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The Science Lab
Case Study: Immersion Cleaning of Aluminum Auto Frames M6310
Cleaning Requirements
There are two manufacturers involved at different points along the manufacturing chain of aluminum automobile frames and need to clean the tubular frames prior to coating/hydroforming and after laser cutting.
Situation
There are two automotive parts manufacturers that need to clean automobile frames during different stages of manufacturing. The frames start out as aluminum tubes that are 16 feet long. The first company removes oils and other machining fluids from the tubes in a wash/rinse, then into a two-tank immersion wash system that employs spray under immersion. The cleaned parts are then coated with a dry film stamping compound. The coated tubes are sent to a second company in the manufacturing chain, which hydroforms the tubes into the shape of an automobile frame. A third company then laser cuts the frames prior to sending them on to the automobile assembler. The challenge here was to remove burned-on oils, dry film stamping compounds, and laser burns residues, all while not damaging the aluminum substrates. To add to the difficulty, the cleaning systems are both immersions with agitation and relatively low mechanical energy relative to both ultrasonics and spray-in-air applications.
In 2005, KYZEN engineers visited the customers’ facilities several times to appraise the cleaning/compatibility issues. KYZEN’s Applications Lab conducted cleaning/compatibility testing with the aluminum tube sections. A spray under immersion process was developed which specified cleaning parameters such as cycle time, temperature, and concentration. Several of the KYZEN METALNOX cleaning chemistries performed well in the removal of the various soils. However, Metalnox M6310 was selected as it cleaned effectively and provided protection for the aluminum during the four-minute heated rinse. Without this protection, the tubes would begin to darken from oxidation within two minutes.
Metalnox M6310 is a mild alkaline, engineered cleaning chemistry that is effective on a broad range of industrial soils. It is safe for all metals and provides extended corrosion protection for aluminum and copper-based alloys such as brass and bronze. M6310 is effective in both immersion and spray-in-air cleaning processes is biodegradable and has excellent worker safety properties.
The KYZEN technical team recommended the following process based on the compatibility test findings, and on cleaning test data contained in KYZEN’s vast cleaning test data library which contains cleaning process data for most of the industrial soils/metals encountered in manufacturing operations:
- Engineered Cleaning Fluid: METALNOX M6310
- Wash Concentration: 5-8%
- Wash Temperature: 120-140°F
- Wash Exposure Time: 4 minutes
- Rinse Temperature: 130-140°F
- Rinse Exposure Time: 4 minutes
Results and Conclusion
At the request of the company first in the manufacturing chain, the KYZEN technical staff assisted in the design of the cleaning system which was built and installed to realize production and cleaning needs. The second company in the chain, conducting laser cutting already had a two-stage immersion washer in place using an alternative but was replaced with Metalnox M6310 after testing proved it to be a superior cleaning product.
Members of the KYZEN Technical Services group conducted a plant trial and then assisted in the process of start-up at both companies. Both companies using Metalnox M6310 have realized shorter cleaning process cycle times as well as versatility with other parts cleaning requirements on-site in their respective plants. Metalnox M6310 contains additional components specifically effective on smut, or carbonized soils. KYZEN engineers visit both customers’ facilities frequently to monitor the cleaning systems and help with process optimization.
Process Control & Optimization Series: Kapture Every Drop
An efficient degreasing process requires a clean solvent. This means keeping up with new solvent, maintenance, and hazardous waste disposal costs that quickly add up. The EPA has many of the solvents under heavy regulation and is phasing certain solvents out completely. This should not come as a surprise once you take a look at the price increases!
The big question on everyone’s minds is why? There are several key factors to look at including:
- Global Shortage of Raw Materials
- Logistics Challenges
- Environmental Impact (TSCA)
- Raw Materials Phase-Out
With these challenges facing the solvent world, it is now more important than ever to not waste a reusable solvent. Recycling allows you to save on new solvent purchases, maintenance downtime, hazardous waste disposal, process time, and environmental impact. Whether you are solvent cleaning based on choice or necessity, the best way to go is using a solvent recycling system.
The KYZEN Kapture is an excellent example of a solvent recycling system. The Kapture takes the dirty solvent and removes the soils and retains them in the Kapture vessel. The clean solvent is then returned to the degreaser for re-use! The waste is periodically discharged as needed.
Recycling solvent is not only environmentally friendly, but business friendly as well. When you “Kapture” every drop – everybody wins.
To learn more about Process Control & Optimization click here to watch the T2T or feel free to reach out to a KYZEN team member today.
The Care Corner
Meet Your Clean Team
Jason Chan- Global Product Line Manager- Semiconductor
Jason Chan is the Global Product Line Manager for KYZEN’s Semiconductor segment. Jason and his family are from Taoyuan Taiwan where he currently lives and plans to stay. Jason received his master’s degree from the University of Detroit Mercy. He married his wife Tina in 2012 and shares two twins with her, Jessie and Brady. Even though they are twins and share the same mom and dad, they have drastically different personalities. Jessie is extremely outgoing, and brave, and enjoys trying new things. On the other hand, Brady is quiet and sensitive.
Some of Jason’s favorite hobbies include hanging out with his friends and family while having a nice meal. He enjoys BBQing and fishing in some of Taiwan’s pristine streams! In his alone time, you can find him watching movies or enjoying some music. While he is in the semiconductor segment now, he majored in construction engineering and computer information system during his time at school. He soon became dedicated to the chemical business in the semiconductor market.
Jason has been a member of the KYZEN team since November 2010! While at KYZEN, Jason has worn many hats. He has held positions that have involved sales, technical aspects, marketing, and product line manager. He says, “Different roles bring different challenges and those drive me to grow. However, the thing that has never changed is the ability to meet customers’ needs and help them improve based on the job function”.
Feel free to reach out to Jason Chan with any cleaning questions you might have.
Jody Saultz- Global Key Accounts Manager
Jody Saultz is KYZEN’s Global Key Accounts Manager and has been with us for three years. He is from Missouri and is a big family guy. Jody has two sons and six grandchildren! Some of his favorite things to do include hunting, fishing, and spending quality time with his family.
Some other fun things to know about Jody is he tried out for three major league baseball teams right out of high school. Was an avid racer of dirt track modified cars and he was once lost in the Colorado Mountains for over eight hours!… (if you are wondering he was found safe and sound.).
Jody brings over 30 years of cleaning experience to his position and enjoys solving problems for our customers. Being a team player, he is often called on to troubleshoot problems no matter where in the world they may occur. Jody is a valued member of the KYZEN Clean Team, and we are happy to have someone with such diverse interests and skills. Be sure to ask Jody about one of his exciting adventures the next time you see him!
Feel free to reach out to Jody Saultz with any cleaning questions you might have.
Preventative Maintenance Planning
When it comes to preventative maintenance, you may think that your business does not need it. You do a solid enough job taking care of your machines and maintenance program, but the reality is… everyone needs to have a preventative maintenance plan in place. There are many advantages to preventative maintenance such as less equipment downtime, fewer interruptions to critical operations, longer asset life, improved efficiency (assets in good repair tend to run better), increased workplace safety, and improved compliance with OSHA. If implemented properly, a preventative maintenance plan can save time, and money, as well as allow assets to last longer!
Here are some common mistakes when it comes to developing your preventative maintenance plan:
- Setting unclear instructions for your team
- Creating unrealistic completion goals and timeframes
- Errors in prioritization
- Forgetting to document all completed work (This is very important for the next PM cycle)
Overall, preventative maintenance is an excellent way to prolong the life of your capital equipment, improve production, and eliminate costly unscheduled downtime. Like any other program, everyone needs to adhere to a schedule to make the most of a well thought out preventative maintenance plan.
Check out our Tech 2 Tech Maintenance Series here – there is something for everyone.
The Age of Technology
In the age of technology, we expect information to be available at the snap of our fingers. Our technical resources page has recently been updated which makes this information even more accessible and in the palm of your hand! Now it is even easier to find the answers to your cleaning questions. Our main sections include our searchable Technical E-library, past volumes of our Cleaning Insights Newsletter, and almost 100 Tech 2 Tech sessions recording and information regarding Global Compliance and Certifications. Each of these sections is brimming with knowledge about KYZEN products and processes, industry information and trends, and so much more. Our hope in updating the Technical Resources page is to make information more accessible to our customers around the world.
If you have not yet explored the page, head there now and check it out!