Vehicle Parts Ultrasonic Cleaning
There are many vehicle parts such as engine block, dpf, Injector nozzles, cylinder piston, vacuum booster valve diaphragm, valve tappets, VVT solenoid valves, timing chain, wheel speed sensor head is with heavy dirty and very difficult to clean. The dirty such as : carbon coking, sludge glue, covered in limescale and rust, metal abrasive.
By ultrasonic cleaning, the car engine is 99.8 of cleaning in particle/ oil, cleaning speed increase 12 times (ultrasonic cleaning takes 13 minutes, while other cleaning needs 3 hours ); cleaning cost save 76%(cleaning aolvent only 1/4 than conventional cleaning ).
ultrasonic cleaning, it can filter the oil and dirty particle from waste water, cut the cost for waste water cost.
Notes clean engine blocks by ultrasonic cleaner:
1.Aluminum parts: Do not use strong alkaline solutions with pH 10 are prohibited (to prevent intergranular corrosion)
2. Precision bearings: must be dismantled for cleaning (to prevent damage from resonance of microbeads).
3. Rubber seals: temperatures of ≤ 70°C (to prevent cracking from aging).
Post-cleaning treatment: must be blown out with inert gas (to prevent secondary rusting of cast iron parts).
How to use ultrasonic machine to wash engine blocks?
1.Dismantling and Sorting:1.1.Dismantling the ECU/sensors and other electronic control components.
1.2. Separate rubber/plastic seals. 1.3.Disassembled cylinder head/oil pan/piston ring.
2. Ultrasonic cleaning : 2.1.Neutral cleaning water (PH 7.2) + 40kHz. 2.2. Ultrasonic power density ≥15W/L.
3. Rinsing washing :
3.1 .swirl rinsing, Bi-directional rotating water flow (30rpm).
3.2. .Automatic spraying of deep holes in oil passages.
4. vacuum drying: 70°C hot air + -0.08MPa negative pressure.
5. Engine film protection:With fully synthetic rust inhibitor solution for ultrasonic cleaning.
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PCB Mother Board Ultrasonic Cleaning
There are many circuit boards such as consumer electronics, automotive EU control Boards, LED aluminum substrates,industrial control power supply boards, flexible circuit boards, packaging boards and other circuits. These circuit boards are with different dirty, such as: post-welding residue, particle attachment,organic pollution。 By ultrasonic cleaning, it save 10 times of cleaning time (ultrasonic cleaning takes 18 minutes, while labors need 3 hours; by ultrasonic cleaning system, drying the circuit board increase 7 times of capability(By ultrasonic system takes 3 minutes, labor drying needs 21 minutes). Besides, ultrasonic cleaning system can contiously working.
Advantages to clean PCB by ultrasonic cleaning system :
1.Increase cleaning effect: Ion contamination control: single tank cleaning effect is 5.81μg/cm² while three tanks cleaning system cleaning effect is 0.02μg/cm² , contamication decrease 99.6% .
2. Highly increase cleaning efficiency : By single tank takes 25 minutes for whole processes, it only takes 8 minutes by three tanks cleaning system.
The drying speed: By single tank takes 2 hours to dry, three tanks system clean 15 minutes. By single tank, every day clean 80pcs, by three tanks system clean 250pcs per day.
3. Zero Damage Guarantee: Spraying wash: use flexible water flowreplacealternative to steel brush , to avoise avoid 0201 resistance off.Ion wind to eliminate static electricity (voltage**5V**, ESD sensitive parts safety).Temperature control + air flow to prevent BGA soldering ball micro-cracking(ΔT3℃/sec.
4. Save cleaning cost :
4.1. Waste liquid volume decrease 82% : spraying tank with recycle filter and purification system, only use water3L/batch.
4.2. Power consumption : Single tank machine power consume: usd0.08/piece, while three-tanks cleaning system only costusd 0.027/piece, cut 66% consumption.
4.3. Decrease PCB failure rate: By single tank, the pcb failure ratio is 8.3% ,and by three tanks system, the failure ratio at 0.05%.
5. Full compliance coverage:
1.Meets Military Standard MIL-STD-2000A Cleanliness (Ion Residue1.56μg/cm²).
2. The drying tank meets the J-STD-033B standard for storage of moisture-sensitive devices.
How to clean PCB mother by ultrasonic cleaning system ?
1.Ultrasonic cleaning tank: (40kHz/60℃/5min ) to clean solder paste/flux from mother board.
2.Spraying washing tank: (55℃ deionized water/0.1MPa pressure), to cleanμm particle residue.
3. Dryer tank: (65℃/15m³/min circulating air)dry the mother boards with zero watermarks and anti-oxidation.
One circuit board cleaning case:
Monthly production capacity:
220,000pcs PCB, return repair&maintenace save 3.8million per year,electricty power consumption save 8 times (Ultrasonic cost 0.17kWh /piece, labor cost 1.53kWh/piece).
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Machinery Parts Ultrasonic Cleaning
There are many machinery parts such as : Bearings, Screw Nuts, Harmonic Reducer Flex Wheels, Linear Guide Sliders, Servo Spools, Piston Pump Swash.
Plates,Proportional Valve Coils, Turbine Blades, Fuel Injectors, Camshaft Peach Tips, Drill Guide Bushings, Milling Machine Collets,
Centrifugal pump impeller, fuel filter housing, air compressor cooler with oil, carbon and dust etc dirty. All these dirty are very difficult to clean.
Advantages to clean bearing by ultrasonic cleaner machine
For gear cleaning, by ultrasonic cleaning is with below advantages than convensional cleaning: Cleaning effect better, ultrasonic cleaning residue is≥99.8%,while conventional only clean 67%-72%;
Mini smudge cleaning better, ultrasonic cleaner clean particleat diameterda≥ R0.1mm, while conventional cleaning clean diameter R≥0.5mm.
Hard particle cleaning ratio,ultrasonic cleaning clean particle≥1μm;while conventionall clean ≥25μm, better cleaning.
Cleaning cost lower. By ultrasonic ,waste liquid cost and defective products isdecreased 87% comparing conventional cleaning.
How to clean turbine gearbox carbon by ultrasonic machine?
1. Pre-clean: 70°C pyrolysis of polyether to dissolve grease matrix.
2. Main cleaning: 40kHz/80kHz sweep cleaning + non-ionic emulsionRinsing.
3. Drying:Pulse vacuum dryinggearnox ultrasonic cleaning result:
3.1. 89% reduction in micropitting area.
3.2.The residual stress on the tooth surface is kept in the safe range of -350±15MPa.
Bearings cleaning example:
Ultrasonic cleaning takes 3 minutes, while labor cleaning needs 30 minutes,
By ultrasonic cleaning, can clean 99% dirty particle while conventional clean 60%; By ultrasonic cleaning, the cleaning cost only needs usd0.3/piece ,while conventional cleaning cost usd1.15 /piece.
Gear cleaning case:
By ultrasonic cleaning, ultrasonic +spraying washing takes 28 minutes, by labor cleaning needs 240 minutes;
The production capacity is 80pieces by labor,and it increase to 650pieces by ultrasonic cleaning.
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3D Parts Ultrasonic Cleaning
3D parts is with FDM/SLA/ DLP and other process residue . To use ultrasonic cleaner to cleanr 3d parts is with advantages . The 3D parts such as : Metal prints,conformal cooling molds, topology optimization building blocks,resin/nylon parts. there variety dirsty on 3d parts such as :titanium orthopedic implants, sintered residue/unfused powder,EDM sludge/anti-corrosion grease,support structure remnants/machining sludge,light curing residual resin/release agent film.
By ultrasonic washing, cleaning 99.9% of dirty particle; by ultrasonic washing, cleaning time is 35 minutes;and it needs 6.5hours for labor cleaning, and production capacity incrase 650% (by ultrasonic washing, clean 300pieces per day, while only clean 40pieces by labor cleaning; By ultrasonic washing, the cleaning cost save 72% (ultrasonic cost usd1.1/pc, labor cost usd6.98/pc ).
How to use ultrasonic cleaner to clean 3d parts?
1.microbubble stripping.
2. Vacuum penetration.
3. Low-temperature rinsing.
4.dry under pressure.
Advantages for ultrasonic cleaner cleaning 3D parts:
1.Micro-level cleaning capability: 0.1mm support residue removal rate:
By hand brushing clean 73%,by ultrasonic cleaning clean 100%.
2.Zero Damage Guarantee:
3. LA cantilever beam structure: amplitude control 5μm (to avoid brittle breakage).
4.SLA lamination protection: shear force 0.1N/cm² (50 times lower than toothbrush scrubbing).
4.1.SLA model cleaning is time consuming: by cleaning takes 35 minutes, by ultrasonic cleaning takes 4 minutes.
4.2.Porous structure drying:
by hand cleaning, drying takes 6 hours, by ultrasonic drying, takes20 minutes.
4.3.Complex internal cavity pass rate: hand cleaning clean 685, ultrasonic cleaning clean 99.8%.
5. preservation of property:
5.1.Tensile strength retention: 100%.
5.2.Dimensional deformation:±0.05mm.
Notes to use ultrasonic wash precison parts:
1.Do not wash the components containing
micro-springs (wire diameter0.3mm).
2. Thermal deformation: Keep cleaning liquid temperature ≤40℃ when cleaning PLA (glass transition temperature sensitive).
3. Frequency exclusion zone: When cleaning ceramic parts, Do not use 80kHz,in case micro-crack extension.
4. Post-treatment: after ultrasonic cleaning, must be rinsed washing with ultra-pure water (to prevent ionic residues from reducing fatigue strength).
Prohitbits to use ultrasonic cleaning:
1.PLA material prohibited to exceed 50℃.
2. Photoresist limited to 90 seconds;
3. Alkaline solution prohibited for carbon fiber reinforced parts
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Electronic Parts Ultrasonic Cleaning
There are many parts, such as, PCB, plate, Connector Terminal, JTAG Pin,Passive Component Pinout,metalic housing,RF Shield, Heat Sink Fins, Heat Sink Brackets,Graphics Card Cooling Copper Pipes etc parts. By ultrasonic cleaners, it can clean varieties of dirty, such as : soldering residue, thermally conductive silicone, oxized black spot,flux crystallization,dust and grease. By ultrasonic cleaning, it save 92% labor cost , save 8 times of cleaning time.
Cleaning electrronics parts case:
To clean SMT Plate
By labor, cleaning time: 32 minutes,
By ultrasonic cleaning, 4 minutes,
By labor, needs 6 men to work per washing,
By ultrasonic cleaning, 1 machine ;
So by ultrasonic cleaning, production capability increase 300%, and maintenace and repair cost save 55% .
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Molding Ultrasonic Cleaning
There are many plastic molds such as :Automotive molds, electronic shell molds, BMC mass material molds, epoxy encapsulation molds, optical lens molds,Medical micro-runner molds, cell phone molds, bumper molds, bottle cap threading molds .
All the variety of molds are with different dirty, such as : EDM oil sludge,coking of mold release agent,plastic carbide,rust oxidizzation.
By ultrasonic cleaning, the minisize particle dirty clean 99.9%, and the cleaning time takes 95 minutes, while it takes 32 hours for labor cleaning , and production capacity, by ultrasonic cleaning clean 42 sets, while labor clean 8 sets only. So by ultrasonic cleaning, it save 88% of total cleaning cost, and cleaning solvent save 74% (ultrasonic needa 7.2L/ set, labor needs 28L/set); and cut the cost for the failure and damaged repairing 97%.
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Metal Parts Ultrasonic Cleaning
There are many metal parts,such as sasteners ( as nuts and rivets), gears and bearings, drills, milling cutters, inserts, valves and cylinders, pumps, cartridges, heat sinks, shields, connectors, nozzles, and platinum metal parts .
these parts with vairety of dirty such as: solid oil pollution, grease, metal abrasive, heat treatment oxidized skin/rust,oil,abrasive residue, sintered carbon,wax,rust ect.
By ultrasonic cleaning, cleaning depth increase 30%; by ultrasonic cleaning takes 22 minutes, while labor cleaning needs 120 minutes, and save 5 times of production time. It save 87% of cleaning solvent, and save 98% of the cost.
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Instruments Ultrasonic Cleaning
Many instruments such as : surgical forceps,dispensing needles,water purification equipment,SMT fixture stencil,pathology sectioning tools,surgical stainless steel Instruments,Liquid chromatography column tubes,Optical platform mounts,lab instruments, medical instruments,dental instruments, surgical instruments all choose ultrasonic cleaners to clean.
These kind of instrument is with rust, blood, corruption,
proteinrester etc dirty particle , by ultrasonic cleaning, save 90% of cleaning time and save 88% of cleaning cost.
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Retainer Aligner Cleaning
There are many dental instruments, such as clear invisalign, clear aligner, moveable denture, retainer, mouth guard, night guard,
orthodontic brackets choose ultrasonic cleaners to clean.
These instruments with dirty such as : salivary protein film/plaque biofilm,food coloring,coffee and tea stains,calculus,fungal plaque,nicotine tar deposition,soft scale clumps,streptococcal colonies,calcified crystals in the archwire gap.
By ultrasonic cleaning, it can clean 99.9% of minisize particle dirty, it takes 3 minutes by ultrasonic cleaning while labor brushing needs 15 minutes, it not only save cleaning time but also save the future maintenance cost.
Notes to use ultrasonic cleaner for instruments cleaning:
1. Do not clean reinforced denture with metal fibers, in case anti-electrolytic corrosion.
2. Do not clean pure titanium implant fittings,in case cavitation leads to micro-vibration fatigue.
3. Do not clean soft lining material, in case silicone layer is susceptible to high-frequency tearing.
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Jewelries Ultrasonic Cleaning
Jewelries such as precious metal products,K gold,platinum gold,silver jewelry, rigid gemstone, diamond, corundum,crystal jewelry all choose ultrasonic cleaners to clean. These jewelries with different dirty, such as : sebum sweat, cosmetic residue,sulfide black spot,Oxide fog film,dust particles,hairspray styling agent or water white marks.
By ultrasonic cleaning, the cleaning effect increase 70% comparing by brushing, polishing time increase 10 times(ultrasonic cleaning take 3 minutes while labor takes 30 minutes), so by ultrasonic cleaning, it save 87% of maintenenace cost and increase 99.4% of damaged ratio.
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