Quantitative standardization of sandblasting process parameters for enhanced coating adhesion in industrial applications

Abstract

Sandblasting is a critical surface preparation technique in automotive and industrial applications, yet the absence of standardized process parameters often leads to inconsistent outcomes. This study investigates the effects of air pressure, spraying distance, abrasive type, and abrasive quantity on the maximum cross-sectional area of carbon steel surfaces subjected to sandblasting. Using the Taguchi experimental design (OA L9) with four factors at three levels, nine parameter combinations were tested, each replicated three times. Non-Destructive Microscopic Testing revealed that air pressure, abrasive type, and spraying distance were the most influential factors. Optimal conditions were achieved at 2 bar pressure, 30 cm spraying distance, and the use of river or silica sand in quantities of 450–650 g, with composition No. 7 (3132) producing the largest and most uniform cross-sectional area (100 µm²). Signal-to-noise ratio analysis confirmed these findings, supporting the physical observations. The results provide a quantitative foundation for optimizing and standardizing sandblasting parameters, thereby improving coating adhesion quality and reducing variability in industrial applications. Future research will focus on fluid dynamics interpretation to refine jet velocity and particle impact efficiency, as well as exploring environmentally friendly abrasive alternatives.