abrasive material.

For fine finishing

SAG/2SF

Our choice

Thanks to the open structure of the unitized web and the 3D abrasive material, this disc effectively removes scratches without deforming the workpiece.

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When finishing is not important

VTMA/RC2

Economical

An economical solution. Less conforming to the shape and providing a less fine finish, but suitable for parts that will be painted afterward.

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Phase 2

Deburring sharp edges

When deburring aluminum edges, a balance must be struck between rounding and maintaining the angle.

Rounding the sharp edge

SA6SF

Our choice

With silicon oxide grit, for rounding and deburring in a single step. Long lifespan.

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Maintaining the sharp edge

CB/120/1151325/C

Our choice

Efficiently removes burrs while preserving the sharp edge.

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Phase 2

Clogging of a cutting disc on aluminum

Aluminum is known for clogging cutting discs, which significantly reduces cutting performance.

SNAN

Our choice

The SNAN cutting disc is a special disc developed for use on aluminum. Its unique composition prevents the disc from clogging while simultaneously protecting the workpiece from damage.

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Phase 3

Leveling the surface

After removing welds or scratches, it is important to make the surface even and consistent, especially when the workpiece will undergo further finishing or painting.

Recommended grains

80 – For smoothing out minor imperfections

120 – For a fine, paint-ready finish

Recommended products

331GR

Our choice

The aluminum oxide grit is coated with zinc stearate, which greatly reduces clogging. Our choice for a consistent, durable finish.

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330GR

Economical

With its paper backing (C-weight), this 330GR disc is less tear-resistant but an attractive alternative for less demanding applications.

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Frequently Asked Questions about Working with Aluminum – FAQ

How do you prevent discoloration when grinding aluminum?

Aluminum can quickly oxidize or develop a bluish tint due to heat and friction. Therefore, work with low pressure, use fine grit options (up to P400), and employ cooling abrasives to maintain an even surface.

What grit size do I need for grinding aluminum?

Use grit P60–P120 for removing light burrs or small imperfections, and grit P180–P320 for finishing and preparing for anodizing, painting, or powder coating.

What is the difference between grinding aluminum and steel?

Aluminum is softer and more malleable than steel, which makes it clog or deform more quickly. It requires cooler, finer abrasives and lower pressure to maintain shine and shape.

Can I polish aluminum after grinding?

Yes. After grinding, aluminum can be polished using fine sandpaper, sanding pads, or polishing compounds to achieve a mirror-like shine.

What are common mistakes when grinding aluminum?

Applying too much pressure, using high speed, or using too coarse a grit can cause scratches, discoloration, or deformation. Aluminum can also clog quickly, so regular cleaning is important.