It’s important to distinguish between “regular cleaning” and “precision cleaning.” True precision cleaning involves removing all contaminants from the surface of the object to be cleaned.

Precision cleaning is vital to the success of industries as varied as aerospace, defense, medical implants, computer tech, and pharmaceutical. In fact, parts in these industries must be cleaned so thoroughly that they can pass microscopic inspection of their surfaces.

If contaminant removal is only partial, this can be expensive, slow down production and have a negative impact on a company’s bottom line and reputation.

Considerations for Precision Cleaning

If you’re going to be having parts precision cleaned, there are certain factors and steps to be taken into consideration.

First, how clean do your parts need to be at the end of the process? What standard are you using, and how will this be determined? In most cases, parts are inspected closely before the cleaning process begins and then they are inspected again according to industry-wide standards and cleanliness levels. You need to determine what is appropriate for your industry and use that as your benchmark.

Once you’ve determined your inspection and cleanliness standards, you’ll need to determine what cleaning strategy you’ll employ.

Precision Cleaning Strategies

When it comes to precision cleaning strategies, there are a wide array of possibilities. These include methods as varied as vapor degreasing, hand cleaning, CO2 snow and mechanical blasting. All the above options have their benefits and drawbacks. For example, some of them require the use of hazardous solvents which create additional workplace safety and environmental considerations. These add further complications and cost to your precision cleaning process. Some processes add intensive time and labor, which can also drive costs up.

To solve the issues caused by intensive labor or hazardous solvents, many precision cleaning operations choose ultrasonic cleaning. For the most intricate jobs requiring a high level of cleaning, ultrasonic cleaning fits the bill, surpassing other methods for most cleaning needs.

What is Ultrasonic Cleaning?

Ultrasonic cleaning works through the generation of high-frequency sound waves through a liquid, using piezoelectric transducers to generate the waves via a diaphragm. When these high-frequency waves strike against the surface of an object, they produce millions of microscopic bubbles which instantaneously collapse. This physical effect is known as “cavitation,” and each collapse causes the snap release of jets of energy. Cavitation produces the power behind ultrasonic cleaning, uniformly “scrubbing” every surface of the object being cleaned, even cleaning down inside blind holes or intricate internal sections

How does ultrasonic cleaning work with precision cleaning?

Once parts have been inspected, they are ready to be sent to an ultrasonic cleaning unit designed for high-end precision cleaning, such as one of the units found in the Omegasonics Pro series.  The parts to be cleaned are placed in a liquid bath along with a detergent formulated specifically for the specific type of application and contaminant addressed in the cleaning.

Once the part to be cleaned is submerged, the ultrasonic cleaning process can begin. The number of ultrasonic cleaning cycles used, length of time in the bath, temperature used, and so on will be determined by the type of contaminant and parts material. Keep in mind that not all materials or applications are suitable for ultrasonic cleaning. We recommend that you get in touch with the ultrasonic cleaning experts using the contact information at the end of this article.

Once the part has been thoroughly cleaned, precision cleaning protocols demand that it also be rinsed in at least one or more water only baths before being quickly and properly dried. For many precision cleaning processes, this involves the use of forced hot air dryers to dry the parts thoroughly. The judicious application of a rinsing agent can help keep water spots from parts, as well as making sure to use distilled water.

Overall, although there are many approaches to successful precision cleaning, ultrasonic cleaning provides a thorough and cost-effective method that works well across industries. Want to know more about how ultrasonic cleaning can transform your precision cleaning operations? Call one of our ultrasonic experts at Omegasonics at 888-989-5560 or email us at Omegasonics@Omegasonics.com. You can also get in touch with us by filling out our online contact form.

BUSINESS TYPE:
✓Hydraulic tubing systems for aviation and marine

PART/PRODUCT CLEANED:
✓Metal tubes: stainless steel,carbon steel, titanium, aluminum, inconel®

SUBSTANCE(S) REMOVED:
✓Lubricants

OMEGASONICS SYSTEM USED:
✓Omegasonics Super Pro
✓Omegasonics Pro Plus
✓Existing tanks retrofitted with Omegasonics components

MONEY/TIME SAVED:
✓At least 20 hours of labor saved per week due to “hands-off” cleaning

Download the Eaton PDF

Eaton Aerospace: Since 1940

Jackson, Michigan is on I-94, halfway between Detroit and Kalamazoo. The Eaton Aerospace facility was founded here in 1940. World War II established the company’s preeminence in fluid power technology as Aeroquip brand components went into America’s military aircraft.

Today, Eaton Aerospace continues the tradition, creating products that convey air, oil, water and Freon for aviation and marine applications. The Airbus 380, the world’s largest passenger jet, uses assemblies made at the Jackson facility in its landing gear.

America’s new fighters, the F-22 Raptor and the F-35 JSF, have wings plumbed with Aeroquip brand fluid conveying products.

Twist and Turns

Bud Greener is a Manufacturing Engineer at Eaton Aerospace in Jackson. He oversees the process that bends straight tubing into complex shapes that go into the world’s most sophisticated aircraft.

Stainless steel, carbon steel and titanium tubes arrive from mills in diameters ranging from 3/4 inch to 3 inches. Tube sections are cut to length and bent with a mandrel, a lubricated tool inserted within the tube to prevent kinking.

Prior to the mandrel’s use, dust and particles must often be cleaned out of the tubes. Post-bending cleaning is mandatory to remove oils and tube bending lubricants. Air is forced through the tubes for final cleaning and drying. “People are fussy about how their tubes look,” said Bud, indicating the need for a clean, well-machined final product that meets internal quality standards.

Solving the Solvent Problem

For many years, Bud and his team cleaned tubing with mineral spirits and Stoddard solvent. The runoff went into a filtered tank, which a contractor would rotate. Stoddard solvent is a petroleum mixture with special storage, usage and disposal considerations. Eaton Aerospace decided to pursue an environmentally friendly solution to their cleaning needs.

The Switch to Omegasonics 

Bud and his supervisor John McKay, Manufacturing Manager of the Bending Area, attended the WESTEC show and discovered Omegasonics, the west coast’s leading manufacturer of ultrasonic cleaning systems, serving companies world wide. H

e was particularly impressed with two models: the Omegasonics Super Pro and the Omegasonics Pro Plus, floor machines equipped with wheels for maximum flexibility in placement and shop layout.”Omegasonics wasn’t the cheapest or the most expensive,” said Bud. “They had an excellent product for the money and a commitment to customer service.”

Eaton Aerospace’s output includes over-sized bent tubes which had dictated the acquisition of two stationary ultrasonic machines, made by a European manufacturer, with an approximate 300 gallon tank capacity.

When the internal components of these units needed replacement, Bud came to Omegasonics. “The tanks were still in fine shape and suited our special requirements,” explained Bud. “We were very pleased with the Omegasonics machines we were already using, so we asked them to retrofit our stationary units.”

Omegasonics consulted with Bud to determine specs for the components that would bring the stationary units back to life. Omegasonics supplied six transducer and generator sets per tank and generators. Eaton Aerospace installed the retrofit components and built the new control panel. “Omegasonics is very easy to work with, even from 2000 miles away,” Bud said. “The retrofit and all other support needs have been handled in a very responsive manner.”

Time Equals Money

Omegasonics reduces the hand labor required to make a tube ready for shipment. “Before we went ultrasonic, we cleaned tubes manually,” said Bud. “Now we just put them in the Omegasonics unit, adjust the settings, and walk away to do something else while they’re being cleaned.”

Bud calculates that ultrasonic cleaning eliminates 5 to 10 minutes of hand labor per tube. Multiplied by the facility’s output, this turns into a conservative 20 hours of saved labor per week.

“Our plant can’t afford to be slowed down or stopped. Omegasonics’ dependability and service is part of our operational success,” Bud confirmed. “As far as our employees and management are concerned, our Omegasonics units are here to stay. For any future needs, Omegasonics is our #1 choice.”

So, what is ultrasonic cleaning?

First off, what is ultrasonic cleaning and how does it work? Ultrasonic cleaning is made possible by the physical action of high-frequency sound waves traveling through a liquid. These waves, produced by a piezoelectric transducer hooked up to a diaphragm, move through the liquid and produce millions of microscopic bubbles when they strike the surface of an object. This effect is called cavitation. Bubbles created through cavitation are “filled” with space, so there’s nothing to keep them open. So, they collapse almost as fast as they are created, releasing tremendous bursts of vacuum energy in the form of heat and pressure. These jets of energy strike against the object to be cleaned, dislodging contaminants such as rust and grime. The result: fast and effective cleaning.

So, what can an ultrasonic cleaner clean?

It’s probably easier to consider what an ultrasonic cleaner can’t clean. After all, ultrasonic cleaning is used across a wide range of industries to clean a huge variety of materials. Ultrasonic cleaning is used to clean everything from medical implants to aerospace parts to carburetors to handguns. It shows its versatility when cleaning household items damaged by flood or smoke damage, for example. Even though ultrasonic cleaning can be used on the toughest industrial parts, it can also clean equally well grandmother’s best china set after a fire has blackened it.

There are only two main categories of items which can’t be cleaned by ultrasonic cleaning: items which shouldn’t be submerged in water because the liquid will damage them and items which can’t be easily dried. That’s it.

So that means everything from Grandma’s china to snowmobile carburetors can be cleaned with ultrasonic cleaners. Even electronic circuit boards can be cleaned. If they’re not connected to electricity at the time, and they’re properly dried out later on, it’s perfectly safe, and they won’t be harmed.

And when an ultrasonic cleaner is combined with a forced air drying cabinet, then you’ve got a potential cleaning assembly line operation going.

Bottom line: if it’s a surface contaminant, it can probably be removed from the object with the combination of ultrasonic waves and a detergent specially formulated for that type of grime.

The list of contaminants that ultrasonic cleaning can’t remove is about as short as the list of objects it can’t clean. Ultrasonic cleaning can remove just about any type of dirt, rust, oil, grime, carbon and more.

So, if you’re looking to clean any type of industrial or commercial part, especially if it’s something that involves a lot of elbow grease and time,  consider investing in an ultrasonic cleaner.

But don’t just take our word for it here. Got a question about what ultrasonic cleaners can clean and want to talk to someone about it? Call one of our ultrasonic experts at Omegasonics at 888-989-5560 or email us at Omegasonics@Omegasonics.com. You can also get in touch with us by filling out our online contact form.

It’s a safe, fast, highly-effective, non-abrasive means of cleaning just about any part or material while remaining completely environmentally sensitive.

From nozzles to hoses to brake parts and delicate machinery, it can handle just about anything, and aerospace providers are starting to learn the importance and effectiveness of this kind of cleaning.

Get the most out of your cleaning and refurbishing of aerospace industry parts with completely safe and effective methods of aerospace ultrasonic cleaning.

How It Works

Ultrasonic cleaning, as you might expect, works using sound waves. These sound waves are higher than the human hearing is capable of detecting, and when combined with water and eco-friendly detergent solutions, the vibrations they create cause bubbles in a process known as cavitation. There are millions of these cavities produced, and as they compress and implode, high temperatures and pressure is created which removes dirt and soil from the parts to be cleaned.

Effectiveness of Aerospace Ultrasonic Cleaning

The effectiveness of aerospace ultrasonic cleaning cannot be understated. Because the entire process is handled by vibrations of tiny bubbles, the cleaning can get into any crack, hole or crevice, no matter how small. The toughest carbon buildups, grease, oil and grime can be removed, and it all happens quickly using materials that are completely biodegradable, doing no harm to the surrounding environment.

There’s no need to disassemble delicate parts, risking damage to the inner workings, and then try to get at tough areas with brushes that could also harm the metals, plastics and rubber involved. Seals, O-rings and other fasteners can be left in place, the part submerged, and it will come out factory-clean and ready to function exactly as intended. It’s safe to use on aluminum, zinc, plastic, rubber, iron or just about any other material.

Frequency, Resonance and Care

The frequency of vibration can be adjusted to alter the size of the bubbles and the effects of the equipment. The viscosity of the cleaning solution will have an effect on cavitation, and both together will be influenced by temperature. Professional ultrasonic cleaning services know how to carefully adjust these issues to abide by strict manufacturer frequency and time limits to avoid damage from the resonance of the vibrations.

These factors are critical in cleaning any parts, but especially the delicate parts used in the aerospace industry. The settings for ultrasonic cleaning must be carefully controlled to remove tough carbon, contaminants and other build ups to get the item clean while avoiding any damage to the parts. Thus, it’s important to carefully follow the manufacturer’s specifications when cleaning.

Is Ultrasonic Cleaning Safe?

Ultrasonic cleaning, when performed by an authorized, skilled and experienced technician with the right equipment, is 100% safe for any part, no matter how delicate it may be. It’s important to use the right device for the right job, and that’s where Omegasonics comes into the picture.

For years we’ve helped a range of industries with the best available, eco-friendly and safe cleaning ultrasonic cleaning equipment. If you need help with aerospace ultrasonic cleaning, call us for more information today!