World Remanufacturing Conference

Transcription

1 ADVOCATE COLLABORATE EDUCATE World Remanufacturing Conference Value Added Aluminum Cleaning Hugh McDaniel Kim Kontra

2 Outline Impacts Cleaning Process Selection Cleaners and Chemistry Applications and Process Fundamentals Quality Control and Common Issues

3 Objective Determine aluminum chemical products that allow remanufactured components to be returned to a like-new or better than new state.

4 Value Added Impacts for Optimized Aluminum Cleaning Improved Velocity Reduced New Parts Usage Reduced Labor Cost Eliminate Component Damage Eliminate Cleanliness Related Warranty Eliminate Ergonomic Impact to Employees

5 Cleaning Process Selection METALLURGY Aluminum only vs multi-metal EQUIPMENT SCOPE Spray Immersion Ultrasonic Vibratory Wet Blasting EHS VOCs HAPs Other restrictions CLEANLINESS How clean should it be? Paint Removal Organic Soils Particle size/counts/weight Brightening PROCESS FLOW Cycle time available Supporting Processes Passivation requirement

6 BUILDERS Contribute to acidity/alkalinity Inorganic acids Hydroxides Carbonates Amines INHIBITORS Metal Protection Stain inhibitors Corrosion inhibitors SOLVENCY Soil and Paint Removal Chemistry Components SURFACTANTS Provide detergency, wetting, emulsify soils Nonionic, anionic, cationic High and low cloudpoint Spray vs Immersion ADDITIVES Fluid stability, specific to application Stabilizers Defoamers Chelators

7 Alkaline Builders Alkaline cleaners use saponification of soils in addition to surfactants/solvency Amines light duty, low residue Carbonate moderate duty Caustic heavy duty high ph & residues Acid Builders Acid cleaners rely on surfactants/solvency & require stainless steel equipment Hydrochloric Acid Phosphoric Acid Sulfuric Acid Nitric Acid Proper selection of alkaline builders is key for cleaning yet maintaining appearance of aluminum parts.

8 Cleaning with Spray Relies on impingement & minimal emulsification Advantages Low foaming Oil splitting Longer sump life Disadvantages Requires good impingement Needs proper part orientation

9 Cleaning with Immersion Relies on solvency & good emulsification Advantages Non-foaming Good solvency Longer sump life Low equipment cost Good contact on areas unreachable by spray Disadvantages Requires good agitation Short bath life due to higher soil loading Longer process times Requires second tank for rinsing

10 Cleaning with Ultrasonics Immersion plus Ultrasonics Advantages Disadvantages Good for difficult Short bath life part configurations High soil loading and complicated surfaces Can remove difficult soils normally not removed by chemistry and immersion alone Requires appropriate chemistry for viscous soils and high solids soils

11 Paint Removal Paint can be stripped using basic or acidic products Considerations in Formulating/Product Selection: Surfactant package compatibility with acid and base Potential odors of solvents Hazardous Air Pollutants (HAPs) Volatile Organic Compound (VOC) Part cleanliness prior to stripping

12 Aluminum Brightening Objective is to have a brighter part or more uniform surface Considerations in Formulating/Product Selection: Type of acid Surfactant package compatibility with acid and base Inhibitors Next step in process

13 Common Issues With Poor Product Selection and Process Control Process Foaming Aluminum Darkening Excess Waste Generation Unnecessarily High Operating Temperature Oxidation on Finished Components Contributes negatively to cost and quality

14 Concentration Monitored by titration using free and total alkalinity or total and free acidity Process Control System Maintenance Spray nozzle Filtration Part orientation & fixtures Soil Load Oil Splitting Metals Analysis Total: Free Alkalinity Ratio Conductivity Other Temperature Time Concentration ph

15 Many factors are considered for optimum cleaning process Chemical Selection Process time System Maintenance Process Control

16 ADVOCATE COLLABORATE EDUCATE Thank You Kim Kontra Hugh McDaniel