selection of chemicals and processes for fine and ultra-fine...
TRANSCRIPT
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SELECTION OF CHEMICALS AND PROCESSES FOR FINE AND ULTRA-FINE CLEANING
Ulrike Kunz – SurTec Deutschland GmbH
Fachforum parts2clean – 24.10.2017
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� What does „Sufficient Parts Cleanliness“ mean?
� Chemicals for fine and ultra-fine cleaning
� Enlarged Sinner‘s Circle
� Requirements for achieving parts cleanliness
� Equipment of plants used for parts with extreme
cleanliness requirements
� Summary
OVERVIEW
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� Sufficient parts cleanliness describes the level of cleanliness of the
parts, which is required for the subsequent process step
� That means: not as clean as possible but as clean as necessary
� Both particle and filmic impurities are considered
WHAT DOES „SUFFICIENT PARTS CLEANLINESS“ MEAN?
source: partikel-scanner.de
source: qe-online.de source: SITA Messtechnik
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Example: Intermediate Cleaning
� Cleaning between different production steps
WHAT DOES „SUFFICIENT PARTS CLEANLINESS“ MEAN?
turning drilling cleaningcleaning
source: www.direct-industry.desource: www.weindorf-metallbearbeitung.de
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Example: „Extended“ intermediate Cleaning
� Cleaning prior to „special“ process steps
WHAT DOES „SUFFICIENT PARTS CLEANLINESS“ MEAN?
coating
heat
treatmentcleaningdeburring cleaning
source: Hildenk.de
source: Cotarko
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Example: Final Cleaning = Fine and Precision Cleaning
� Cleaning before functional coating (PVD/CVD), gluing, or final cleaning
of components of high functional density or medical-technical products
WHAT DOES „SUFFICIENT PARTS CLEANLINESS“ MEAN?
final
inspection
inspection/
installationcleaningpolishing cleaning
source: dd-optic.de source: videoportal.bosch-presse.de
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� If the components are not cleaned properly, problems may occur during
the usage of the components, e.g.:
� Clogging of fine nozzles
� Short in electric circuits
� Jamming of valves
CONSEQUENCES OF INSUFFICIENT PARTS CLEANLINESS
source: focus.de
� Total failure of the component
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� Ultra-fine particles and impurities which
� disturb the following process step
� impair the function of the part
� prevent the function of the part
CONTAMINATIONS IN THE PROCESS CHAIN
minerals metals salts organics/fibres oils/fats
source: RJL Micro&Analytic
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Blasting processes
Mechanical processes
Thermic processes
Special processes
Others
OVERVIEW CLEANING PROCESSES
59%
20%
13%
4%
3%
1%
Wet processes
source: Fraunhofer IPK, 2012
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OVERVIEW CLEANING PROCESSES – WET PROCESSES
76%
7%
8%
6%
3%
aqueous processes
chlorinated hydrocarbons
hydrocarbons
alcohols
special processes
source: Fraunhofer IPK, 2012
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CHEMICALS FOR FINE AND ULTRA-FINE CLEANING SOLVENT CLEANING
Halogenated organic solvents
CHC (chlorinated hydrocarbons)
� perchloroethylene (Per)
� methylene chloride (MeCl)
Non-halogenated organic solvents
HC solvents (hydrocarbon solvents)
� nonpolar solvents
(e.g. isoparaffins, test fuel)
� semi-polar solvents
(e.g. alcoxy propanol, ester)
� polar solvents
(e.g. NMP, alcohols)
� Physical Processes
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ADVANTAGES AND DISADVANTAGES OF SOLVENT CLEANING
Principle: „similar dissolves similar“
Non-polar solvents dissolve non-polar impurities (oils, fats).
Contaminations are removed by dilution.
+ independent of material and geometrical shapes
+ good creeping properties
+ fast drying
- only moderate removal of pigments, particles and inorganic residues (salts)
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CHEMICALS FOR FINE AND ULTRA-FINE CLEANING AQUEOUS CLEANING
Aqueous Detergents
�„Builder“ as basis (neutral, alkaline and acidic)
� Surfactants
� Corrosion inhibitors
� Additives (defoaming agents, inhibitors etc.)
� Chemical-physical Processes
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� Emulsifying of oils and fats
� Saponification of vegetable and animal oils and fats
� Dispersing of particle impurities
� Dissolving/complexing of metals, metal oxides and metal salts
CHEMICAL AND PHYSICAL CLEANING EFFECTS
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ADVANTAGES AND DISADVANTAGES OF AQUEOUS CLEANING
+ good or very good removal of inorganic contaminations
+ good removal of swarfs and particles
+ cleaning by abrasion possible
+ produces highly active surfaces e.g. for further coating
- adaption to material and geometrical shape necessary
- separate drying and corrosion protection required
source: MAV-online.de
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Sinner‘s Circle
FACTORS FOR ACHIEVING PARTS CLEANLINESS
Optimal result
Chemistry
Application
Temperature
Time
Initial contamination Medium cleanliness
Drying air
Interior of the washing plant
Cleaning (maintenance)
cycles of the washing plant
Handling after cleaning
Protection against re-contamination
Medium preparationMedium monitoring
Batch volume
Special
goods carrier
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� Make up with demineralised water
� Completely analysable multi-component cleaning systems
� Usage of demulsifying, recyclable cleaning systems
� Salt-free if possible, for easier maintenance of the subsequent rinsing bath
AQUEOUS CHEMICALS FOR FINE AND ULTRA-FINE CLEANING
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WATER QUALITY FOR FINE AND ULTRA-FINE CLEANING
Possible ingredients of drinking water
calcium, magnesium
� lime spots
chloride, sulfate
� corrosion
sodium, potassium, other salts
� increased salinity
various organics
� stains, foam
watercleaning agent
5 %
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Builder and surfactants are consumed in different amounts
Depending on: oil and dirt contamination
maintenance system (e.g. filtration, oil separator etc.)
For constantly good bath quality and for saving the resources:
Use of recyclable, demulsifying cleaning systems:
WHY USING MULTI-COMPONENT SYSTEMS?
� 2-Component-Systems
Builder
concentr
ati
on [
%]
Week
Surf
acta
nt
concentr
ati
on [
%]
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� In the fine and ultra-fine cleaning sector, efficient rinsing systems are as
important as the cleaning process itself!
� Rinsing off the pre-dissolved impurities
� Achieving low-stain/spot-free surfaces
� The more alkaline the cleaning solution the more difficult the rinse ability
� Salt-free cleaners are easier to rinse off as salt-containing cleaners
Thus: Adapt the rinsing intensity to the cleaning medium!
RINSING SYSTEMS IN THE FINE AND ULTRA-FINE CLEANING
Important: The drag-in of cleaning chemicals into
the rinsing systems and the necessary action for
maintenance has to be considered in order to avoid
stains! source: Kramer-Oberflächenzentrum
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1. Adapted Cleaning Parameters:
� Effective cleaning technique
Spray
Immersion
Immersion/ultra sound
Flooding
CNP
…
PRECONDITIONS FOR GOOD CLEANLINESS RESULTS
Sources (v.o.n.u.): Dürr,
Fotosearch, LPW
source: LPW
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1. Adapted Cleaning Parameters:
� Good accessibility to the parts
PRECONDITIONS FOR GOOD CLEANLINESS RESULTS
source: Metallform
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1. Adapted Cleaning Parameters:
� Appropriate cleaning chemicals
Use of recyclable, multi-component products
Demulsifying if using oil separators
Silicate-free if using evaporators or membrane filtration
PRECONDITIONS FOR GOOD CLEANLINESS RESULTS
source: atech innovation
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2. Effective Discharge of the Dissolved Contamination
� Processing has to be adequately dimensioned
� Adapted facility design
PRECONDITIONS FOR GOOD CLEANLINESS RESULTS
source: Dürr Ecoclean
cleaning cleaning rinsing rinsingDI-
rinsing
oil separator
membrane filterevaporator
drying
warm air
vacuum
Oily Phase
Driving Carriage
Mixed bed
active carbon
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3. Prevention of Re-contamination
� Clean drying air
� Optimised handling of the cleaned parts
PRECONDITIONS FOR GOOD CLEANLINESS RESULTS
source: Antalis
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4. Monitoring the Bath Parameter
� Cleaner concentration (Builder and Surfactant)
source: SITA
PRECONDITIONS FOR GOOD CLEANLINESS RESULTS
source: pce-instruments
source: Hach
source: Sensaction
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4. Monitoring the Bath Parameter
� Bath condition (degree of contamination)
PRECONDITIONS FOR GOOD CLEANLINESS RESULTS
source: Sita
UV beam
Opticalfilter
Light guide rod Bath
contamination, e.g. oil drops
Fluorescence
UV light source
Photo diode
bath contamination particle
Softened laser light
Continuous flow bath sample
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EQUIPMENT OF LINES FOR PARTS WITH EXTREME CLEANLINESS REQUIREMENTS
� Adapted facility design (without etches/corners to avoid particles to gather in)
� Specially adapted racks for cleaning, reduced filling volume
� Increased ultra sonic power (should be adapted to the residual dirt analysis)
� Extended application times
� Limited contamination input e.g. by pre-cleaning in a second line
� Exclusive usage of the line for final cleaning
source: upl-service.desource: sauberkeit-und-reinraum.com
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EQUIPMENT OF LINES FOR PARTS WITH EXTREME CLEANLINESS REQUIREMENTS
� Needle-felt filter inserts for high particle separation
� Filter units phased from 25 µm to 1 µm; if necessary: ultra or micro filtration
� Additionally use of magnet cores
source: Mahle Industriefiltration
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EQUIPMENT OF LINES FOR PARTS WITH EXTREME CLEANLINESS REQUIREMENTS
� Filtration of the drying air
� Counting the particle number in the baths
� Monitoring of the oily contamination in the baths
� Overpressure to prevent the intrusion of ambient air
� Separation of the cleaned parts from the environment by using tunnels,
direct interlinking into the controlled clean areas or clean room
source: Epcos.de
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EXAMPLE FOR PRODUCTION PROCESSES WITH OPTIMIZED CLEANLINESS
Process without special requirements
Drawing
Cleaning (standard system)
Hardening inclusive cleaning and
tempering
Installation
Conservation
Packaging (standard)
Process for enhanced cleanliness
requirements
Drawing
Cleaning (special system)
Hardening inclusive cleaning and
tempering
Vibratory finishing
Cleaning (special system)
Installation
Cleaning of the installed part (special system)
Packaging (special packaging)
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CLEANLINESS REQUIREMENTS � PLANT DESIGN
200 µm 400 µm 600 µm 800 µm 1000 µm
Cleaning system for extreme cleanliness requirements
Clean room required
Controlled clean areas + additional measures
Controlled clean areas required
Cleaning system for enhanced cleanliness requirements
Cleaning system for standard cleanliness requirements
Maximum allowed particle size
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COSTS CAUSED BY ENHANCED CLEANLINESS REQUIREMENTS
Standard cleanliness
Enhanced requirements
Extreme requirements
Plant investment 1 + 30% + 50 %
Cycle time 1 factor 2 factor 4
Baskets / washing racks 1 factor 10 factor 20
Filling volume 1 50 % 25 %
Utilisation rate (down time due to filter change / new make-up)
100 % 90 % 80 %
Effort for parts handling 100 % 100 % 125 %
Additional working steps no yes/no yes/no
Overall assessment 1 factor 5 - 10 factor 15 - 20
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� The selection of chemicals and the decision for a process is based on the
knowledge of the sufficient parts cleanliness
� For fine cleaning the „wet cleaning“ method is the most common kind of cleaning procedure
� Cleaning chemicals, plant engineering and processing methods must be
coordinated
� Extreme requirements concerning the parts cleanliness require special
additional measures and cause higher investment costs
SUMMARY
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THANK YOU!
Further information:
Tel: 06251/171-712
www.SurTec.com