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Polishing Porcerax
What is the best way to polish porcerax so that we maintain maximum venting with a polished surface?

1 EDM the surface to a fine finish.

2 Clean using Ultrasonic Cleaner to remove EDM fluids

3 Blow* DRY** air, using approximately 40 psi, back thru the Porcerax II while polishing to purge grit and debris from the Porcerax II. Make sure you wear goggles & some kind of air mask while polishing the Porcerax II. This is to ensure you do not get particles in your eyes or breath any particles in.

4 Lubricants:

A For Flat and Contoured surfaces use lite oil: EDM fluid, Kerosene, Mineral Spirits or Lacquer.

B If you are polishing Ribs do not use any lubricant.

5 What type of polishing instrument?

A If you are polishing a flat surface use stone. This gives a more even surface since the stone is flat, but a finger could give slight surface irregularities.

B If you are polishing a contoured surface you can use stone or water proof paper.

C If you are polishing Ribs use ceramic sticks.

6 Stone using 400 grit

7 Clean the Porcerax II using the Ultrasonic Cleaner several times during the polishing process. This ensures that any materials not ejected with the DRY** air are cleaned out and not building up causing potential blockage.

8 Stone using 600 grit This surface will fit most applications.

9 Stone using 800 grit

10 *** You can go up to a 1000 grit polish, but you are closing the pores doing this.

11 Then clean the Porcerax II using the Ultrasonic Cleaner to clean out any debris or solvents inside the Porcerax.

12 Purge the Porcerax II with DRY** air after Ultrasonic Cleaning to ensure nothing is left inside the Porcerax that could cause blockage or cause rusting.

13 * Blowing air, approximately 60 80 psi, on the face surface will not push any of the debris or moisture trapped inside the Porcerax II out. The air will just bounce off the surface. (This is like
spraying paint into a corner.) You need to do at least one of the following:

A You need to use the hole you put in the back of the insert for venting the gases to the atmosphere. What you do is tap the hole so the air hose can be fastened to the insert. This way the air cannot escape except by going through the Porcerax II.

B If this example will not work make a fixture with a O ring type seal between the Porcerax II and the fixture plate thus not allowing the air to escape except by passing through the Porcerax II.

14 ** Use DRY air, because Porcerax II has an iron and copper binder. If you use moist air this can cause the Porcerax to rust and eventually clog. Also ensure that you dry not only the outside of the Porcerax II, but also the inside by blowing DRY air through the insert. Any moisture left inside the Porcerax II will lead to rust forming and eventually clogging the Porcerax II.

15 *** Remember even with polishing you will be able to see where the Porcerax II has been inserted. The resin molded over the Porcerax does not get as high a gloss, as the resin molded over conventional steel. The reason is there is no laminar layer of air between the resin and the Porcerax like there is between the resin and the conventional steel.
Paul W. Britton
National Sales Manager
Mold Products Division
International Mold Steel
TOLL FREE: 1-800-625-6653
EMAIL: [email protected]

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