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The Best Way to Grind Aluminum

Aluminum is considered a soft metal and requires special care when being ground. Unlike steel and other hard metals, aluminum has a lower melting point. This means the heat generated by the spinning wheel of a grinder can easily melt the aluminum, creating a metallic gum that clogs the abrasive surface of the disk -- rendering it useless. Using a lubricant and a moderate speed on your grinder eliminates this problem, allowing you to grind without bringing the aluminum to the melting point.

Things You'll Need

  • Electric grinder
  • Grinder disks
  • Lubricating oil
  • Hand-held electric carver with sanding bits
  • Soap
  • Water
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Instructions

    • 1

      Attach a sanding disk of about 250-grit to your grinder. Test the grinder on a small piece of aluminum, to see the results before working on a larger area. Lubricate the aluminum with a kerosene-based polishing oil. Firmly secure the test piece with clamps, to prevent it from shifting as you grind it.

    • 2

      If the wheel looks as if it's getting gummed up from melting aluminum, add more lubricant and try again -- grinding at a slower speed. Once you are satisfied with the results, clamp the larger piece into place and lubricate the surface.

    • 3

      Move to a higher grit, once you have finished grinding with 250-grit. With every higher grit you use, remove all the marks from the previous grit. Achieve a nice, polished surface by finishing with 500-grit wet sandpaper. Mix some soap with the water and grind the surface, to remove any remaining marks.

    • 4

      Etch the aluminum using the grinder with grinding wheel attachments, as opposed to sanding disks. Use lubricant and avoid grinding at high speed, to keep the metal cool.

    • 5

      Grind hard-to-reach areas with a hand-held carver, using the same grit as you use for the angle-grinder.

    • 6

      Experiment with different types of grinding wheel attachments to see the effects. The type of grinding you desire will determine the attachments you need.

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