Switching wire brushes can help achieve greater efficiency

The larger diameter not only means more knots, but also that the brush naturally spins faster.

Traditionally 4-inch wheels were the only option with 4 1/2-inch right-angle grinders, new 4 1/2-inch options optimize efficiency and product life.

Traditionally 4-inch wheels were the only option with 4 1/2-inch right-angle grinders, new 4 1/2-inch options optimize efficiency and product life.

The 4 1/2-inch grinder is one of the most popular tools used in the surface conditioning market today. While it is the most popular size of small right-angle grinder, welders, welder’s helpers and fabricators who use this tool most frequently pair it with a 4-inch-diameter stringer bead wheel.

It’s a common pairing because the 4-inch wheel traditionally was the only option available. However, manufacturers now offer a 4 1/2-inch power wire brushes specifically designed to fit the tool and deliver optimal efficiency and longer product life.

Selecting a 4 1/2-inch stringer bead wheel when using a 4 1/2-inch right-angle grinder offers advantages in many applications, including surface preparation, inter-pass and hot-pass weld cleaning, and the removal of rust, mill scale, oxidation and heavy burrs.

A 4 1/2-inch stringer bead brush designed for 4 1/2-inch grinders typically features a higher knot count and can offer a shorter trim length. The larger diameter not only means more knots, but also that the brush naturally spins faster.

This combination can improve performance because it allows more wire tips to strike the surface of the base metal at a greater speed, when compared to a 4-inch brush, resulting in more aggressive and quicker cleaning action.

We’ve found the Weiler 4 1/2-inch Roughneck stringer bead brush results in a 35 per cent improvement in cleaning action, up to 20 per cent less wire loss and 50 per cent longer brush life, versus comparable 4-inch stringer bead wheels.

Stringer bead brushes are aggressive but not abrasive, making them a good option when the application calls for a slag-free surface without the need or desire to remove any base material. This type of product is often a good choice for surfaces that will be painted.

Because the wire tips are doing the work with a stringer bead brush, holding the tool at the appropriate angle in relation to the work surface is important. Holding it at the wrong angle can lead to faster brush wear or long wire breakage. While it’s common to hold the tool at an angle when using a grinding disc or flap disc, avoid holding the wheel at an angle in relation to the work surface when using a 4 1/2-inch power wire brush.

That’s because the brush is designed to be used on its end so the wire tips strike the surface and do the cleaning work.

Another common mistake is applying too much pressure. Too much pressure bends the wires and contributes to wire breakage.

It also keeps the wire tips from striking the surface as designed.

A common speed rating for a 4 1/2-inch angle grinder is 10,000 rpm, so the wheel should be rated at 10,000 rpm or greater for safe usage. And the 4 1/2-inch power wire brushes on the market are available in a variety of materials, including carbon steel and Type 302 stainless steel wire, and also in a variety of arbor hole options.

While the 4 1/2-inch stringer bead brushes may require a slightly higher initial investment, they can offer faster payback time, because product changeover can be reduced and brush life extended. Choosing a brush that is specifically designed to fit on one of the most common and frequently used tools in the welding or fabrication shop helps improve performance and efficiency, resulting in increased productivity, cost savings and more efficient use of labor time for operators and companies.