How Ultrasonic Cleaners Effectively Clean Industrial Machined Parts

Machined parts that come directly from a production environment will be contaminated with a variety of substances. These parts may have picked up contaminants from the shop environment and machining can often leave particles on the machined surfaces. Industrial ultrasonic cleaners offer an efficient and cost-effective solution to meet these types of cleaning needs.

Contamination can be harmful especially if machined parts are used in systems which have high levels of cleanliness. These requirements are needed in certain industries such as food, pharmacy, and medicine.

There are many ways to clean machined parts. Cleaning and rinsing machined parts with solvents may remove the contaminants with simple geometries but they cannot clean the intricate crevices and holes. Plus, rinsing may leave residues as well. Manual scrubbing, another cleaning option, may remove contaminants but may damage the machined surfaces.

That's why ultrasonic cleaning is the best alternative to these traditional cleaning methods, since it effectively removes all grease, oil, dirt, particles and all other sorts of contaminants.

Ultrasonic cleaning starts with the ultrasonic generator which sends an electric high-frequency signal to the ultrasonic cleaning transducers immersed in the cleaning solution. The ultrasonic waves create cavitation bubbles which form in their troughs and collapse in the wave peaks. This formation and collapse of bubbles in the liquid result in a powerful scrubbing and cleaning action as the bubbles effectively dislodge dirt and other foreign particles from the machined surfaces.

One of the primary benefits of using industrial ultrasonic cleaners is that the bubbles work where there is a cleaning solution, and you can select the frequency range as to how intense the cleaning you would like it to be. As a result, cleaning is thorough and effective around both simple surfaces and more intricate crevices, holes and along the ridges. No need to use harsh chemicals that may leave residues, or mechanical scrubbing that may damage the machined parts.

The article “How Ultrasonic Cleaners Effectively Clean Industrial Machined Parts” explains more details. For more information or to get a free consultation on how ultrasonic cleaners can be used for your cleaning application, contact Kaijo at 408-675-5575 or by email at info@kaijo-shibuya.com.

How to Specify Equipment Size and Options for an Ultrasonic Cleaner

Selecting the right equipment size and options for industrial ultrasonic cleaners is just as important as using the right frequency to obtain optimum cleaning performance. Depending on the cleaning application requirements, either a flexible system or a system designed for one particular task may work best.  Also selecting the corresponding options will influence how the system can be used.

In ultrasonic cleaning systems, the parts to be cleaned are immersed in a solution contained within ultrasonic cleaning tanks. The tank should be big enough to hold the largest parts or parts with unusual shapes (for tanks of custom shapes), but the power of the system also has to be adequate to fill the tank with ultrasonic sound waves.

Small or delicate parts may be easily damaged by vibrations if they come into contact with the walls and/or bottom of the tank. Placing the parts in a basket will help in reducing the possibility of vibration damage, so the basket has to be large enough to hold the parts and the tank has to be large enough as well to hold the basket.

Ultrasonic transducers can be immersible, bolt on or permanently installed on the cleaning tank. Among the three, immersible transducers are the most flexible because they are independent units that can be placed into any cleaning tank, whenever they are needed. Bolt-on transducers can be removed or replaced when needed, while mounted transducers are usually the part of a turn-key ultrasonic system that can’t easily be changed.

Ultrasonic cleaning generators produce an electrical signal at the selected ultrasonic frequency. A generator can be designed to produce just one frequency, several frequencies or a wide range of frequencies. Depending on the cleaning requirements and the application, an ultrasonic system may need a generator that produces one or multiple frequencies.

Customers can choose industrial ultrasonic cleaners that are turn-key, or they can have them assembled from the individual components to meet their requirements.

Read the complete article, “How to Specify Equipment Size and Options for an Ultrasonic Cleaner” to learn more. For questions or to schedule a free consultation, contact Kaijo at 408-675-5575 or email info@kaijo-shibuya.com.

Tuning into the Right Frequency for Your Ultrasonic Cleaning Application

Ultrasonic cleaning is an excellent solution for removing contaminants from a variety of components and parts without the use of strong, corrosive cleaning chemicals or mechanical brushing. It provides a faster, safer and a more effective solution for many different cleaning applications.

The key to successful ultrasonic cleaning is choosing the right operating frequency. This is to avoid damage of the parts to be cleaned and for rapid and complete removal of contaminants.

An ultrasonic cleaning generator produces the selected frequency for the system. When the ultrasonic waves pass through the cleaning solution, they produce cavitation bubbles that form and collapse quickly. As these bubbles collapse, they produce a powerful jet that dislodges dirt, contaminants and other foreign matter from the surface of the parts that are being cleaned. It is important to choose the right ultrasonic generator for the application to optimize the cleaning power but avoiding damaging the part being cleaned.

Low frequency (25 kHz) – the lowest ultrasonic frequencies produces bigger cavitation bubbles, stronger jets, and a powerful cleaning action. This is used for removing heavy contaminants from parts with hard and durable surfaces. This frequency is not recommended for delicate parts as they could be damaged and soft surfaces could suffer pitting.

Intermediate frequency (40 kHz) – suitable for any common cleaning applications, the bubbles are smaller compared to those generated by low frequency and therefore this frequency is suitable for cleaning glass, jewelry, and machined parts.

High frequency (80 kHz) – this frequency produces smaller cavitation bubbles and a gentler cleaning. This is ideal for cleaning more delicate parts with a fragile surface finish, such as hard disc drives, LCD's and aluminum parts. The gentle cleaning action avoids pitting or roughening of softer parts.

Highest frequencies (130-160 kHz )- the highest frequencies are used for very fragile parts or parts that have soft surfaces. The cleaning action is light but effective for applications that include electronic components, semiconductors, and delicate medical instruments.

The complete article titled “Tuning into the Right Frequency for Your Ultrasonic Cleaning Application” provides more details on choosing the ultrasonic cleaning generator. Contact Kaijo at 408-675-5575 or email info@kaijo-shibuya.com if you have questions or would like to discuss your particular cleaning requirements.

What Exactly Does Precision Cleaning Mean?

The term “precision cleaning” describes a process that requires a clearly defined maximum allowable level of particle, film or impurity contamination on the surfaces to be cleaned. Precision cleaning is usually done with reference to a standard, such as a particle count or film contamination.

Compared to ordinary cleaning wherein a significant amount of impurities on the surface of the parts to be cleaned is removed but doesn't specify how much is left, precision cleaning cleans until the targets for the remaining contamination are reached.

Many industries, including medical, pharmaceutical and aerospace use precision cleaning standards in their manufacturing processes. Coating metal parts, plating components, cleaning tools prior to disinfection and cleaning silicon prior to diffusion, require high standards of cleanliness. It means that an inspection of the part shows that it has been cleaned to confirm any remaining level of contamination is within the permissible tolerances.

Cleaning with chemicals and manual cleaning are some of the methods used for precision cleaning. They may be expensive, time-consuming and labor-intensive. These methods do not guarantee that the parts are thoroughly and precisely cleaned.

Cleaning with ultrasonic cleaners addresses all these drawbacks and offers a complete cleaning solution for precision cleaning needs. Ultrasonic cleaning works by producing high-frequency sound waves at specified power levels in water or in a gentle cleaning solution. The parts to be cleaned are immersed in the cleaning solution and the ultrasonic waves dislodge dirt and contaminants from surfaces. The ultrasonic waves penetrate wherever there is cleaning solution and delivers an even and thorough cleaning action. Ultrasonic cleaning is ideal for parts with intricate shapes, holes, and crevices. Kaijo Shibuya is a leading ultrasonic cleaning manufacturer that offers a complete line of ultrasonic cleaners and components for precision cleaning applications.

The complete article, “What Exactly Does Precision Cleaning Mean?” provides more details about this topic. If you have questions or would like to set up a consultation about using ultrasonic cleaners, contact Kaijo by email at info@kaijo-shibuya.com or calling 408-675-5575.

How to Select the Best Ultrasonic Generator for Your Cleaning Applications

Among all the components of an ultrasonic cleaning system (generators, transducers, and a cleaning tank), it is the ultrasonic generator that determines its main characteristic of the system. Therefore, choosing the right ultrasonic generator is essential for obtaining the specified performance desired. The generator needs to have the right operating specifications and capabilities required for the cleaning application. In addition, the transducers and tank size have to match the generator as well. If the right generator is not selected, the system may work more slowly than expected or may not clean completely.

 Selecting the power of the ultrasonic generator depends on the size of the parts being cleaned. The parts must fit inside the cleaning tank and be submerged in the cleaning solution. The tank size, in turn, determines how much power is required to fill the tank evenly with ultrasonic waves.

The generator frequency determines the intensity of the ultrasonic cleaning action. A low frequency creates large cavitation bubbles that deliver robust scrubbing and cleaning action (appropriate for cleaning parts made of hard materials). A high frequency, on the other hand, creates smaller cavitation bubbles that deliver gentle cleaning action (appropriate for cleaning more delicate parts). An ultrasonic generator should be selected that produces the corresponding frequency, multiple frequencies or a frequency range that is needed for the specific cleaning application.

 Kaijo’s Quava high power ultrasonic generator, for instance, delivers up to 1200 W power and is configurable to 10 frequencies which range from 26 kHz to 950 kHz. This generator is ideal for cleaning parts ranging from metal engine components encrusted with oil, grease, and deposits to delicate circuit boards or optical components.

The Phenix Hyper ultrasonic cleaning generator provides a standard sweep mode or in a special hyper mode to improve cleaning performance. Hyper mode allows ultrasonic energy produced by the generator to fill the cleaning tank evenly. This provides optimum cleaning for many kinds of parts, even those with complex shapes, quickly and completely. This ultrasonic cleaning generator operates at 78 kHz with 1200 Watts of power and has an auto-tuning function that keeps the frequency adjusted when operating conditions change.

For more details read the complete article “How to Select the Best Ultrasonic Generator for Your Cleaning Applications”. If you have questions, want a free consultation, or quote, contact Kaijo at 408–675–5575 or email info@kaijo-shibuya.com.

Why Ultrasonic Cleaning Systems Are Used in the Metal Finishing Industry

Metal finishing involves applying coatings or other kinds of treatments to metal parts surfaces. This is to change the metal part's characteristics, harden the surfaces, or preventing corrosion. Ultrasonic cleaning systems are able to clean these metal surfaces quickly and completely.

These metal finishes include electroplating, which uses an electrode in applying a thin metal film to metal parts; plating using a chemical process; and plating which involves pressing a foil of metal onto part surfaces at high temperature and pressure.

For these metal finishing processes to be successful, the underlying metal surfaces have to be completely clean. Otherwise, the coatings may not adhere properly if the contaminants (such as grease or oil) remain on the metal surface.

Clean and contamination free surfaces allow for the proper adhesion of metal coatings, that's why metal parts must be cleaned completely for the coatings and claddings to adhere. Ultrasonic cleaning systems effectively clean metal surfaces quickly and thoroughly.

In ultrasonic cleaning process metal parts to be coated are immersed in a bath of pure water (or water mixed with a mild detergent). A high-powered ultrasonic generator transmits an electrical signal to an ultrasonic transducer that is placed in the bath and produces ultrasonic waves in the liquid at a selected frequency. The sound waves generate tiny cavitation bubbles that produce a strong scrubbing and cleaning action against the metal surfaces in the bath, dislodging particles and removing contaminants.

Other cleaning methods that use chemicals or mechanical cleaning are often used in metal applications. However, the use of ultrasonic cleaning systems and equipment is faster and does not require the use of harsh cleaning chemicals or intense mechanical scrubbing. Since ultrasonic cleaning requires no chemicals costs are reduced and it is more environmentally friendly.

Read our complete article, “Why Ultrasonic Cleaning Systems Are Used in the Metal Finishing Industry” to learn more. If you have questions or would like to set up a consultation, contact Kaijo Shibuya at info@kaijo-shibuya.com or call 408-675-5575.

How Ultrasonic Cleaners Are Used in Flat Panel Glass Processing

The flat panel glass is used in many products including flat screen products. The manufacturing steps in flat panel glass processing involve the application of coatings, adding semiconductor functions and special treatments of the glass. Manufacturing processes also often leave residues and the glass itself can pick up dirt and contaminants from the shop environment. Before it can be processed further, flat panel glass must be effectively and completely cleaned. Industrial ultrasonic cleaners used in these applications only require the use of mild detergents is safe for workers and the environment.

After flat glass sheets have been cut, the edges need to be polished and the corners rounded. The resulting flat panel glass that has a specific size and shape will then go through additional processing.

The additional process steps can include the addition of color or polarizing filters, layers for liquid crystal displays or chip on glass applications. For each of these process steps, having a clean glass surface is essential. Industrial ultrasonic cleaners are essential to the cleaning process to ensure surface contamination is removed and ensure quality flat panel glass products are produced.

While each of the process steps requires cleaning glass panels, the actual cleaning requirements needed for each steep may be different. For rough cleaning and removal of heavy contamination from the glass itself, the strong cleaning action from a low-frequency ultrasonic system may be appropriate. For filter coatings and chip on glass cleaning requirements, however, higher-frequency systems delivering gentle cleaning without damaging delicate films and components may be required. Since there are many cleaning applications in flat panel manufacturing specific requirements and customized ultrasonic systems may be required.

Kaijo can help flat panel manufacturers effectively use ultrasonic cleaning systems in their production lines to ensure high-quality products are produced. For more information read the complete article titled “How Ultrasonic Cleaners Are Used in Flat Panel Glass Processing.” For more information on Kaijo’s complete line of industrial ultrasonic cleaners and equipment including their turn-key industrial ultrasonic cleaning systems, call 408-675-5575 or email info@kaijo-shibuya.com for a free quote or consultation.