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In the field of metal surface treatment, steel shot and steel grit are commonly used abrasives, and their cost economy is the key to selection.Which one is more cost-effective needs to be analyzed from multiple dimensions.

First, Raw materials and manufacturing costs

Both are mainly made of steel, but the manufacturing process is different. By spraying molten steel into the mold or cooling medium, the steel shot uses the surface tension to form a ball, the process is mature and stable, and the scrap rate can be controlled within 5%. The steel grit needs to be crushed and screened, and the steel loss is up to 15%-20%, and the requirements for screening equipment are high. Under the same quality standard, the raw material utilization rate of steel shot is high, and the manufacturing cost may be 5%-10% lower.

Second, the service life and wear rate

1. Working principle and wear difference: the steel shot is spherical, in contact with the workpiece point, the impact force is concentrated, and the wear is uniform and slow. In the cleaning of castings with a surface roughness of up to Ra1.6μm, it can work stably for a long time. The steel grit is irregular, touching the workpiece on many sides, and the edges and corners are easy to wear. In high-intensity rust removal operations, the initial efficiency is 20%-30% higher than that of steel shots, but with use, wear accelerates and effective grinding capacity decreases.

2. Comparison of service life example: In an auto parts manufacturing workshop, when processing parts of the same material and specification, the steel shot works continuously for 200 hours, and the wear amount is about 10% of the initial weight. The grit worked for 150 hours and was worn at 15%, and some of it needed to be replaced due to severe wear. This shows that the steel shot has a long service life and can reduce procurement costs in the long run.

Third，Processing efficiency and energy consumption

1. Treatment efficiency analysis: due to the irregular shape of steel grit, the initial cleaning speed is about 30% faster than that of steel shot for workpieces with serious rust and thick oxide scale. For example, in the rust removal of large ships, it can quickly remove rust in a large area. But with wear, the efficiency decreases. Although the initial stage of steel shot is slow, the wear is uniform, and the comprehensive efficiency is 15%-20% higher than that of steel grit in continuous operation with high surface quality requirements and large processing capacity.

2. Energy consumption difference: Taking a 50kW shot blasting machine as an example, the average power consumption per hour using steel grit is 45 kWh, while that of steel shot is 40 kWh. Based on 8 hours of work per day and 22 working days per month, the steel shot can save 880 kWh of electricity per month compared to steel grit, and the energy consumption cost difference is significant in long-term large-scale production.

Fourth, the adaptability of application scenarios

In the finishing of precision mechanical parts, steel shot can achieve the roughness standard of Ra0.8 - Ra1.6μm on the surface of the workpiece. If steel grit is used, more than 30% of the workpiece needs to be additionally polished due to irregular impact, and the cost will increase by 20%-30%. In scenarios with low surface treatment requirements, such as construction steel rust removal and pretreatment, the initial efficiency of steel grit is high, the cost is low, and it is more economical.

To sum up, the cost economy of steel shot and steel grit has its own advantages and disadvantages. When long-term continuous production and high requirements for surface quality, steel shot has obvious advantages; For short-term, low-surface roughness requirements and severe rust treatment, steel grit is more economical. Enterprises should consider their own production needs, workpiece characteristics and cost budgets to achieve the best cost-effectiveness.

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