When an international aerospace component supplier in Asia approached our team, seeking to optimize their cleaning process, we were eager to put our parts cleaning experts on the case.
Their specific requirements involved the cleaning of multiple types of tubes made from titanium and aluminum alloys. The cleaning objectives included the removal of processing and machining oils, particulate and process debris, as well as corrosion inhibitor oils.
The goal was to achieve thorough cleaning at the end of the manufacturing process, just prior to packaging. With our expertise and commitment to customer satisfaction, we worked with the supplier to implement process adjustments, providing a reliable cleaning solution to meet their needs.
Originally, the customer’s equipment design encountered challenges related to excess foam generation and drag-out issues during the cleaning process. Excessive foam was observed in the wash tank, then carried over into the rinse tank.
The customer also reported concerns regarding incomplete rinsing and spotting on the parts, which affected the overall quality of the cleaning process.
The customer used a three-tank ultrasonic immersion system: one tank for washing with the aqueous detergent, one tank for rinsing with deionized (DI) water and compressed air agitation, and finally one tank for rinsing with hot DI water without compressed air agitation.
During testing, we worked with the client to uncover multiple issues in the process that could be resolved.
The first issue was too much foam in the wash tank, due to the agitation of jets very near and parallel to the liquid’s surface and subsequent blow-off toward the overflow skimmer.
The second issue was foam in the wash tank dragging-out to the rinse tank, which used compressed air agitation. The agitation in the rinse tank only led to more foaming. Due to the foaming, the rinse was incomplete—an issue our team needed to help them resolve.
To address these challenges and enhance the cleaning process, we worked closely with the customer and made the following adjustments:
Our parts cleaning advisor team initially recommended switching to a different, lower-foaming aqueous detergent. Considering the inherent foaming characteristics of AquaVantage® 815 GD, we recommended switching to a low-foaming detergent for their immersion system.
However, the client was very pleased with AquaVantage® 815 GD due to its extensive approvals and test compliance. We designed our solution to make sure it was compatible with AquaVantage® 815 GD.
Additionally, we implemented prior processing steps. These steps included surface treatment using Henkel Turco Airlion T-4090, then cleaning after the surface treatment, then another surface treatment using Alodine 1200s, i.e., Cr+ ions for coating.
The customer expressed great satisfaction with the enhanced cleaning performance achieved using AquaVantage® 815 GD. By implementing the recommended equipment modifications and process adjustments, we successfully addressed the issues of excess foam and drag-out. The customer experienced improved control over the cleaning process and achieved the desired cleanliness levels for their aircraft tubes.
We continue to monitor the customer’s cleaning process and offer support as needed. Our commitment to customer satisfaction extends beyond the initial implementation, ensuring a long-term partnership built on reliable cleaning solutions and ongoing assistance.
Through collaboration and tailored process adjustments, we effectively addressed the challenges faced by the international aerospace component supplier. The customer’s satisfaction with the cleaning performance and control achieved using AquaVantage® 815 GD reinforces our commitment to providing reliable solutions that meet aerospace specification approval and testing requirements.
The expertise of our industrial parts cleaning advisors in optimizing cleaning processes allows us to deliver exceptional results, enhancing the efficiency and quality of operations for our valued customers in the aerospace industry.