Above: Weldcote developed its flap discs to withstand the high pressure created while operating a right-angle grinder.

High-quality ceramic grains provide increased performance

July/August 2019 - Ceramic grain products are the fastest growing abrasive technology in the marketplace, says Joe O’Mera, CEO of Weldcote Metals, a manufacturer and wholesaler of high-quality welding supplies. “We expect the market share of ceramic to double over the next five years, as ceramic grain costs and prices are reduced.”

In countries with higher wages, such as the United States and Canada, he adds, “the total labor cost of salary and benefits per employee, versus the cost of the product, means that high stock removal is very important.”

Abrasive products that have an open design, such as coated abrasives, will provide much faster stock removal when compared with bonded abrasives that are held together with adhesives and fiberglass, which O’Mera says “are drags on the cutting speed of products.” He recommends that companies measure the E ratio, which reflects metal removal per minute of grinding, to gauge efficiency.

Weldcote specializes in made-in-the-USA flap discs and has migrated “multiple customers this year from zirconia flap discs into ceramic flap discs,” O’Mera continues. The company introduced its C-Prime and C-Prime Plus in February 2019. The C-Prime line features a ceramic grain with strong polyester backing for aggressive grinding applications that do not require excessive flexibility, and the C-Prime Plus flap discs feature a poly-cotton backing with a high-quality ceramic grain, which provides both stretch and flexibility.

Real-world results

The ceramic grains in Weldcote’s flap discs contain a grinding aid for cooler running temperatures, which reduces the risk of discoloration and heat-induced deformations of the final workpiece.

“The C-Prime Plus flap discs feature a proprietary compressed design that gives the user a tough edge, increased performance and 50 to 60 percent higher stock removal rates over standard ceramic flap discs,” O’Mera notes. “These increased removal rates can provide significant savings and increased productivity for our customers in the field. We have had multiple successes where customers have achieved a 20-percent reduction in overall grinding costs.”

As the materials that manufacturers work with continue to evolve—becoming harder and stronger, for example—abrasives makers must ensure their products meet customers’ changing needs. O’Mera says Weldcote keeps current by performing extensive in-house testing with abrasive experts, along with a select group of abrasive testers in the marketplace. “Weldcote focuses on actual end-use testing with multiple grinder brands and multiple applications versus a controlled machine test that doesn’t match real-world results,” he explains.

For example, many of Weldcote’s flap discs are available in a compressed design that was developed with input from large users around the world. The design helps to extend product life and substantially reduce inventory costs for the entire supply chain. 

Effective use

Bill Roland and John Pandorf, Weldcote’s founders, built the company on flexibility, adaptability and innovative thinking. Wanting to supplement and expand the offerings available to the market, the company makes more than 900 products.

To accommodate hundreds of applications, Weldcote works “with end users to identify the machine they are using and then develops a recommended sample of abrasives that they should try,” says O’Mera.

“It is expected that the customer already has determined the abrasive tool and the power source. After that, the type and quality of tool is determined, and Weldcote will make a determination of abrasive product samples that should be used.”

O’Mera also recommends users take advantage of Weldcote’s training resources to get the most out of the abrasive products they choose. “Weldcote developed a program where we can either bring the customer into our facility for training or, if more convenient, we visit them with abrasive samples and work with the employees who are doing the grinding to educate them on best practices specific to their applications.”

A theme common among many abrasive purchasers is buying low-end products because they perceive that end consumers don’t think about or care which type of abrasives are used. However, says O’Mera, “It takes minimal effort to learn how to use a quality product and to let the product do the work. It’s far easier to work longer and more effectively with higher-quality abrasives. Higher-quality products enhance product throughput and reduce employee turnover.” 

Weldcote Metals
Kings Mountain, North Carolina
704/739-4115