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Flap Disc

Flap Disc

Flap Disc

Flap discs are overlapping cloth flaps of bonded abrasive on a fibreglass backing - the workhorse fabrication finishing disc. Held flat to the workpiece, the flap face blends a grinding mark down to a smooth surface in a single tool change. Cooler running and longer life than aluminium-oxide grinding discs on stainless and alloy steel.

Also known as: Sanding Disc (angle grinder), Flap Sanding Wheel, Flap Wheel Disc, Alpha Silver Series, Zirc Flap Disc, Ceramic Flap Disc.

Alpha Silver Series and Klingspor flap discs - the most-stocked sub-cat in the Abrasive range (49 SKUs). 40, 60, 80 and 120 grit in 100mm and 125mm sizes. Alpha Silver Series uses zirconia and ceramic grain for stainless and alloy steel stock; Klingspor stocks aluminium-oxide for general steel.

GRIT AND GRAIN

Zirconia alumina and ceramic grains are the premium flap disc grain types - the grain fractures as it wears, exposing fresh sharp edges (self-sharpening). This keeps the disc cutting fast through stainless and alloy steel where aluminium oxide flap discs would glaze over. Aluminium oxide grain is the cheaper option for general mild steel and shop-floor work where premium grain life isn't justified.

USAGE AND TECHNIQUE

Hold the grinder flat (or at a slight 5-10 degree angle) to the workpiece. Move the disc smoothly along the surface - don't dwell in one spot. Light hand pressure is more effective than heavy pressure (heavy pressure glazes the disc and shortens life). Step through grit ranges: 40 or 60 for blending grinding marks, 80 for pre-paint prep, 120 for fine finish work.

SAFETY AND RPM

Same RPM rules as cutting and grinding discs - max disc RPM equals or exceeds grinder no-load RPM. Grinder guard must be fitted. Face shield mandatory for sustained use. Replace flap discs once the flap layers are worn down to the fibreglass backing - using a worn disc reduces stock-removal rate and risks fibreglass exposure.

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