Our client, an industry-leading engine component manufacturer, plays a pivotal role in the aerospace sector. Their core specialty lies in the production of intricate airframe and turbine engine parts.
The parts they manufacture are key to high-stakes aircraft operations and are made of a diverse range of materials. These materials include resilient titanium, heat-resistant nickel alloy, corrosion-resistant stainless steel, and lightweight aluminum. During the client’s manufacturing process, these components are exposed to machining coolants that facilitate their shaping and assembly.
While these coolants are integral to the manufacturing process, they must be entirely removed from the parts to ensure their optimal functionality and safety.
One key reason these coolants need to be removed is due to the application of Non-Destructive Testing (NDT). In this context, NDT is used to detect and assess any defects or irregularities that might compromise the component’s performance or safety.
For those unfamiliar with Non-Destructive Testing, NDT is a suite of analysis techniques used in science and technology industries, including the aerospace sector, to evaluate the properties of a material, component, or system without causing damage. These techniques include radiography, visual inspection, magnetic particle testing, ultrasonic testing, and penetrant testing
For NDT to be effective, the parts must be thoroughly cleaned before testing. Any residual soils or machining coolants can lead to false readings, potentially overlooking dangerous flaws.
Our client contacted our trusted parts cleaning team because they knew the detergent used for this pre-NDT cleaning must be chosen carefully. It is crucial that the detergent does not leave behind any residue that could hide cracks or other structural weaknesses during the NDT process.
The challenge, therefore, lies in striking a balance between an effective cleaning process and maintaining the integrity of these sensitive engine components. The solution our team needed to design had to ensure a residue-free surface that allowed for precise and accurate NDT, supporting the client’s overall goal of manufacturing reliable, high-quality aerospace components.
The original cleaning process employed by the customer involved the use of Cee Bee 300LF at a concentration of 18%. The equipment they used was an immersion washer with mechanical agitation (recirculation pump). The initial washing process was originally conducted at 140°-150°F (60°-66°C) for 10-15 minutes, followed by two ambient temperature rinses using municipal water.
However, the customer was facing significant challenges they needed help to overcome. The cleaning process led to many issues with staining and white residues/spots, particularly on aluminum parts. These issues persisted even after testing the cleaning process in the lab under a wide range of conditions, including reducing the detergent concentration to 10%.
Furthermore, the tank life had reduced to 2-3 months as the production rate increased. These challenges affected the efficiency and quality of the manufacturing process and necessitated a solution that could deliver consistent, high-quality cleaning.
Upon a thorough analysis of the customer’s needs and challenges, our team recommended a transition to AquaVantage® 815 GD. The new cleaning solution was administered at a lower concentration of 12% while maintaining the same washing temperature and time.
This adjustment was designed to address the issues of staining and white spots on the components. Moreover, the equipment and rinse processes remained unchanged from the original setup.
The transition to AquaVantage® 815 GD resulted in several immediate and significant improvements.
Thanks to a collaborative effort with our dedicated parts cleaning team, the aerospace customer expressed high satisfaction with both the product and the changes implemented.
Even still, though the original goals were achieved merely by changing the detergent, the team went a step further to identify additional opportunities for improvement. Specifically, upgrading the quality of rinse water could potentially enhance the cleaning process even more, ensuring consistent, high-quality cleaning for all components.
Switching to AquaVantage® 815 GD proved to be a game-changer for this engine component manufacturer. From eliminating staining and white spots on aluminum parts to extending the tank life and reducing the strength of the detergent required, the switch to AquaVantage® 815 GD brought about a multitude of benefits.
These improvements enhanced both the efficiency and the quality of the manufacturing process, testifying to both AquaVantage® 815 GD’s exceptional cleaning capabilities and our team’s persistent dedication to delivering solutions that reduce operating costs, saving our customers money.