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The major classifications are - cloth, paper, vulcanized fiber, and combinations of these laminated together, as well as the various types of abrasive grains for the abrading media and resins, varnishes, glues and fillers for the adhesive or bonding systems. Many of these materials have been developed solely to meet the requirements of the coated abrasive industry. For example, the backings and bonds used on coated abrasive products today provide flexibility with strength, resistance to stretch, insulation from heat, and overall uniformity unobtainable in such products until the coated abrasive industry created the demand.
Abrasives
Silicon Carbide – The hardest and sharpest manufactured abrasive and bluish-black in appearance. Its hardness and sharpness make it ideal for sanding, polishing, and finishing non-ferrous metals (aluminum, bronze, brass, magnesium, titanium, etc.), glass, plastics, rubber, fibrous woods, and other low tensile or soft materials. Recent product developments include utilizing silicon carbide grain with chemically active bonds for special metal applications.
Aluminum Oxide – A tough durable manufactured abrasive characterized by long life of its cutting edges and points and perhaps the most widely used of the man-made minerals. It ranges from white to dark brown depending on the titanium content and can be toughened or alloyed with other minerals depending on the need. It is well suited to high tensile materials and is used over a broad range of ferrous and non-ferrous metals, and both soft and hardwoods.
Zirconia Alumina – A high performance alloyed abrasive formed by zirconia deposited in an alumina matrix. Excellent for heavy-duty stock removal requirements for virtually all type of metals as well as some woods.
Ceramic Alumina – A new, high-performance alumina base abrasive. This man-made mineral is a chemical rather than a fused material. The excellent structure created by the chemical manufacturing process and the addition of magnesia provides for controlled fracturing and thus the continuous renewal of sharp cutting edges. The abrasive is well suited to a broad range of medium to heavy stock removal jobs on steel, cast iron, aluminum, forgings, fabrications, etc.
Garnet – A natural abrasive. In appearance, it is reddish-brown. By special heat treatment a tougher, sturdier grain is produced for use on coated abrasives. It is used almost exclusively in wood sanding.
Flint – A natural abrasive, grayish-white in appearance. Quite sharp, the abrasive lacks toughness and therefore, is generally limited to use in sheet form for home repair, etc.
Emery – A natural abrasive that is dark gray in appearance. It is used rather extensively for light polishing of metal surfaces where its blocky shape enhances finishing action.
Backings
Paper - It is available in several different weights, thicknesses, and widths according to the application for which it is intended. Two specific types of paper are used - Fourdrinier and Cylinder. The particular characteristic of Fourdrinier Paper is that it is a balanced sheet having a high resistance to tearing and is very flexible. It is made in a single layer which can be obtained in several different weights. Cylinder Paper is made of several plies with the fibers distributed to provide maximum strength in the lengthwise direction. This feature makes it especially adaptable for use in the form of belts and drum covers.
Both types of paper come in large rolls, in the following weights:
A weight, Fourdrinier only -40 lbs. per ream*
C weight, Fourdrinier only - 70 lbs. per ream"
D weight, Fourdrinier only - 90 lbs. per ream'
E weight, Fourdrinier, and Cylinder - 130 lbs. per ream*
F weight, Cylinder only - 170 lbs. per ream*
(*A paper maker's ream is 480 sheets 24" x 36", not 9" x 11".)
Prior to the coating of each roll, the roll is carefully checked by experienced technical personnel to maintain rigid standards
Cloth – Several different types and weights are used in the manufacture of cloth-backed abrasives. These range from soft flexible jeans to the very heavy duty sateens and knits. Some coated abrasive manufacturers will use a variety of backing material including heavy-duty ducks and lightweight twills. All cloth backings manufactured by Carborundum Abrasives Company are engineered to established technical specifications under rigid quality control.
J - is commonly used to designate a lightweight twill weave cloth. It is most frequently used in applications where the flexibility of the abrasive product is required to conform to shapes and contours in the workpiece. Flexbac Metal Cloth, Flexbac Resin Cloth, Moulding Cloth, and light-duty Resin Cloths are some of the major users of jeans.
X - is commonly used to designate a medium to heavy-duty backing which can range from medium /heavy twills (drills) to specially designed sateens for tougher applications. High strength and low stretch are the key elements while major requirements can range from general-purpose non-waterproof to the most heavy-duty wet or dry application, depending on the commodity.
Y - is commonly used to designate a very high strength low stretch heavy-duty twills, sateen, or knit backed product. Specific applications would include heavy-duty stock removal requirements in metalworking and wood planing industries.
S - is commonly used to designate a special sateen weave engineered to be used exclusively for sectional belts.
Fibre - vulcanized fibre backing made of several layers of impregnated paper resulting in very hard and strong material. This backing is primarily used on resin bonded fibre discs for portable disc grinder applications.
Combination - backing is made by combining strong paper stock and lightweight cloth with adhesive; is used where resistance to tearing and breaking is a requirement. It is more commonly used in floor refinishing applications.
Adhesives
Glue - The glues employed in coated abrasives are specially made animal hide glues with great strength and flexibility. They are used dry, on less severe mechanized operations, and for hand sanding.
Calcium Carbonate Filler - When mixed with glue, tends to provide denser and more heat-resistant bonds, lending the product for uses on tougher work. This type of adhesive is used on most dry mechanized operations.
Resin - the resins are either urea or phenolic resins with the latter most widely used. Phenolic resins are hard, tough, and heat-resistant adhesives and well suited to the most demanding coated abrasive applications. Because they can be manufactured to fit virtually any applications, resin bond products are the most widely used coated abrasives. The addition of fillers further influences the strength and heat dissipation. Resins will continue to evolve into new forms as the market demands.
Finishing Coated abrasive products are coated in widths from 36 inches to 68 inches depending on the end uses for which they are intended. They are dried or cured, or both, and conditioned to the proper moisture content for future processing into the form required by the various consumers. They are then wound into rolls which vary in length from 200 yards to approximately 2,000 yards. These are called 'Jumbo Rolls". The average diameter is 36 inches. The rolls are stored in controlled-temperature storage rooms until they are transferred to the finishing plant. The method of processing Jumbo Rolls of coated abrasive products for consumer use in belts, sheets, discs, etc., is known as "finishing" The finishing methods used to convert Jumbo Rolls of coated abrasives include flexing, splicing, slitting into roll form, automatic sheet cutting, disc die-cutting.
