Sandblasting Oxidation Aluminum 6061 Part Prototype

1 Research Method

1.1 Design Concept

The prototype development employs a systematic evaluation of surface treatment effects. Aluminum 6061 specimens were prepared with identical dimensions (50×50×5 mm) and initial machining conditions to ensure reproducibility. The research focused on quantifying the interaction between mechanical blasting and chemical oxidation.

1.2 Data Sources and Materials

Experimental data were collected from laboratory-controlled treatments. High-purity alumina particles (50–150 μm) were used for sandblasting. Oxidation employed a humidified oven maintained at 120°C ± 2°C. Surface analysis was conducted using SEM (Hitachi SU5000) and 3D optical profilometry (Bruker Contour GT). Hardness tests utilized a Vickers microhardness tester with a 500 g load. Corrosion resistance was evaluated according to ASTM B117 salt spray standards over 48 hours.

1.3 Experimental Procedure

1. Surface Preparation: Specimens degreased with acetone and dried.

2. Sandblasting: Varied particle size (50, 100, 150 μm), pressure (0.3–0.7 MPa), and exposure (30–120 s).

3. Oxidation: Heated in controlled environment (120°C, 50% RH) for 1–3 hours.

4. Analysis: SEM images acquired at 1000× magnification; roughness measured at five points per specimen. Hardness measured at three locations; corrosion resistance evaluated as area of pitting over time.

2 Results and Analysis

2.1 Surface Morphology

SEM images (Figure 1) reveal that medium-sized particles (100 μm) generate uniform micro-indentations, promoting a consistent oxide layer formation. Smaller particles produce finer but uneven pits, while larger particles create deep irregularities.

Figure 1. SEM images of sandblasted Aluminum 6061 surfaces (1000×)

2.2 Roughness and Hardness Analysis

Results indicate a 15% reduction in peak-to-valley surface roughness for specimens treated with 100 μm particles. Hardness measurements show an average increase of 12% compared to untreated samples, supporting improved wear resistance.

2.3 Corrosion Resistance

Salt spray tests demonstrate a 20% reduction in surface pitting for sandblasted and oxidized samples relative to untreated controls. This improvement is consistent with the formation of a uniform oxide layer.

3 Discussion

3.1 Mechanism Interpretation

Sandblasting increases surface area and generates micro-indentations that facilitate oxide layer adherence. Oxidation at controlled temperature promotes a uniform, dense oxide film. The combination of mechanical roughening and chemical oxidation contributes to simultaneous improvements in hardness and corrosion resistance.

3.2 Limitations

The study is limited to laboratory-scale specimens; results may vary for larger industrial components. Particle size selection is limited to alumina; other media may produce different surface textures.

3.3 Practical Implications

The optimized sandblasting-oxidation parameters provide actionable guidance for aerospace and automotive prototype fabrication. Industrial adoption can enhance component longevity and performance without extensive post-processing.

4 Conclusion

Sandblasting with 100 μm alumina particles followed by oxidation at 120°C for 2 hours significantly improves surface uniformity, hardness, and corrosion resistance of Aluminum 6061 prototypes. The findings inform surface treatment selection for high-performance components and suggest avenues for scaling to industrial production. Further studies may explore alternative blasting media and extended oxidation protocols.

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Tolerance: +/- 0.01~+/-0.005mm

Material:2024, 5083, 6061, 6063, 7075, etc

Surface treatment: Oxidation, electro-phoresis, sand blasting, electroplating, chemical treatment, painting, hard anodizing, heat treatment, etc

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Tolerance: +/- 0.01~+/-0.005mm

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TA1, TA2/GR2, TA4/GR5, TC4, TC16, TC18, TC21, TC22, TC26, TC118B etc

Surfacetreatment: Electroplating, galvanizing, spraying, oxidation, polishing, spray grinding, passivation, heat treatment, pickling, shot peening, etc

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Surface treatment:Spraying, sand blasting, painting, pickling, alkali cleaning, anodizing, ion implantation, thermal transfer printing, engraving, etc

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