Sandblasting Aluminum: Ultimate Guide

sand blast aluminium

Sandblasting is a process that uses solid abrasive materials to forcibly apply pressure to an aluminium surface. This can be done to smoothen or roughen the surface, remove paint, or change its features. Sandblasting aluminium can be done for a variety of reasons, including removing paint or primer, cleaning up after damage, pre-treating for powder coating, and smoothing rough surfaces.

There are several types of abrasive materials that can be used for sandblasting aluminium, including glass beads, sand, aluminium oxide, and sodium bicarbonate. It is important to choose an abrasive material that is less rigid than aluminium to avoid damaging the surface. The pressure settings are also crucial, as blasting at excessively high pressures can damage the aluminium.

Sandblasting aluminium has several advantages, including creating smooth surfaces, using minimal equipment, saving time, and providing excellent surface preparation for secondary procedures. However, there are also some limitations, such as the need for expensive equipment and adequate space.


Sandblasting equipment

Sandblasting aluminium requires a variety of equipment, from the sandblaster itself to the media used to strip the surface.


A sandblaster is a device that generates a strong flow of abrasives to strip away surface contaminants. Sandblasters are ideal for cleaning aluminium substrates when conventional methods fail.

Propulsion Mechanism

The flow of the abrasive medium is usually created by an air compressor, which pressurises air to expel the medium at a designated pressure. The flow and direction of the abrasive stream are controlled by a nozzle, which comes in various sizes and forms.

Blast Pot

Blast pots are pressure-resistant containers that hold the pressurised air and abrasive media. The size of the blast pot varies depending on the type and quantity of media used.

Blast Cabinet

Sandblasting under high pressure is performed inside a blast cabinet, where the aluminium substrate is placed. The cabinet is operated using specially designed gloves, and it collects the dust and abrasive particles, allowing for recycling.

Blast Room

Similar to a blast cabinet, a blast room is used for treating larger objects such as motor vehicles and aircraft.

Blasting Guns

Blasting guns are commonly used for custom aluminium abrasive sandblasting operations. They function similarly to blast pots, with the abrasive media exiting through the housing.

Abrasive Media

The choice of abrasive media depends on the desired finish and the specific application. Common media for sandblasting aluminium include:

  • Glass beads: Used for polishing aluminium and removing automotive paint.
  • Sodium bicarbonate (baking soda): Ideal for stripping paint or cleaning without causing damage to the aluminium surface.
  • Crushed glass: Creates a rougher surface suitable for coating or painting.
  • Aluminium oxide: Suitable for repainting or powder coating, as it leaves an anchor profile for better adhesion.
  • Walnut shells: Natural organic material suitable for sensitive applications like polishing and cleaning.
  • Corn cobs: Soft, natural abrasives made from ground corn cobs, used for delicate sandblasting and polishing.
  • Silica sand: Formerly a popular choice but now limited due to its toxic nature; can cause respiratory issues.

It is important to note that steel-based media should be avoided when sandblasting aluminium, as it can impregnate the surface and cause corrosion.

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Sandblasting safety

Sandblasting aluminium can be a dangerous process, so it's important to follow safety precautions. Here are some key tips for staying safe while sandblasting:

Secure the Environment

Ensure the blasting area is free of hazards that could cause slipping, tripping, or falling. Prohibit activities such as eating, drinking, or smoking in the blasting area, as these can endanger workers. Verify that all ventilation systems, air compressors, power supplies, and wash stations are fully functional.

Check Equipment and Use Less Toxic Abrasives

Inspect blasting equipment for any damage, such as cracks or leaks, especially in the blast hose. When possible, opt for less toxic abrasives such as walnut shells, corn cobs, or baking soda. Keep the blasting equipment in proper containment structures, and restrict access to non-enclosed blasting areas.

Ensure Protective Gear Is Worn

Provide workers with the necessary protective gear, including helmets, clothing, gloves, safety footwear, earplugs, safety goggles, and respiratory protection. Respiratory equipment is critical, and anyone using the blaster must wear an abrasive blasting respirator that covers the head, face, neck, and shoulders.

Implement Proper Cleanup Procedures

Use water-based cleaning methods or HEPA-filtered vacuuming systems for post-sandblasting cleanup. Avoid using compressed air as it will disperse dust.


Ensure that workers are properly trained on the risks involved with sandblasting and the safety measures required. They should also be trained on how to operate the machinery and the importance of wearing personal protective equipment.

Electrical Equipment

Keep electrical equipment at least 50 feet away from the sandblasting site, and ensure safe grounding. When working indoors, disconnect all electrical connections to prevent unintended connections.

Gases and Vapours

Sandblasting aluminium can produce hazardous gases and vapours, such as fly ash and silica dust, which can cause respiratory issues. Ensure proper ventilation and respiratory protection to mitigate these risks.

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Sandblasting media

Aluminium oxide is a popular sandblasting media used for preparing a range of surfaces, including aluminium. It is the chemical name for alumina, which produces aluminium when further refined. It is a hard and strong material, with a rating just lower than diamond on the Mohs scale. This means it can remove most contaminants and retain its kinetic energy upon impact.

Aluminium oxide is available in a wide range of sizes, from fine powder to coarse grit. This makes it suitable for various applications, from decorative frosting on glass to preparing hydraulic shafts for hard chrome plating. Its angular shape is another advantage, as it creates a deep, sharp profile on the surface being coated, making it ideal for specialised coatings.

When sandblasting aluminium, it is important to consider the specific needs of the project. For example, if you are looking to brighten up aluminium engine components, you might want to use coarse glass beads, which will leave a dull grey finish that serves as an excellent base for paint or powder coating. On the other hand, if you are removing old paint from aluminium suspension, you might need a more aggressive medium like crushed glass.

Another factor to consider is the pressure used during the sandblasting process. For example, when using glass beads, it is recommended to use a maximum pressure of 60 psi to avoid over-fracturing the beads and ensure their longevity. Additionally, baking and rinsing with denatured alcohol may be necessary to remove contaminants from aluminium that has been soaked in oil.


Sandblasting pressure

The pressure you use when sandblasting aluminium is key. Aluminium panels are often thinner than other materials, making them susceptible to warping when blasted. To avoid warping or creating significant indentations in the product’s surface, it is recommended to start with a very low pressure and gradually increase. Typically, you will end up with a blasting pressure of around 50-60 PSI. However, it is always best to start at the lowest pressure and increase gradually to ensure you do not create any issues with warping or indents.

Direct Pressure vs Siphon Machines

Direct pressure machines require less pressure than siphon machines. Siphon machines are normally operated at 60-90 PSI, whereas direct pressure machines can function at 15-80 PSI. Operating at lower pressure reduces the work hardening of the surface and reduces warping of thin parts.

Blasting Angle

The gun should always be aimed at a 60° to 45° angle to the surface being cleaned. When the gun is aimed at 90°, peening occurs, and the abrasive particles collide with the abrasive, bouncing off the surface, which causes a very high rate of media wear.

Blasting Distance

In a siphon machine, the gun should be kept at least six inches from the surface being blasted. This allows the spray to spread out and cover a larger area. Blasting a larger circle allows for better overlap of the pattern and yields a more even and appealing finish. Direct pressure units can effectively operate at distances of one foot or more.

Nozzle Size

The size of the nozzle will also affect how much PSI you need to use. The larger the blast nozzle, the more air pressure you will need to effectively blast.


Sandblasting applications

Sandblasting is a versatile process used for aluminium surface treatment. It is a preferred technique for treating aluminium surfaces due to its ability to provide both functional and aesthetic benefits.

Applications of Sandblasting Aluminium

Removal of Paint, Primers, and Coatings

Sandblasting is effective in removing paint, primers, and coatings from aluminium surfaces. This is useful during restoration processes for automotive and marine vehicles.

Surface Preparation for Coatings and Treatments

Sandblasting creates a textured surface profile that enhances the adhesion of coatings and treatments. This process ensures better bonding and a longer-lasting finish. It is often used as a pre-treatment for anodizing and powder coating.

Cleaning and Rust Removal

Sandblasting can be used to clean aluminium surfaces by removing contaminants, oxides, mould, and rust. This application is particularly relevant for boat hulls, motors, antique surfaces, and other aluminium products.

Smoothing and Deburring

Sandblasting can smoothen rough aluminium surfaces and remove sharp edges. It is also effective in deburring processes, helping to smoothen out edges and prepare surfaces for further finishing.

Fire Damage Cleanup

Sandblasting can be used to clean up and restore aluminium surfaces affected by fire damage.

Decorative Purposes

Sandblasting can be used to create decorative elements on aluminium surfaces, such as adding a matte or satin-like finish. This finish is popular in industries where a refined yet not overly reflective appearance is desired.

Frequently asked questions

Sandblasting, or abrasive blasting, is a process that involves forcibly applying solid abrasive materials to a surface to clean, strip, or prepare it for painting or other types of finishing.

Materials such as glass beads, sand, aluminium oxide, baking soda, and sodium bicarbonate can be used for sandblasting aluminium.

Sandblasting aluminium can remove defects, imperfections, and contaminants like rust, paint, and grease, resulting in a smooth and clean surface that is ready for further treatment or finishing.

Sandblasting aluminium requires specialised equipment, which can be expensive. Additionally, it needs adequate space and ventilation to manage dust and fumes, and there are health risks associated with inhaling certain abrasive materials.

It is recommended to start with low pressure, around 40-55 PSI, and gradually increase as needed. This helps to avoid damaging thin or fragile aluminium surfaces.

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