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  1. #1
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    Default Dry milling aluminium dangers?

    Does dry milling aluminium create any dangerous dust?

  2. #2
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    I wouldn't think so,but it would probably create poor surface finish,excessive build up of swarf on cutting tool edges (clogging) and heat.

  3. #3
    BobL is offline Member: Blue and white apron brigade
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    Although pure Al has been "linked to some health problems" I doubt any of you are working with pure Al but rather with its alloys.
    In alloys, the Al is generally considered less of a problem than the additives, eg Si, Mn, Cu, Zn, Cr, Pb and Ni, with the latter two are not deliberately added but may be present due to processing.
    I do recommend reading the full MSDS on all the alloys, the 6XXX type alloy MSDS is available here (http://www.alcoa.com/global/en/envir...oadMSDS=180947)
    Interestingly the recommended OHS level for Al in air is the same as for soft woods (TWA 5 mg/m^3)
    Bear in mind that what your eyes see is rarely the full story. Machining and sanding creates a lot of "invisible" dust that hangs around in a workshop for hours and so you may think you are OK when you are not.
    Risk will depend on total exposure (concentration in air X time) but at a minimum I would be wearing a P2 level dust mask.
    If you live in Perth, I could be available to come and measure your dust levels for you

  4. #4
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    Hi Bob,

    Do you think coolant would have much effect on the levels of very fine dust?

    Quote Originally Posted by BobL View Post
    Although pure Al has been "linked to some health problems"
    I hope you arent talking about alzheimer's, last I heard that guy is looking for a new career



    You also have half of thermite

    Stuart

  5. #5
    BobL is offline Member: Blue and white apron brigade
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    Quote Originally Posted by Stustoys View Post
    Hi Bob,
    Do you think coolant would have much effect on the levels of very fine dust?
    It probably helps quite a bit - maybe even enough to negate the problem. Next time I have a piece on the lathe I will will do a with and without test with my particle detector.
    I don't think low speed turning and machine generates a lot of dust anyway compared to a say a CNC machine or sanding.

    I hope you arent talking about alzheimer's, last I heard that guy is looking for a new career
    Yes I heard this has been discredited. The Alcoa MSDS sheet does say that Al has a Low health risk by inhalation. Generally considered to be biologically inert (milling, cutting,grinding) but remember that is pure Al.

    You also have half of thermite
    Sure but it has to be intimately mixed with iron oxide and ignited by a high temperature to get the reaction started.

  6. #6
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    Hi Bob,

    Thank you

    Quote Originally Posted by BobL View Post
    Next time I have a piece on the lathe I will will do a with and without test with my particle detector.
    Will be interesting to see what you come up with.

    Quote Originally Posted by BobL View Post
    Sure but it has to be intimately mixed with iron oxide and ignited by a high temperature to get the reaction started.
    Yeah I'm a little short on ribbon (though it is surprisingly cheap on ebay)

    Stuart

  7. #7
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    There was a thread posted recently in the UK describing a chap suffering a severe face flash while grinding steel on a bench grinder, major burns and a time in hospital.

    Apparently his son had ground some aluminium previously and didn't clean up the debris.

    John.

  8. #8
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    Quote Originally Posted by electrosteam View Post

    Apparently his son had ground some aluminium previously and didn't clean up the debris.

    John.

    Grinding aluminium is not recommended.

    It clogs up the grind stone to the point of uselessness and can cause the stone to disintegrate from surface pressure build up of the metal, especially as it gets hot and expands from the friction.

    Are you sure that wasn't the issue ?

    Rob

  9. #9
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    Rob,
    I agree with your comments, but the posting is proving difficult to track down.
    When I find it I will post the link, perhaps someone else can assist here.
    My memory says that there was virtually no follow-up details.
    The age of the son was not stated, so it could have been a junior experimenting on dad's tools.

    John.

  10. #10
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    Located the reference, not a forum post but a magazine item.

    Letter to the Editor, from J. Purdy in BC Canada, Model Engineers Workshop May 2001, No. 73, Page 57.

    Described as a "2 foot diameter fireball of no more than 1/2 second".
    Damage was similar to severe sunburn, first degree burns to areas of the face and hands, with some skin actually hanging off.
    Clothing smouldering.
    No eye damage due to use of glasses.

    The aluminium content was described as 12 x 1/8 inch pop rivet heads ground off.

    Makes you think, doesn't it.
    How close have many of us been to the same scenario ?
    John.

  11. #11
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    Quote Originally Posted by electrosteam View Post
    Makes you think, doesn't it.
    How close have many of us been to the same scenario ?
    John.
    It certainly does. Most of us will never know how close we have come to receiving a Darwin Award in our lifetime! I dare say I must have come close, mostly as a kid "experimenting in the backyard" with stuff from Dad's shed! I'm pretty sure I survived a pipe bomb explosion after my homemade solid fuel rocket booster for my lego car went pear shaped....

    Yea yea OK maybe not the same scenario, but....

    Simon

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