Ultrasonic Cleaning: Handicaps
and Limitations
Hi…
Thanks for dropping by!
This is Chandrakant from ESP
Ultrasonic .
Last week, while I was visiting an
Auto Component manufacturer, I was asked by their production manager Mr.
Thirumuragan, what was exposure that i considered most valuable , as a Sales
Professional.
Without hesitation I blurted out, “We
don’t have a solution for every need.”
It’s true, we don’t!
We deal with various Industry
verticals and each one of which are so well tuned with their expectations of
process fit, budget considerations, Safety standards and Production . No two
experiences are the same.
More often than not, we have to
devise solutions. By networking with like minded professionals, process experts
and by reviewing resources online , we work out a fitting solution. The
internet has changed the outlook to successful marketing personnel to that of a
marketing consultant. We source popular solutions and work with industry
defined norms of acceptance and economy.
Our ability to offer solutions is
important because we can offer technical options, which generally are not
available to an outsider or on the internet.
The Limitations of Ultrasonic
Cleaning
Industrial Cleaning is evolving and
so is technology, process and metallurgy .
As salesmen, we have the most exciting occupation . Each client has a different
challenge.
After about six months of follow up,
I met the Senior Vice President of a company and he put forth his requirements
.
“Can you dry clean a component”, he
asked me.
In my head, I was thinking,
‘Obviously, NOT!
Since I could not offer them any of
the wet cleaning options, I took time off to check alternatives.
Finally,we arrived at a solution that could give them the ‘dry cleaning’ that they required.
Ultrasonics do have their
limitations. There are two obvious challenges:
a) The Montreal protocol has prohibited the use of various solvents by
restricting the use of the most compatible ones.
This was a body blow to the industry.
After working on development of alternatives, the result was the emergence of
water soluble solvents and aqueous based systems. The trends are emerging that
this seems to be the best way out for most component cleaning challenges.
b) The other limitations of
Ultrasonic Cleaning is that it doesn’t work in moving (flowing) media (be it
water or solvents).
Yet considering the general methods
of cleaning, Static media can’t flush out contaminants in deep recess parts or
inside the intricate designed component.
In order to bridge the gap between
these two challenges, Ultrasonic technology emerged by using slow flowing media
or intermittent pressure jets or rotating component basket. Equipment designs
have arisen where media is subjected to sudden turbulence created by blade
propelled movement.
Another technique is to gently rock
the component back n forth to dislodge deep set contaminant.
Hybrid technologies have also
developed.
The good news is that cleanliness
levels of 0.04 mg have been achieved using aqueous equipment.
The application of creativity and
plethora of chemicals has ensured that almost every requirement for cleaning
systems are addressed using Ultrasonic in total or in conjugation with other
technologies. This has prompted most professions to adopt a solution based
approach rather than a technology based approach.
Strengths of Ultrasonic Cleaning
Well, I think we should also look at
the bright side of using Ultrasonic in cleaning.
The ideal system is built on using the
combination of the technologies that mask the handicaps and limitations of the
other.
Let’s take another example -
Cleaning Materials Exposed to Radioactive Particles.
This has traditionally been a
stronghold of Vapour degreaser and High Pressure jets. However the flushing of
beta and gamma radiations have been a very closely guarded technology as
exposure is fatal and the contaminant cannot be disposed off.
With the challenge for recycling the
irreplaceable resource, it was decided to develop a nano-filtration system that
works to collect the particulate matter and remove the metal or non-radioactive
substances.
Now 99.999% of the required can be
achieved with beta filtration using multiple Ultrasonic tanks and jet spray
arrangement. This system is well set to increase the profitability of the
cleaning process.
Also, new designs have emerged in the
stainless steel tank construction, micro polishing of inner surfaces and use of
acoustic technology like resonance, etc.
Ultrasonic Cleaning has emerged as a
modern, flexible and dynamic cleaning technology. The technology can be tuned
to adapt strengths from water blasting, to that of vapor based cleaning.
In
washing, ultrasonic has ceased to exist as a technology. Its now a
solution based to a specific challenge.
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