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.

What’s the difference between solvents and detergents?

The essential difference between solvents and detergents is that solvents break down and dissolve contaminants in the cleaning solution while aqueous detergents surround and lift away contaminants so they can be washed away. As everyone knows, water and oil don’t mix, repelling one another. To help water “get at” oil-based grime, detergents use additives known as “surfactants” that help water get “wetter” to lift dirt and oil away from the surface of the object being cleaned.  The detergent’s chemical properties pull grime away from the object’s surface and surround it with water so it can be washed away. Overall, solvents and detergents act in very different ways when used for cleaning.

How solvents work

As mentioned earlier, solvents are a compound that tends to dissolve away certain other materials placed in it. Technically, then, water is a solvent and is known as the “universal solvent,” simply because almost anything can be dissolved in it. However, what most people think of as solvents are so-called “organic solvents,” which include substances such as nail polish remover, paint thinner, and so on. These organic solvents are great at dissolving grease and fat-based spills and stains, something that water typically can’t handle well. When it comes to parts and industrial cleaning, you typically find solvents made from petroleum distillates, naphtha, acetone, light mineral oils, and other specialized organic or synthetic compounds. These types of solvents tend to be formulated depending on their intended application and use.

Issues with solvents

Over the past few decades, solvents have come under greater government and public scrutiny because of the undesirable effects of using them. They are often flammable, give off noxious fumes that are bad for workplace air quality, and they can be hazardous for workers to use, both in the short term and long term. Not only that, but they have been classified as an environmental hazard and must be both handled and disposed of with great care. There have been some recent reformulations of common solvents to make them somewhat more environmentally-friendly, and they still hold between 60 to 70 percent of the industrial cleaning market. However, they are losing ground to aqueous cleaners, due to better detergent formulations being developed and overall environmental concerns.

How Detergents Work

Water-based detergents start out of the gate possessing many advantages over solvents. These include non-flammability, few offensive fumes and little to no health risks for workers handling them. What’s more, many detergents are biodegradable, making them easier to dispose of safely and in an environmentally-friendly fashion. The traditional downside of detergents has been their perceived lack of effectiveness at the rapid removal of contaminants such as grime, rust, and scale from industrial parts. However, as noted earlier, more recent formulations of detergents have improved. Moreover, when they are placed in combination with the power of ultrasonic cleaners, their effectiveness becomes similar to or even surpasses that of solvents, without all the environmental and workplace safety concerns.

Ultrasonic cleaning and detergents

When paired with ultrasonic cleaning, water-based detergents have proven to be effective and thorough at cleaning every surface of industrial parts and many other objects. The detergents contact surfactants that help loosen the hold that contaminants have on the object, while the cavitation effect stemming from the high-frequency sound waves hitting the object produces millions of microscopic bubbles that blast away at the grime. Together, both ultrasonic cleaning and detergents form a powerful dynamic cleaning duo.

How do you choose the right cleaner?

There’s no exact answer, but you do have a few factors to consider. One of those is your setup and operation. You need to consider what you’re trying to clean and the regulations surrounding your work environment.

Another factor you should consider is the overall cost. Solvents are in general are more expensive than detergent solutions. Detergents are typically sold in highly concentrated form and work out to be much less expensive when you add water. Plus, you need to consider that you may be able to reuse some detergents more than you can with solvents, depending on whether you have a filtering system.

Another factor to keep in mind when looking at cost, as well as environmental impact, is the disposal of the used solvent or detergent. Properly disposing of some solvents may add quite a bit to your overall overhead costs. Some detergents may need minimal treatment before being disposed of, and others may use a technique called “bioremediation,” which uses unique microbes that clean up the solution, with only the addition of extra water and additional solution necessary periodically. Other maintenance for detergent-based systems may include filter changes, which are also inexpensive.

Don’t know whether solvents or detergents are best for your cleaning process? Why don’t you get some free advice? Contact one of our 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. We look forward to hearing from you!

Two common industrial cleaning type machines: ultrasonic and agitation washers. In one sense, ultrasonic cleaning is agitation cleaning, just at a microscopic scale. Both kinds of cleaning have their benefits and uses and are used for precision and industrial parts cleaning across industries.

What is ultrasonic cleaning?

Ultrasonic cleaning makes use of the physical forces caused by ultrasonic sound waves moving through the liquid and striking against a hard surface. Ultrasonic waves are produced through electrical pulses traveling through a piezoelectric transducer. The transducer vibrates a diaphragm, which transmits the high-frequency sound waves through a liquid bath. These waves produce microscopic cavitation bubbles when they contact the surface of the object to be cleaned. As the bubbles form and collapse, they release high-powered plasma jets that dislodge stubborn grime from the object. Ultrasonic cleaning is used for a wide variety of industrial and precision cleaning applications, including machined parts, disaster restoration, and electronics cleaning.

What is agitation cleaning?

Agitation cleaning is merely another method of cleaning away stubborn grime from the surfaces of machine parts. It utilizes a combination of immersion in a surfactant or perhaps a solvent along with agitation, whether through drum rotation or a platform moving up and down in the liquid bath.
This type of cleaning requires objects that can stand being shaken and moved about without being damaged. Ideal objects that can be cleaned with this method include turbine blades, cylinder heads, pistons, and rods.
Agitation cleaning does a good job of getting the cleaning agent (detergent or solvent) into contact with the bulk of the object’s surface. It relies mostly on the chemical action of the surfactant used and requires the least amount of mechanical energy. It works best for situations where you have a lot of time to clean parts, since it may take hours for stubborn grime to be washed away.

So, which is better: ultrasonic cleaning or agitation cleaning?

The answer to whether ultrasonic cleaning or agitation cleaning is better depends on several factors:

—What are you trying to clean? If it’s a part that can stand up to rough handling, like a cylinder head, then either agitation or ultrasonic cleaning will probably work, though agitation may take longer. However, if it’s a more delicate or intricate part or object, it may be damaged by agitation. Ultrasonic cleaning provides an effective, but gentler method of cleaning every surface of even the most intricate objects.

—How much time do you have? If time is not much of a factor, then agitation may work for you. Admittedly, agitation cleaners can be cheaper and use less power, but the tradeoff is the amount of time it takes for them to clean parts. You have to consider whether it’s worth your time and money investment to have your cleaning operations be slow or inefficient. Calculate your ROI (Return on Investment) for both types of cleaners to see which one comes out ahead for your needs.

—What’s your budget? In general, agitation cleaners can cost less initially than ultrasonic cleaners. If you’re looking at a low spend, then you may want to consider an agitation cleaner. However, when you’re considering cost, you need to take into account the entire cost, including production time lost for cleaning, overall energy used, employee time spent, and so on. Return on Investment (ROI) is another significant cost factor. Depending on your operation, you may find that investing in an ultrasonic cleaner produces more significant savings in the long run by cutting down on production time lost to cleaning, for example.

Overall, whether ultrasonic or agitation cleaning is better depends on your operational needs and other factors. To get some guidance on the best type of cleaner for your situation, you should contact one of our experts at Omegasonics at 888-989-5560 or by emailing us at Omegasonics@Omegasonics.com. You can also get in touch with us by filling out our online contact form. We look forward to hearing from you!

Fortunately, cleaning technology has advanced along with the tech that powers these futuristic engines. Ultrasonic cleaning has come into its own, allowing aerospace parts to be cleaned in mere minutes instead of hours, and with a minimum of effort. Not only do ultrasonic cleaners clean thoroughly, but also cleans gently, extending the life of aerospace parts and keeping them from weakening or being damaged, increasing flight safety overall. All this adds up to significant savings within the aerospace industry, money which can, in turn, go back to further research or to other needs.

What is Ultrasonic Cleaning?

Ultrasonic cleaning works through a physical principle known as “cavitation.” Cavitation occurs when ultrasound waves created by a transducer pass through a liquid and strike against an object immersed in that liquid. The ultrasonic waves create millions of tiny bubbles which release strong jets of energy when they collapse. These energy jets produce an intense force that dislodges grime from the object being cleaned. One advantage of ultrasonic cleaning is that it cleans from every surface of the object, even interior, hard-to-reach spaces, and crevices. Also, ultrasonic cleaning is relatively gentle and avoids the use of harsh chemicals and solvents.

Precision Cleaning with Ultrasonic Cleaners

Companies that do precision cleaning for aerospace contracts, as well as the aerospace companies themselves, can benefit from the time and cost savings–as well as the more thorough cleaning–they can achieve using ultrasonic cleaners. For example, in the past, cleaning a machined part such a manifold containing many small holes meant difficult and painstaking labor and potentially substandard cleaning. With ultrasonic cleaning devices such as those manufactured by Omegasonics, however, grime and contaminants are easily loosened and can be rinsed away. What’s more, Omegasonics offers a wide variety of models for every industrial need and capacity, from small machines suitable for cleaning dental instruments or handguns, to large capacity machines for cleaning car or aerospace parts. Some of these machines feature filtration systems that allow the detergent solution to be reused, a feature which some ultrasonic cleaners lack, causing them to have to be emptied and cleaned frequently.

There’s an Omegasonics Ultrasonic Machine for Your Exact Need

One of the things Omegasonics is known for is customer service and adapting its offerings according to the need for the customer. For example, one precision cleaner wanted to purchase ultrasonic cleaners, but decided that for its workflow, automating the entire cleaning process was not a good practice because it required a lot of calibration and maintenance. Bottomline for them: some parts cleaning required a human touch to ensure they were completely and thoroughly cleaned. Omegasonics worked with them to select ultrasonic cleaning machines that helped this company strike a good balance between automation and the human touch, enabling the precision cleaning company to automate a good section of its workflow but still leave room for finishing the cleaning with manual brushing and rinsing.

Want to know more about how ultrasonic cleaning can enhance safety in the aerospace industry while lowering costs? Contact our experts at Omegasonics at 888-989-5560 or email us at omegasonics@omegasonics.com

Omegasonics will provide local sales and development of Layton’s range of specialized equipment which already has an established and growing base of users in the US, as well as established representatives and company offices on the East Coast.

Layton is known worldwide for its pioneering development of systems for the safe use of flammable cleaning solvents including IPA and acetone, which also have ultrasonic cleaning capability and are designed to meet specific standards such as ATEX and regulations such as environmental impact, risk management and assessment. The systems are also approved to UL standards.

For more information about Layton Technologies in the U.S., see LaytonPrecisionCleaning.com