FAPRE Industrial Co., Limited. is a high-tech enterprise committed in R&D, production, and sales of abrasives products. We have 6 branch factories today, 400 employees, total area of 120,000 square meters and more than 30 new products developments per year.
Excellent Product Quality
FAPRE has advanced equipment and a professional technical development and management team for high quality assurance. Our factory environment, management system and product quality all meet the abrasives manufacturing factory system qualification standards.
Rich Products
Our products include Resin Bonded Abrasives, such as Grinding Wheels For Metal, Grinding Wheels For Stainless Steel (INOX), Flexible Grinding Wheels, Ceramic Cut Off Wheels, Zirconia Cutting Wheels, Cut Off Wheels For Metal, Cut Off Wheels For PipeLine, Cut Off Wheels For Stone; Coated Abrasives, such as Aluminum Oxide Flap Discs, Quick Change Flap Discs, Ceramic Flap Discs, Zirconia Flap Discs, Aluminum Oxide Fiber Discs, Zirconia Fiber Discs, Emery Cloth Roll; and Brown Corundum And White Corundum etc.
One-Stop Service
There is no intermediate link when ordering products from our company. We provide one-stop service from design, processing, sample trial production to mass production.
Leading Service
We have many years of industry experience, a complete production management, quality supervision, and sales service operation system. Whether you want to purchase Resin Bonded Abrasives or Coated Abrasives, just email your requirements and we can customize the product for you.
Ceramic flap discs are another strong abrasive that can grind metal surfaces from carbon steel to aerospace alloys. Ceramic flap discs are ideal when it comes to grinding most metals and work best with moderate pressure. The shape and structure of the ceramic minerals give the discs their sharp grinding edge. It is also how it maintains its cutting power and stability over use.
Quick change abrasive discs are small grinding discs that are ideal for confined spaces that larger sanding discs cannot be maneuvered into or when you only need to work on a smaller area. Quick change discs are used for general purpose grinding, stock removal and deburring. Other uses include cleaning up welds, removing scale oxidation, paints, and protective waxes, surface leveling, mold, and cavity grinding. They come in a variety of designs that look like mini sanding disc versions of other full-size abrasives like flap discs, surface conditioning discs, polishing discs, etc.
Emery cloth is a type of woven fabric that has a grayish-black abrasive combination of corundum and magnetite coated on one side. During manual labor, it is used to smooth metal surfaces. Emery cloth works well for cleaning dirt, corrosion debris, and extra paint from a metal's surface. Emery cloth is composed of several grits. The smaller grain size makes it harsher than sandpaper. Emery cloth with grit 120 is used for fine finishing. The number of abrasive particles per inch is referred to as the grit number. The surface will be more uneven the higher the abrasive density.
Suitable for surface grinding and grinding at any angle. Advantages: high tensile strength, strong elasticity and self-sharpening, high efficiency and low energy consumption.
For grinding tasks such as weld seam dressing on planar surface, suitable for duty deburing and beveling work on stainless and high temperature steels.
Aluminum Oxide Fiber DiscsMax Speed: 80M/S
Raw Abrasives: Aluminum Oxide
Application: Metal, Steel, Stainless Steel, INOX, Non-ferrous metals, Plastics, Aluminum and wood
Zirconia alumina grain (Z) is the preferred abrasive material on alloyed and unalloyed steels. zirconium fiber discs are perfectly suited for edge breaking work, cutting of difficult-to-machine materials, high alloy stainless steels and high temperature non-ferrous metals with cool grinding properties and a long service life.
Wear-resistant aluminum oxide abrasives and premium cloth back make this durable sand paper roll. Featuring less-clogging and anti-static. This cloth-backed sandpaper roll can be used in both wet and dry sanding.
What are Zirconia Flap Discs
Zirconia flap disk is a type of abrasive disk used in metal fabrication shops for removing welds and blending on hard metals, including carbon steel, stainless steel, and titanium. It features the Zirconia Alumina grain, which has a larger crystalline structure and is a very tough grain with a good product life. The overlapping coated abrasive cloth flaps provide several layers of abrasives, making the disc flexible, long lasting and a great choice for one step grinding/ blending.
Advantages of Zirconia Flap Discs
Flap discs offer numerous advantages over traditional grinding wheels, making them a popular choice for various applications. These advantages contribute to their versatility, efficiency, and overall effectiveness in metalworking projects.
Fast Stock Removal
Flap discs are known for their ability to remove material quickly. The overlapping abrasive flaps on the disc provide a larger surface area for grinding, resulting in faster stock removal compared to grinding wheels.
Versatility
Flap discs are designed to perform multiple tasks with a single product. They can grind, blend, and finish, eliminating the need for switching between different tools or discs. This versatility saves time and improves project efficiency.
Smooth Finish
When it comes to achieving a smooth finish, flap discs excel. The layered flaps constantly expose fresh abrasive material, ensuring a consistent and even finish. This is particularly beneficial when working on metal surfaces that require a polished or refined appearance.
Reduced Noise and Vibration
Flap discs are designed to minimize noise and vibration during operation. The layered flaps act as a cushion, reducing the impact and resulting in a quieter and more comfortable working experience.
Improved Control
The flexibility of flap discs allows for better control and maneuverability. This is especially advantageous when working on curved or irregular surfaces, as the flaps can conform to the shape of the workpiece, ensuring precise and accurate grinding.
Extended Lifespan
Flap discs generally have a longer lifespan compared to grinding wheels. The layered flaps distribute abrasive wear evenly, ensuring that the disc remains useful even as the flaps erode. This results in cost savings and reduced downtime for disc replacement.
Applications of Zirconia Flap Discs
Zirconia Flap Discs are commonly used in welding and metal fabrication applications. They are ideal for grinding and finishing welded seams, as well as removing excess material from metal surfaces. Type 27 flap discs are best suited for grinding flat surfaces, while type 29 flap discs are better for contouring and shaping.
Zirconia Flap Discs are also commonly used in auto body work. They are ideal for grinding and finishing metal surfaces, as well as shaping and contouring body panels. Type 29 flap discs are best suited for this type of work, as they allow for greater surface contact when grinding at an angle.
Zirconia Flap Discs are also used in woodworking applications. They are ideal for removing excess material from wood surfaces, as well as shaping and smoothing contours. Type 29 flap discs are best suited for woodworking applications, as they allow for greater surface contact when grinding with an angle grinder.
Zirconia Flap Discs are also commonly used for cleaning and finishing tasks. They are ideal for removing rust, paint, and other surface contaminants, as well as for achieving a smooth and uniform finish. Type 27 flap discs are best suited for cleaning and finishing flat surfaces, while type 29 flap discs are better for cleaning and finishing contoured surfaces.
Zirconia Flap Discs are used in the construction industry to prepare the surface for coating or painting and to grind down concrete. They are extremely effective in concrete repair operations because of their vigorous cutting action and capacity to remove uneven layers of concrete.
●Shapes
Zirconia Flap Discs for angle grinders come with 4 specialty shapes – Trimmable, Aluminum-backed, Mini, and Angled.
Trimmable: Trimmable flap discs have a trimmable composite backing cloth for added versatility and flexibility and minimum marks to work on hard-to-reach areas like odd-shapes and fillet welds.
Aluminum-backed: Aluminum-backed discs are supportive of heavy-duty applications like water pipeline fabrication.
Mini: A mini disc has a diameter of only 2 to 3 inches. This compact size makes them ideal for performing in tight spaces or hard-to-reach areas. These small flap discs can be used as an alternative to blending discs.
Angled: These flap discs have curved flaps around the blacking plate's edge, providing easy maneuverability over various grinding angles. You can use these discs for fillet welds, T-joint grinding, or even on flat surfaces.
Sizes
The size of a Zirconia Flap Disc is measured by its diameter. A Zirconia Flap Disc often has a diameter of between 4 inches and 7 inches. Discs with smaller diameters rotate faster, making them suitable for fast, smooth grinding in tight spaces. Larger discs can spin slower, but they provide more abrasive and durable for large stock removal.
Width of Each Flap
Most Zirconia Flap Discs on the market have a width of 25mm, while some large-scaled ones have a width of 30mm. Larger flaps are suitable for high-volume, aggressive grinding applications, thanks to their expansive grinding surface.
Flap Density
Unlike standard Zirconia Flap Discs, high-density Zirconia Flap Discs have more abrasive backing cloth for added performance and control. There are 2 flap density levels for a Zirconia Flap Disc:
Type 27: This straight disc density can blend, grind, or finish flat surfaces with an angle of 0-15 degrees.
Type 29: This angled/conical disc density is often used in aggressive stock removal or smoothing odd-shaped surfaces at an angle of 15-35 degrees.
Grit Size
Like sandpaper pads, Zirconia Flap Discs come in a wide variety of abrasive grit sizes, ranging from 36 to 120. Smaller grit sizes indicate coarse grit, while larger ones indicate finer grit. For example, a 20 grit Zirconia Flap Discs can be used for rust removal on old steel furniture but is not efficient when working on fine polishing. You should generally begin with a coarser grit size to remove stock and shape your workpiece, then use the finer grit size in the finishing step (like blending and repairs). The grit sizes are divided into the following ranges:
For heavy stock removal: 36 to 40 grits
For edge beveling and chamfering: 36 to 60 grits
For weld grinding and blending: 40 to 60 grits
For deflating and deburring: 60 grits
For blending and rust removal: 60 to 80 grit
For delicate applications like finishing and cleaning: 80 to 120 grits
Backing materials
There are 3 backing materials for a sanding flap disc:
Phenolic: A phenolic backing is lightweight and wear-resistant because it consists of many layers of resin and glass-based fabric. This backing reduces scratches to the working surface.
Aluminum: A disc with an aluminum backing is best for heavy-duty applications. This backing is sturdy and stable, allowing it to smoothen bevels with no stuck pits. Aluminum backings can also be recycled easily.
Composite: You can make a small size and shape adjustment on hard-to-reach areas effortlessly with no markings with the help of a composite backing.
Zirconia Flap Discs Shape
Zirconia Flap Discs come in different shapes, and knowing the various options is crucial for achieving the best grinding results. The two most common types are flat and conical discs, each suited for specific applications.
Flat Discs (Type 27 Flap Discs)
Best Use: These discs perform exceptionally well at shallower angles, typically between 0 and 15 degrees.
Applications: Ideal for smooth finishing and blending on flat surfaces. They can also adeptly handle slight contours.
Advantage: Their design is optimized for precision work and finishing touches.
Conical Discs (Type 29 Flap Discs)
Best Use: These are designed for grinding at angles between 15 and 35 degrees.
Applications:Best suited for aggressive stock removal, especially on flat surfaces, due to their saucer-shaped grinding surface.
Advantage:They maximize surface contact, making them perfect for initial high-volume grinding.
Specialty Shapes and Styles of Zirconia Flap Discs：
Trimmable Discs
These discs have a trimmable composite backing, enhancing their flexibility. They are ideal for hard-to-reach areas like filet welds and irregular shapes. The trimmable feature increases flap overhang, and the backing prevents workpiece marking.
Aluninum-Backed Discs
These discs have a sturdy, permanent aluminum backing. They provide rigorous support for high-stress, heavy-duty tasks like pipeline fabrication.
Mini Discs
Typically 2 or 3 inches in diameter, these discs are much smaller than standard ones. Their compact size is perfect for working in tight spaces and grinding hard-to-reach areas. A 2-inch mini disc can often replace a blending disc.
Angled Discs
These discs have curved flaps that wrap around the disc's edge. They enhance operator control, allow for a wider range of grinding angles, and are especially useful for filet welds and T-joint grinding. They also maintain robust performance on flat surfaces.
Safety Precautions for Using Zirconia Flap Discs
Safety is paramount when working with Zirconia Flap Discs. These powerful tools, while efficient, can pose risks if not used properly. Adhering to safety guidelines ensures both the operator's well-being and the integrity of the work.
Personal Protective Equipment (PPE)
Eye Protection:Always wear safety goggles or face shields to protect against flying debris.
Hand Protection: Durable gloves should be worn to protect hands from abrasions and cuts.
Hearing Protection: Earplugs or earmuffs are recommended due to the high noise levels during grinding.
Respiratory Protection:Use a dust mask or respirator, especially when working with materials that generate hazardous dust.
Body Protection:Wear long sleeves and sturdy work clothes to shield the body from sparks and debris.
Safe Operating Practices
Inspect the Zirconia Flap Discs: Before use, check for any signs of damage or wear. Do not use a disc that appears compromised.
Ensure Proper Installation:Mount the disc correctly and securely on the grinder. Improper installation can lead to disc detachment or breakage.
Check Compatibility with the Grinder: Verify that the disc is suitable for the speed and size of your grinder.
Maintain a Safe Work Area:Keep the area clear of flammable materials and ensure it is well-ventilated.
Use Correct Technique: Operate the grinder at the appropriate angle and pressure for the disc type. Avoid excessive force which can lead to disc damage or breakage.
Be Aware of Surroundings: Keep bystanders at a safe distance, especially from the direction of potential debris ejection.
Store Zirconia Flap Discs Properly: Keep them in a dry, secure place to prevent damage.
Frequently Asked Questions
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