| Surface problem | Likely cause | Direction to test |
|---|---|---|
| Surface looks smeared rather than cut | Media pressing rather than cutting | Change media grade or type before lengthening the cycle |
| Fine scratches remain | Earlier stage left marks too deep to remove | Add a controlled intermediate stage |
| Edges have rounded too far | Cycle time or energy too high for the part | Shorten the cycle and recheck the edge |
| Finish is uneven across the batch | Loading or parts shielding each other | Reduce the load and improve distribution |
| Dull after drying | Compound film or water spots | Separate rinsing from drying |
Directions to test on a representative sample, not validated results for a specific component.
When an aluminium part comes out with the wrong surface, the appearance usually identifies the cause before any adjustment is made. Learning to read it saves a great deal of trial and error.
A surface that looks rubbed or smeared rather than cut points to media that is pressing rather than cutting. This is the characteristic failure on aluminium, and the response is to change the media grade or type. Increasing the cycle time makes it worse, because more pressing produces more smearing.
A surface that is bright but still shows a pattern when tilted points to insufficient staging: the fine media polished over the marks left by a coarser one rather than removing them. The response is to add an intermediate stage rather than to run the finishing stage longer.
Edges that have changed shape point to cycle time or energy rather than to the media. Aluminium is soft, so the same settings that work on steel can alter an aluminium edge visibly. This is checked against the starting condition, not judged by eye alone.
A finish that varies between parts from the same cycle points to loading rather than to the process. Parts that nest or sit in a corner are shielded from the media while the parts at the edges of the mass are worked fully. Reducing the load and improving distribution is the response, and it is generally more effective than any adjustment to the media or the cycle.
Where a batch includes more than one alloy, some variation between parts is unavoidable, because different alloys respond differently to the same settings. Running similar alloys together is what makes the batch predictable.
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