How Ultrasonic Cleaners Protect Components from Rust

Metal components often suffer from rust and/or corrosion if they are not treated and protected, even stainless steel. To prevent corrosion, metal is treated with various finishing processes such as passivation, which consists of increasing the thickness of the oxide layer.

However, for the metal finishing to be effective, it first needs be completely clean before the process is applied. If the part is not completely clean, the oxide layer may leave gaps, which is possible for the rust to attack through the holes. Using industrial ultrasonic cleaners means the impurities are removed and contamination is not an issue.

When contaminants are present, they can prevent passivation process keeping acid away from the surface of the metal. This keeps the thicker layer of chromium oxide from forming. When the surface of the metal is not cleaned completely, passivation may allow some surface areas to rust and may damage the part itself.

Industrial ultrasonic cleaners are the ideal solution to clean various parts, including metals that are to be treated with anti-corrosion finishing processes. Ultrasonic cleaners remove impurities from the metal part surface to allow the finishing to produce a seamless oxide layer.

Industrial ultrasonic cleaners use high-frequency sound waves in a cleaning tank of water to dislodge particles and contamination from the surfaces of metal parts. In an ultrasonic cleaning system, transducers are immersed in a cleaning tank and produce the sound waves in the liquid. The ultrasonic sound waves create microscopic cavitation bubbles that deliver a scrubbing action when in contact with the surface of the parts which are being cleaned. Dirt, oil, grease and other contaminants are easily removed.

Kaijo provides a full product line of Industrial Ultrasonic cleaning equipment that can be used in a wide range of cleaning applications to effectively remove contamination for parts and components. This is something that traditional cleaning with manual scrubbing or using harsh chemicals cannot easily achieve.

The complete article, “How Ultrasonic Cleaners Protect Components from Rust” goes into further detail. If you have questions or would like to set up a free consultation to discuss your particular needs, contact Kaijo Shibuya by email at info@kaijo-shibuya.com or call 408-675-5575.

Using Ultrasonic Cleaning Manufacturer Solar Panels

Solar panels consist of silicon wafers that have been etched and cleaned before being mounted behind glass sheets. Several of the intermediate steps require cleaning of the silicon wafers and glass sheets.

Unlike traditional cleaning methods that use manual scrubbing or harsh chemicals, ultrasonic cleaning systems remove contaminants and residues quickly and completely, while leaving the underlying silicon wafers or glass sheets unaffected.

Making solar cells involve fabrication steps such as etching the silicon, doping the wafers to create positive and negative charge areas and the depositing of conducting and non-reflecting films. The wafers have to be treated with chemicals; they are rinsed thereafter but these chemicals may remain and can shorten the life span of the solar cells and reduce their efficiency.

Silicon wafers may also have to be masked to produce conducive paths on the solar cells (and the masks have to be removed once the conductive film is deposited). Ultrasonic cleaning removes chemical contamination from the surfaces of the wafers and leaves them ready for subsequent fabrication. It can also remove the masking substance without damaging the thin and delicate conducting paths that have been deposited.

After all, the process steps are completed solar cells have to be assembled into bigger units to create solar panels. These solar cells are mounted on a backing, covered by a sheet of glass and sealed. While the solar cells may have been completely clean, the glass sheets may be contaminated or have residues. These contaminants can hurt solar panel functions and break the seals, allowing moisture to penetrate the panel, corrode the conductors, and block the sunlight that produces solar panel power.

Ultrasonic cleaning systems are an ideal solution for cleaning glass surfaces. Using just a bath of plain water, this cleaning method makes sure that no chemical residues are left on the glass surfaces. Traditional cleaning of silicon wafers and glass sheets require special rinsing to remove traces of contaminants. Moreover, they clean too slowly. It also uses harsh chemicals, whose handling, storage and disposal which can be quite costly.

Ultrasonic cleaning, on the other hand, cleans silicon wafers and glass sheets quickly and thoroughly. It also saves money from spending on harsh cleaning chemicals.

Read the complete article “Using Ultrasonic Cleaning to Manufacture Solar Panels” to learn more. If you have questions or would like to set up a free consultation, contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com.

When Are High Frequency Ultrasonic Cleaners Needed?

High frequency ultrasonic cleaners are needed when the parts to be cleaned are delicate and easily damaged.

How ultrasonic cleaners clean parts?
Ultrasonic cleaning systems use the scrubbing action of microscopic cavitation bubbles to clean dirt and contaminants from the surface of the parts being cleaned.

The ultrasonic frequency generator produces an electrical signal that the ultrasonic transducer converts to sound waves in the cleaning solution. Cavitation bubbles form in the troughs of the sound waves and collapse in the peaks. When they collapse, the bubbles create many tiny high-energy jets of cleaning solution. If the bubbles are near the surface of the parts being cleaned, the jets hit part the surface and dislodge any contaminants that are present there.

How can cavitation bubbles damage parts?

Selecting the right frequency is one of the keys to achieve the optimal cleaning performance.

Low frequency systems generate larger bubbles that deliver robust cleaning. These bubbles are so powerful that they can effectively remove heavy contaminants, but they can also cause damage to parts made of delicate materials.

High-energy jets produced from low frequency systems can also cause damage to parts with complicated structures such as printed circuit boards. They can also strip away protective coating of plating parts of some materials such as coated lenses, hard disk media or flat panel glass.

High-frequency jets are the key

High-frequency ultrasonic cleaners (over 100 kHz) generate smaller bubbles that deliver gentle cleaning. These bubbles form weaker jets. These jets don't clean as fast as the jets of the lower frequency systems, but they are also too weak to cause damage to delicate parts.

High-frequency bubbles are ideal for cleaning delicate parts and components. They are gentle enough not to cause pitting to soft parts or strip away the coatings, but they have adequate power to remove contaminants that negatively impact the coated parts. The gentle cleaning action of the high-frequency bubbles will maintain the integrity of delicate parts being cleaned.

If you would like additional information, please read the complete article “When Are High Frequency Ultrasonic Cleaners Needed?” Contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com to set up a free consultation to discuss your specific cleaning requirements.

How Ultrasonic Part Cleaners Keep Employees Safe

Ultrasonic cleaning allows workers place the parts in a water-based solution and leave them there for a short period until they are clean. This is in sharp contrast to traditional cleaning methods that require extensive handling of parts, soaking them in harsh chemicals and scrubbing them.

Ultrasonic part cleaners keep the workers safe in many ways:

1) Less handling of parts reduces accidents
Traditional cleaning of parts is labor-intensive. Some parts have complex shapes that may require manual scrubbing. The handling of heavy parts and parts with sharp edges and corners can result in strain, cuts and bruises. Ultrasonic part cleaners minimize handling of parts, thus reducing the risk of accidents and injury.

2) Less use of sharp cleaning tools
Manual cleaning and brushing of contaminated parts consists of using wire brushes and scrapers which can penetrate or cut through protective gloves, thus injuring employees. Ultrasonic part cleaners can clean parts without the use of sharp cleaning tools.

3) Minimized use of harsh chemicals
Traditional cleaning also consists of using harsh chemicals. But storage, handling, use during cleaning of the parts and disposal of these toxic chemicals can present safety hazards to both humans and the environment. Ultrasonic cleaning requires no special solvents beyond mild detergents in a water solution for heavy contamination with grease or oily deposits. Moreover, these detergents are not hazardous and require no special disposal after use.

Ultrasonic parts cleaners are the ideal alternatives to traditional cleaning of parts that require manual scrubbing or using toxic cleaning chemicals. Moreover, they clean the parts quickly, thoroughly and effectively while keeping the workers and the work environment safe.  Employees simply place the parts to be cleaned in ultrasonic cleaning tanks turn on the system to run for a specified time.

For more details read the completed article titled “How Ultrasonic Part Cleaners Keep Employees Safe”. If you want a free consultation or quote, please contact Kaijo at 408-675-5575 or email info@kaijo-shibuya.com.

Why Ultrasonic Cleaners Are Used in the Medical Industry

Since medical devices are often delicate and have high cleaning standards, industrial ultrasonic cleaners provide an ideal solution, offering gentle cleaning and complete removal of contaminants.

Medical devices that include surgical instruments and medical implants are used inside the body and are subject to extremely high standards of cleanliness and sterility. In addition, medical devices have complex structures that mean intricate surfaces, tiny crevices, dead-end holes and even inside slots and threaded holes.

Many medical devices cannot be exposed to heat, harsh cleaning chemicals and intense scrubbing which are typically used in traditional cleaning methods. Not only these methods costly and cause potential damage to medical devices, but they also do not guarantee that they provide complete cleaning.

Industrial ultrasonic cleaners rely on sound waves, which produce microscopic cavitation bubbles in the cleaning solution. The formation and collapse of these bubbles agitate the cleaning solution near the medical device surfaces to dislodge any dirt or contamination that may be present.

Low ultrasonic frequencies produce comparatively large bubbles with an intense cleaning action for rugged devices. High ultrasonic frequencies, on the other hand, produce smaller bubbles with a gentle cleaning action which is the frequency used to clean delicate parts such as medical devices.

No matter how complex medical devices are, once they are immersed in the cleaning solution, the microscopic cavitation bubbles are formed inside the tiniest crevices and dislodge any contaminants, cleaning down to the original surface. A complete cleaning is extremely important, especially for implants. If these implants still have leftover contaminants due to improper and incomplete cleaning, it could result in the rejection of the implants.

 While industrial ultrasonic cleaning systems effectively remove contaminants, they do not, by themselves, kill or eliminate bacteria. Thus, adding a sterilizing solvent to the cleaning solution helps the cleaning action process and the action of the cleaning bubbles heightens the sterilizing effect as well.

For more information read the complete article, “Why Ultrasonic Cleaners Are Used in Medical Industry”. Contact Kaijo for a free consultation or quote by email info@kaijo-shibuya.com or call 408–675–5575 to discuss your cleaning requirements.

Selecting the Right Ultrasonic Tank and Transducer for Your Application

An ultrasonic cleaning system consists of several different components:

• Ultrasonic generator – Produces the electric ultrasonic frequency;
• Transducer – Converts the electric signal to sound waves; and
• Tank – Holds the cleaning solution and the parts to be cleaned.

Choosing the right ultrasonic cleaning tank and transducer for your specific application helps ensure that the ultrasonic cleaning system works as expected and satisfies the requirements of your cleaning application.

When selecting the right tank, you need to consider several characteristics:

• Size – the tank must be large enough to hold the cleaning solution and the parts to be cleaned and not over-sized which results in inefficient operation.
• Basket – the basket holds the smaller parts, so that they won't be damaged against the tank’s bottom and walls from the vibration caused by the ultrasonic frequency.
• Heating – some cleaning applications will benefit from a tank that can distribute heat in the cleaning solution.
• Thickness of tank material – the thickness of the tank enhances the sound distribution and prevents cracking.

Ultrasonic cleaning transducers are sealed metal containers that can be either immersible, bolt-on, or directly mounted types:

• Immersible ultrasonic transducers – are the most flexible type of transducers because they can be moved and placed in any tank. It is waterproof and is attached to a cable, which is then plugged into the ultrasonic generator. It can be suspended in the cleaning solution to produce the ultrasonic sound waves.
• Bolt-on transducers – are fixed to the bottom or sides of the cleaning tank. Bolt-on transducers can be exchanged but they are not as flexible as immersible transducers.
• Mounted transducer – it is fixed to the bottom or sides of the cleaning tank. Mounted transducers often come with turnkey systems and are integrated into the ultrasonic cleaning system.

 It is also important to choose the right ultrasonic cleaning tank and transducer combination. Kaijo provides expert advice for ultrasonic cleaning installations to ensure your system delivers the performance you expect.

Read the complete article “Selecting the Right Ultrasonic Tank and Transducer for Your Application” to learn more. Contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com if you have questions or want a free consultation on choosing the right ultrasonic system for your needs.

How Ultrasonic Cleaning Systems Eliminate Manufacturing Production Delays

Incomplete cleaning of tools and parts used in manufacturing production lines, such as cleaning injection molds, can result to slow operation, down times and overall operation and production delays.

The use of ultrasonic cleaning systems ensures that cleaning injection molds and related parts are completely and properly cleaned. It also reduces the time needed for finding and solving cleaning problems that are usually encountered with conventional cleaning methods.

The use of ultrasonic cleaning technology allows even hard to clean part surfaces and textures to be completely and effectively cleaned. The ultrasonic waves result in the formation and collapse of the cavitation bubbles in the cleaning solution. This action of cleaning bubbles helps in dislodging contamination and other undesirable particles from the surfaces of the parts that are being cleaned. The cavitation bubbles can even clean intricate shapes and hard-to-reach places of the parts being cleaned.

To achieve the optimum cleaning performance in an ultrasonic cleaning system, the right tank size, power and frequency levels should be selected carefully.

The ultrasonic cleaning system is so effective that it doesn't need aggressive cleaning chemicals or use mechanical scrubbing action. Operator safety is greatly enhanced and costs for the use, handling, storage and disposal of chemicals are eliminated. With the elimination of chemicals, the ultrasonic cleaning system is also environmentally compliant.

For more details read the complete article “How Ultrasonic Cleaning Systems Eliminate Manufacturing Production Delays” to learn how Kaijo can help you. For a free consultation or quote call 408-675-5575 or email to info@kaijo-shibuya.com. Ultrasonic cleaning systems are an ideal solution for quick, thorough and efficient cleaning of industrial and manufacturing parts, such as injection molds. Using a proactive cleaning process, you won't have to encounter down times and unnecessary production delays any longer.

What Are the Advantages of Turn-Key Ultrasonic Cleaning Systems?

An ultrasonic cleaning system contains three essential components: the ultrasonic generator, the transducer, and the cleaning tank.

These components can be purchased together in a complete turn-key system or purchased separately. If components are purchased separately customers need to make sure that the components and specifications match otherwise the system will not perform or provide less than ideal results.

Turn-key ultrasonic cleaning systems from reputable manufacturers are built with components that have the required characteristics. The system design ensures that the selected components are matched correctly and together deliver the best performance.

Aside from the frequency, power and tank size, the type of controls, the tank material and the operating temperature should be considered.

• General-purpose cleaning or cleaning rugged components – low frequency (26 kHz or 38 kHz)
• Cleaning delicate parts – high frequency (130 kHz or 160 kHz)

The size of the tank should and a number of transducers needed must be determined. Tanks need to be large enough to hold the biggest or longest parts to be cleaned. The tank material also needs to be impervious to withstand any cleaning solutions used as well as the high temperatures (if heating is needed).

Control systems should be run in either fixed mode or sweep mode to produce even distribution of the ultrasonic waves. The system controls also adjust the power.

Citing the time-consuming and expensive nature of the application of these design configurations, any mistakes will adversely affect the ultrasonic cleaner's performance and may even damage the parts that are being cleaned.

Kajio's Phenix III is a turn-key ultrasonic cleaning system will eliminate those potential problems. It delivers general ultrasonic cleaning for a variety of industrial parts in a reliable and cost-effective manner. It is easy to use and offers flexibility in operations.

It offers various standard tank sizes to accommodate different powers and frequencies. Custom sized tanks are also available. The 3mm-thick stainless-steel tank can withstand high temperatures (up to 100 degrees centigrade) and common detergents, therefore delivering superior cleaning performance. The transducers and the tank can also withstand high-temperature operation.

The Phenix III is available in 26 kHz and 38 kHz models as well as 600w and 1200w models. It can operate in either fixed or sweep mode.

For additional flexibility, the single-phase 50/60 Hz AC power supply is selectable for 200V, 208V, 230V or 240V. The unit draws 6A for the 600 W model and 10 A for the 1200 W model.

To learn more about Kaijo’s Turn-Key ultrasonic cleaning system, read the complete article “What Are the Advantages or Turn-Key Ultrasonic Cleaning Systems?” For a free consultation or quote email info@kaijo-shibuya.com or call 408-675-5575 to discuss your requirements.

Top 5 Things to Consider When Buying an Ultrasonic Cleaner

Industrial ultrasonic cleaners have become the preferred choice for many manufacturing and research facilities. They provide a more effective solution for a lot of cleaning applications and they clean more quickly than traditional cleaning methods that involve hard manual scrubbing and the use of caustic cleaning chemicals.

1) Ultrasonic cleaner frequency
The ideal frequency of an ultrasonic cleaner determines the level and size of cavitation bubbles which produce the cleaning action in the cleaning solution. Low frequencies result in bigger bubbles which are ideal for robust cleaning of parts with hard surfaces. Higher frequencies produce smaller bubbles that are ideal for gentle cleaning of soft and delicate parts.

2) Ultrasonic cleaning tank size
The ultrasonic tank contains the cleaning solution where you immerse the parts to be cleaned. The cleaning system tank size is important in relation to the size of the parts to be cleaned. These parts must fit adequately into the tank.

If many different parts must be cleaned, a basket may be needed. Baskets keep the small parts clear of the tank bottom and sides because the vibrations against the tank walls during cleaning may damage the parts.

3) Ultrasonic cleaner power
Power is also an important factor when choosing an ultrasonic cleaner. Turnkey systems automatically have the right power levels for the ultrasonic system, however, if the ultrasonic generator, transducer, and cleaning tanks are purchased separately, adequate power needs to be generated based on the size of the tank. The ultrasonic power rating, as well as the configuration of transducers, can affect cleaning performance.

4) Cleaning with mild soaps and detergents
Industrial ultrasonic cleaners usually clean with deionized (DI) water alone, however, mild soaps and detergents may be required to remove more stubborn contaminants and to facilitate cleaning. For contaminants that are harder to clean, a solvent specific to the contaminant will often speed up cleaning and improve cleaning performance.

5) Using heat to improve cleaning performance
Sometimes the application of heat is used in ultrasonic cleaning to soften and remove heavy contamination to speed up cleaning. If heating is to be used, the tank and the transducer must be able to operate in temperatures up to 100 degrees Celsius. The tank must be fitted with the heater and the parts to be cleaned should also be able to withstand the high temperatures. Depending upon the contaminants to be cleaned, the cleaning process may take more time.

The key to buying the right ultrasonic cleaner is looking at the right characteristics and features:
For more details read the complete article “Top 5 Things to Consider When Buying an Ultrasonic Cleaner”. For a free consultation or quote contact Kaijo at 408–675–5575 or email to info@kaijo-shibuya.com.

Can Ultrasonic Cleaners Clean Aluminum Parts?

Ultrasonic cleaners are quite versatile. They can clean hard, rugged parts such as those made from brass or steel – even when they are heavily contaminated. Low frequencies are ideal in cleaning such parts quickly and thoroughly, but how about parts made of aluminum? Can industrial ultrasonic cleaners also be used to clean them as well?

Getting rapid and effective cleaning of aluminum parts is, in fact, more difficult. Since aluminum is a softer metal, cleaning aluminum parts requires more care and attention to prevent damage. At the same time, aluminum reacts with both acidic and base cleaners, so a neutral cleaning solution is required for an ultrasonic cleaning bath.

In general, parts with heavy contamination are cleaned with lower frequencies (between 19.5 kHz and 26 kHz) because the cleaning action of the cavitation bubbles is more intense. The cavitation bubbles also appear larger and produce high-energy blast when they collapse at sound wave peaks. This formation and collapse of bubbles generate robust cleaning action, which is effective for cleaning hard parts such as brass or steel parts.

For cleaning more fragile parts or parts with softer surfaces, a higher frequency (38 kHz and higher) must be used. The high frequency produces smaller and less energetic cavitation bubbles that will not damage aluminum parts.

If the cleaning application regularly cleans a variety of parts, including steel and aluminum parts, an ultrasonic cleaning system that can produce two or more cleaning frequencies should be used. That way, steel, and similar hard and rugged parts can be cleaned quickly at low frequencies. For aluminum parts, higher frequencies are used that produce smaller (low energy) cavitation bubbles that typically result in prolonged cleaning times.

Ultrasonic generators need to produce one or more frequencies or a range of frequencies that is right for aluminum parts.  There are other measures that can be applied for faster ultrasonic cleaning at all frequencies, but especially at high frequencies. These include using heat and/or adding cleaning agents.

Depending on the type of the contaminant to be removed, cleaning agents are usually acidic or base. Since aluminum is highly reactive to both acids and bases, neither of these cleaning agents is used in an ultrasonic bath.

Based on these restrictions, the best option for cleaning aluminum parts is to use an industrial ultrasonic cleaner at a high frequency in a heated bath with a neutral cleaning agent. The heat softens the contaminants while the neutral cleaning dissolves them. The high frequency produces small, low-energy bubbles that will clean even the most intricate aluminum parts without damaging them. This combination will produce the best cleaning results.

Read the recently published complete article “Can Ultrasonic Cleaners Clean Aluminum Parts?” to learn more. Contact Kaijo for a free consultation at 408-675-5575 or email info@kaijo-shibuya.com to discuss your ultrasonic cleaning requirements. 

How Ultrasonic Transducers Work and Are Used in Industrial Cleaning Applications

The role of a transducer in an ultrasonic cleaning system is converting the electric high-frequency signal (produced by the ultrasonic generator) into physical sound waves in the cleaning solution. Ultrasonic cleaning transducers can work at different frequencies and produce enough power to fill the cleaning tank with ultrasonic waves.

Ultrasonic cleaning transducers consist of a thick metal plate and active parts that vibrate when an electric signal is applied. When the ultrasonic waves pass from the transducer's metal plate through the cleaning solution, the wave troughs create low-pressure regions that generate cavitation bubbles. The bubbles form in the wave troughs and collapse in the ensuing wave peaks, releasing jets of energy. The collapse of the bubbles dislodges the dirt and contamination from the surface of the parts being cleaned.

In this way, the transducer turns the electric signal from the generator into physical scrubbing and cleaning action.

There are two types of transducers according to materials:

•    Piezoelectric transducer – Historically, they were constructed from delicate materials and thus had a relatively short useful lifespan when used in ultrasonic cleaning applications. The active parts consist of piezoelectric material that changes shape in tune with the vibration of the electric signal. However, recent advancements in piezoelectric materials have contributed to the re-emergence of the piezoelectric transducer. The newer materials are more rugged and can resist even the highest megahertz frequencies.

•    Magnetostrictive transducer – These consist of metal plates and coils of wire that are not easily damaged. The metal plates vibrate in tune with the high-frequency magnetic field created by the electric signal. The use of higher frequencies require shorter plates, however, there is a limit on reducing the size of the plates. As a result, magnetostrictive transducers can only be used for the lower frequencies.

There are different types of transducers can be used:

•    Immersible transducer – an independent unit with a sealed case and waterproof cable attached. As the name implies, it is usually immersed in the cleaning solution and can be placed into an ultrasonic tank to produce the required ultrasonic sound waves.

•    Bolt-on transducer – the most appropriate for new installations with a new cleaning solution tank. It can be bolted onto the sides or the bottom of the cleaning tank.

·       Permanently mounted transducer – used with turnkey ultrasonic cleaning systems that are ready to operate as a self-sufficient system.

The complete article titled “How Ultrasonic Transducers Work and Are Used in Industrial Cleaning Applications” provides more details on this topic. For a free consultation or quote contact Kaijo at 408-675-5575 or email to info@kaijo-shibuay.com.

Important Questions Customers Ask about Ultrasonic Cleaners (Part Two)

Do you have questions about using ultrasonic cleaners for your industrial cleaning application? Here are some more of the important questions customers often ask about using Kaijo Shibuya's industrial ultrasonic cleaners and our answers.

1) “Do I need to use a heater?”
It depends on your specific cleaning application. Ultrasonic cleaning systems do not normally use or require a heater but it can speed up the cleaning process.

2) “What does Sweep Mode do?”
As the ultrasonic waves spread through the cleaning tank, the parts to be cleaned interfere with the ultrasonic waves, creating spots where the waves become stronger and other areas where the waves become weaker. This can cause uneven cleaning. To avoid this, the sweep mode is used to automatically vary the ultrasonic frequency slightly, which causes the weak spots to move around. The result is a more even cleaning.

3) “Is the use of auto-tuning important?”
Yes, with auto-tuning the generator monitors and adjusts the power that is conducted to the transducer array. This allows the system to maintain the ideal calibration as the conditions change in the process tank during operation. This means any changes to temperature, water level, or chemical changes will not affect the power level in the cleaning tank. 

4) “What ultrasonic frequency should I use?”
Low frequencies result in larger cavitation bubbles that deliver an intense cleaning action – you should use this type of frequency when you clean robust parts such as metal parts. High frequencies, on the other hand, result in comparatively smaller cavitation bubbles that deliver a less energetic cleaning action. You should use the lowest frequency that will not damage delicate the parts that are being cleaned.

Our recent article has additional information for each of the questions above, as well as eight others. You can read them by going to the complete article “Important Questions Customers Ask About Using Ultrasonic Cleaners.” If you have questions not included in the list, or if you would like to set up a free consultation, call us at 408-675-5575 or send an email to info@kaijo-shibuya.com.

Important Questions Customers Ask about Ultrasonic Cleaners (Part One)

The following are some of the key questions that customers asked about selecting and using industrial ultrasonic cleaners, especially when they use them for their specific applications.

1) “When should I use an ultrasonic cleaner?”

You should use an ultrasonic when you want a quick, thorough and more efficient cleaning action without the use of harsh cleaning chemicals or mechanical scrubbing. It is important to choose the right power, frequency, type of transducer and the size of the unit to arrive at an ideal and desirable cleaning result. It also takes the right type of ultrasonic cleaning system to do it.

2) “How do ultrasonic cleaners work?”

The ultrasonic generator produces a high-frequency electric signal which is converted to ultrasonic waves in the cleaning solution by the transducer. The cavitation bubbles form in the ultrasonic waves. When the bubble collapse, they deliver a powerful scrubbing and cleaning action that dislodges dirt from the surfaces of the parts that are being cleaned.

3) “How do I select the right equipment?”

The best way for you to select the right industrial ultrasonic cleaning system is to discuss your requirements with your manufacturer/supplier. They should have extensive experience and be willing to offer advice on how to achieve your cleaning goals. Can existing tanks be re-used? Do you clean one kind of part or multiple parts? Do you need additional measures like heat or mild cleaning solvent? There are many factors that can influence your decision in choosing the best solution for you.

4) “How do I specify equipment size?”

Parts to be cleaned must be immersed within a cleaning solution in a cleaning tank large enough to hold the parts. Oddly shaped parts may require the use of a custom tank size depending on the size and shape of the part.  But if you clean mostly small parts or delicate parts that can easily break, you will need a parts basket to support them and to prevent them from touching the bottom and sides of the tank as the vibration might cause breakage. If you clean with many different types of parts of various sizes, the tank needs to accommodate the largest part.

See more answers to questions often asked by reading our complete article “Important Questions Customers Ask About Using Ultrasonic Cleaners.” If you have questions not included, or would like to set up a free consultation, call 408-675-5575 or send an email to info@kaijo-shibuya.com.

Using Industrial Ultrasonic Cleaners to Clean Disk Drives

Disk drives and components that include aluminium disk platter blanks and metal read/write heads are usually manufactured in standard industrial facilities. The processes used in their fabrication includes machining, stamping, punching, polishing, and molding using industrial chemicals for cooling, lubrication and as abrasives.

Before they are sent to special facilities for assembly, the hard drive components arriving from the industrial manufacturer must be cleaned thoroughly. Traces of industrial chemicals, contaminants added during shipment and particles adhering to platter surfaces must be removed completely. The components of hard disk drives must be especially clean, since the heads float very close over the platter surface and excessive contamination will not allow them to gather and store data.

High performance industrial ultrasonic cleaners can perform these types of cleaning tasks quickly and effectively. An industrial ultrasonic cleaning system produces microscopic cavitation bubbles in the solution of a cleaning tank. The bubbles form and collapse in time with the ultrasonic frequency. When a bubble collapses by the surface of a hard disk component, it produces a scrubbing action that removes dirt and contaminants. The bubbles form wherever the cleaning solution can penetrate, even around crevices, tinier holes and irregular shapes of disk read/write head.

To achieve optimum cleanliness, hard disk drive manufacturers usually use several frequencies to clean various components to remove specific contaminants. Deionized water is the preferred cleaning solution since cleaning agents leave traces that then have to be removed as well. For components that have surface lubricants, a mild detergent and/or heating the cleaning solution may make complete removal easier.

Kaijo offers free consulting to help customers choose the right industrial ultrasonic cleaners that will meet their requirements. Read the complete article “Using Industrial Ultrasonic Cleaners to Clean Disk Drives” to learn more. If you would like a free consultation or have questions, contact Kaijo at 408-675-5575 or email info@kaiijo-shibuya.com.

Why Are Higher Ultrasonic Cleaning Frequencies Required?

Choosing the right high frequency ultrasonic cleaner is the key to successfully cleaning parts that have a delicate physical structure. However, if the ultrasonic cleaning system frequency is set too high, cleaning could take longer and become less effective. If the frequency is set too low, it could damage the more delicate parts. Ultrasonic cleaning systems are extremely versatile and effective in most cleaning applications, but only if the operating frequency matches the tasks to be performed.

Ultrasonic cleaning systems generate a high-frequency electric signal that is converted into sound waves by an ultrasonic transducer. The transducer is submerged in the cleaning tank filled with water and generates sound waves in the liquid. Microscopic cavitation bubbles appear wherever the cleaning solution can penetrate. They form in the low-pressure troughs and collapse in high-pressure peaks.

This collapse of the bubbles is responsible for the cleaning action of an ultrasonic cleaning system. The bubbles can clean inside hollow tubes, in the thread of bolt holes, inside dead-end holes, and in cracks.

Low frequency — have longer cycle times and the wave troughs are wider resulting in bigger bubbles. Typical candidates for low-frequency cleaning include automotive parts such as cylinder valves and carburetors.

High frequency — have smaller bubbles because there is less time for them to grow in the comparatively narrow troughs. Using a high frequency ultrasonic cleaner is required for cleaning delicate parts such as medical instruments, semiconductor components, and computer parts. The selection of the ultrasonic frequency has to balance between the need for reduced cleaning power due to the fragility of the parts and the type of contamination that is being removed.

Kaijo has a full product line of industrial ultrasonic cleaning equipment and has extensive experience in the field of ultrasonic cleaning. For more information read the complete article “Why Are Higher Ultrasonic Cleaning Frequencies Required?”. If you have questions or would like to set up a free consultation to discuss your industrial cleaning requirements, contact Kaijo Shibuya at 408–675–5575 or email info@kaijo-shibuya.com.

Kaijo's New Phenix+ Ultrasonic Generator Optimizes Cleaning Performance

Kaijo's new Phenix+ industrial ultrasonic generator improves the functions used in the ultrasonic cleaning system’s performance. It provides better efficiency and takes ultrasonic cleaning control to whole new level.

Kaijo analyzed the possible sources of problems with using ultrasonic generators and used this to design the Phenix+ ultrasonic generator. It includes features that make the units easier to use, more efficient and offer better control of ultrasonic cleaning system functions.

The Phenix+ ultrasonic generator includes the following features:

• Touch panel controls for easy-to-use operator interface.
• Improved power output monitoring and control.
• Advanced automatic turning for changed process environment or a changed transducer.
• A standard frequency modulation mode which ensures an even and uniform ultrasonic wave distribution.
• More efficient cooling of the generator unit for increased efficiency.
• Reduced power use due to a more efficient power circuit.

These features make the Phenix+ ultrasonic generator an ideal source to create a high-frequency electrical signal used within an ultrasonic cleaning system. Operators can use the additional functions to control the cleaning process more precisely and deliver optimum cleaning performance.

Touch panel controls, automatic adjustment for the cleaning environment, uniform ultrasonic wave distribution, and increased efficiency from cooling requirements make the new Phenix+ industrial ultrasonic generator a great choice.

As a leading ultrasonic equipment manufacturer, Kaijo is focused on continuously improving their ultrasonic cleaning system components. They are committed to bringing the most advanced and cost-effective ultrasonic cleaning solutions to their customers.

For further details read the complete article, “Kaijo’s New Phenix+ Ultrasonic Generator Optimizes Cleaning Performance”. Contact Kaijo Shibuya at 408-675-5575 or email to info@kaijo-shibuya.com if you have questions or would like to set up a free consultation.