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What is an ultrasonic cleaner?
Advantages of ultrasonic cleaning
Different ultrasonic cleaning machines
Ultrasonic cleaning solutions
Ultrasonic cleaning process
Part 1: What is an Ultrasonic Cleaner?
An ultrasonic cleaner uses a process known as cavitation, which causes microscopic bubble bursts that create a vacuum-like scrubbing action that removes contaminants and dirt It is a cleaning device that uses mechanical vibrations to produce sound waves in a solution. The combination of cavitation, sonic irrigation and detergents provides a highly efficient cleaning system for delicate, sensitive and delicate instruments and devices. As the tiny vibrations propagate at ultrasonic frequencies, the cleaning medium is compressed and fractured.
The efficiency of the process depends on the design and frequency and power of the ultrasonic system, which are the main factors to consider when purchasing an ultrasonic cleaner. depends on its density.
How Does Cleaning Work?
Cavitation is a physical phenomenon that occurs when there are regions of high pressure that oscillate and fluctuate for short periods. In an ultrasonic cleaning machine, an extremely high frequency wave is transmitted to the cleaning solution to create the fluctuating pressure. Small bubbles or voids are formed that instantly burst. The explosions produce small but powerful shock waves. These shock waves are invisible to the naked eye, but at a microscopic level, they break up residues in the part being cleaned.
In other industrial equipment, cavitation is considered a serious damaging phenomenon that can easily erode metal parts such as pump impellers and casings. Therefore, when used in cleaning applications, the cleaner process parameters must be carefully controlled. Creating strong cavitation can damage the part being cleaned.
An ultrasonic cleaner consists of three main parts: the generator, the converter, and the tank. The ultrasonic generator is the main component responsible for taking mains power and converting it into an electrical signal. This electrical signal oscillates at the target process frequency. The standard mains power frequency is typically 50 or 60 Hz. In contrast, the generator's output frequency is thousands of times higher and ranges from 20 kHz to 80 kHz. Megasonic frequencies, i.e. 100 kHz and above, are now possible with today's technology.
The second part is the ultrasonic transducer, which converts the electrical signal into mechanical vibrations. This is achieved through the reverse piezoelectric effect or magnetostrictive phenomenon. When an electrical signal is applied, the dimensions of the piezoelectric/magnetostrictive material vary from 1 to 0.1 microns.
A magnetic transducer is a device that expands and contracts ferrous metals in a magnetic field. It is a type of mechanical transducer that works on the idea that the ultrasonic cleaner's box resonates and produces mechanical ultrasonic waves in an elliptical motion.
Piezoelectric transducers have crystals that have electrical properties. When electricity passes through the crystals, they change shape and produce linear vibrations. Piezoelectric transducers are used mostly in Europe and Asia.
Transducerml; type is an important factor in the ultrasonic process. Initially, metal transducers were used to create mechanical vibrations. They produced more aggressive vibrations and damaged the instruments. Modern ultrasonic cleaners use softer and more effective ceramic transducers.
The last major part is the ultrasonic cleaning tank. The tank is used to hold the cleaning solution and the part. This is also where the transducers are mounted. Most tanks are made of corrosion-resistant materials like stainless steel. However, some are made of other materials like plastic and ceramic. The size of the tanks varies depending on the number of gallons of solvent they can hold and are designed to last and are extremely durable.
Other components of an ultrasonic cleaner include the heater and the strainer basket. The heater is used to control the temperature of the cleaning solution. In physics, the power of cavitation depends on the vapor pressure of the liquid and hence its temperature. Precise control of temperature will greatly affect the cleaning quality and care given to the part.
The strainer basket holds the part in place while it is submerged. Most installations do not allow the part to touch the bottom or sides of the tank, as this can affect the quality of the vibrations imparted to the cleaning solution.
Part 2: Advantages of Ultrasonic Cleaners
Ultrasonic cleaners are increasingly being accepted as an alternative cleaning method in a variety of industries. Typical applications include medicine, dentistry, electronics, plastics, metalworking and machine parts manufacturing. Below are several benefits of using ultrasonic cleaning machines.
Excellent for Delicate Parts: Unlike traditional cleaning methods such as brushing, polishing, scrubbing, water jet or spray cleaning, compressed air cleaning, chemical cleaning, ultrasonic cleaning does not damage the part being cleaned. In addition to dirt and debris, mechanical and chemical tools can remove some materials from the surface of the part being cleaned. This can cause unsightly surface defects, scratches, corrosion and discoloration. This makes ultrasonic cleaners highly suitable for cleaning delicate and sensitive items such as jewelry, dental and surgical equipment, microelectronics and complex machine parts.
Precise and Smooth Cleaning: The ultrasonic cleaner works by applying vibration to the entire cleaning environment. This way, all wetted surfaces are cleaned at the same rate. This helps to prevent over-cleaning of a specific area, which can eventually damage the part. Moreover, by properly wetting the part, even hard-to-reach areas such as crevices and cavities can be reached and cleaned thoroughly.
Faster and More Thorough Cleaning: Ultrasonic cleaners are both fast and effective. The normal cleaning time for even the most delicate parts is only 10 to 15 minutes. Cleaning only takes one cycle. More cycles are usually not needed to increase cleaning efficiency. Its speed is also attributed to multi-tank installations where multiple parts can be cleaned at the same time. The parts are immersed in several tanks containing only one ultrasonic cleaning unit.
Can Remove Most Contaminants: Ultrasonics are not limited to removing dirt, they can also remove other unwanted materials. Examples include mineral deposits, rust, oil and grease, carbonized material, plastic and elastic residues, pigments, molds and proteins. This makes ultrasonic cleaners a versatile piece of cleaning equipment. Targeting various residues is easily accomplished by changing the machine parameters and using the appropriate cleaning solution.
Relatively High Power Efficiency: Compared to other mechanical cleaning methods ultrasonic cleaning requires less power. Other methods use motors, pumps and compressors that consume a lot of power and convert only a small amount into actual cleaning action. Ultrasonic cleaning, on the other hand, can easily convert electrical energy into vibration. The efficiency of the ultrasonic generator is 95%, while the efficiency of the transducer is 65% to 70%. The overall efficiency of ultrasonic cleaners, especially piezoelectric types, can reach around 70% or higher.
Minimal Space Requirement: Ultrasonic cleaners are compact and space-saving. Only the tank is needed to house the cleaning bath and the part. No other equipment or accessories are needed. In some installations, another tank is used to rinse the solution. This is completely different from other cleaning methods such as chemical cleaning, which uses multiple chemical baths or water sprays, and compressed air cleaning, which uses pumps and compressors to pressurize the cleaning media.
Easy to Use: Ultrasonic cleaner controls are often digital, and some are even automatic. Most desktop machines only require the user to enter the cleaning time. Industrial and manufacturing ultrasonic cleaners use temperature, power, can change parameters such as density, wave amplitude and frequency. After setting the operating parameters, the operator simply dips the part into the tank and lets the machine do its job. Rinsing is usually done afterwards. This simple process eliminates the need for an operator throughout the cleaning process. contrasts with other methods that hear.
Section 3: Different Ultrasonic Cleaning Machines
There are different types of ultrasonic cleaners on the market. They mostly differ depending on the type of part or material they are designed to clean. Each is tailored to a specific application.
Medical and Dental Ultrasonic Cleaners: Ultrasonic cleaners can remove blood, tissue, and protein-based contaminants while protecting the delicate surfaces of the device. They are used to prepare instruments for sterilization because they can attack most contaminants. Common medical and dental items prepared for sterilization include surgical instruments, implants, surgical screws and fasteners, needles, blades, cutters, laboratory supplies, and more.
Jewelry Ultrasonic Cleaners: Ultrasonic cleaning is a popular method in jewelry making. The process utilizes the gentle, precise cleaning of ultrasonic cleaners. Ultrasonic cleaners can create cavitation in hard-to-reach areas. It also does not scratch or damage the intricate surface of the jewellery, which is particularly important in the crafting process.ml;beyond, ultrasonic cleaning can be combined with ultrasonic polishing to create a much better shine than other cleaning methods.
Ultrasonic Gun Cleaners: There are many hollow areas, grooves and crevices in the assembly areas of guns that brushes and polishers cannot reach. Even when the gun is disassembled, there are areas that cannot be washed by hand or brushed. Moreover, traditional gun cleaning often uses solvents that are harmful to the environment. This is not the case with ultrasonic gun cleaners. Ultrasonic gun cleaners, also known as ultrasonic firearm cleaners, can reach all areas as long as they are properly wetted with the cleaning solution. Ultrasonic gun cleaners can also be used with ultrasonic gun lubrication. Both processes are similar: they use cavitation. The full ultrasonic cleaning and lubrication process eliminates the need to disassemble the gun each time maintenance is required.
Electronic Ultrasonic Cleaner: Ultrasonic cleaners are used for cleaning circuit boards and electronics due to their simple operation, high efficiency and gentle cleaning. Electronic ultrasonic cleaners can remove different types of residues commonly found on semiconductors and in electronics manufacturing processes. Small metal chips and shavings can be removed without damaging the fine features of electronic components. This ensures a defect-free product that performs reliably.
Industrial Ultrasonic Cleaners: Industrial ultrasonic cleaners clean various machine elements and components of automobiles and aircraft. These are large cleaning machines designed to contain components such as compressors, radiators, pumps, valves and gearing. They are highly effective at removing oil and grease. In addition, despite the large size of the component being cleaned, the cycle time is only a few minutes longer than smaller types. However, cleaning is done evenly across the wetted surfaces of the component.
Medical Part Cleaning During Manufacturing: Sanitation and sterilization are vital to eliminate potentially harmful microorganisms from medical devices. Additionally, the component parts of medical devices must be cleaned prior to assembly and sterilization.
The purpose of cleaning medical devices prior to sterilization is to remove contaminants such as particles and fluids that may have accumulated during processing and assembly. For example, devices made of stainless steel and titanium, such as joint implants, may have metal shavings trapped in holes or connection points. Fluids used to cut and shape implants must be removed prior to subsequent steps in manufacturing. Medical instrument products are cleaned multiple times during assembly and before the product is sterilized.
Ultrasonic precision cleaning is the industry standard for cleaning medical devices during manufacturing. It is particularly effective for cleaning intricately designed parts and hard-to-reach crevices or blind holes, and for further improving subsequent surface treatment processes. Surgical instruments, implants, surgical screws and fasteners, needles, blades and cannulas to catheters, stents,has proven to be the ideal solution for precision cleaning of everything from grain to laboratory utensils and test tools.
Ultrasonic Mold Cleaners: Ultrasonic cleaners are used to clean molds for plastics and other materials because of the non-contact nature of their system, which does not alter, damage, alter or change the design of mold cavity details. A critical part of mold geometry is strict adherence to mold tolerances, which is necessary to ensure the quality of the formed products. Unlike other cleaning methods that use harsh toxic chemicals, ultrasonic cleaning does not come into contact with the mold surface, yet it is still capable of precisely cleaning the most intricate and detailed areas of the mold.
The turbulence of ultrasonic cavitation increases the cleaning effect by exposing surfaces to fresh chemical cleaning. The process, when combined with heat and cleaning solvents, creates a cleaning effect that penetrates blind holes, crevices and intricate design features of molds. Burnt polymers and mold residues left from mold components are removed, extending the life of the mold without damaging or damaging the surface. Cooling ports and channels are free of debris, which helps improve polymer flow.
Side-mounted submersible transducers are a new innovation in ultrasonic cleaning and provide more intense and focused cavitation than bottom-mounted transducers. Plastic injection molds are rectangular with design details on the tank side surfaces. Side-mounted transducers provide a more efficient and concentrated cleaning process for the location of the most intricate details of the mold.
Tank Interior Showing Side-Mounted Transducers (Courtesy of Emerson)
Ultrasonic the turbulence of cavitation increases the cleaning effect by exposing surfaces to fresh chemical cleaning. The process, when combined with heat and cleaning solvents, creates a cleaning effect that penetrates blind holes, crevices and intricate design features of molds. Burnt-on polymers and mold residues are removed from mold components, extending the life of the mold without damaging or damaging its surface. Debris is removed from cooling ports and channels, which helps improve polymer flow.
Side-mounted submersible transducers are a new innovation in ultrasonic cleaning and provide more intense and focused cavitation than tank bottom-mounted transducers. Plastic injection molds are rectangular with design details on the side surfaces of the tank. Side-mounted transducers provide a more effective and concentrated cleaning process for the location of the most intricate details of the mold.
Immersible Ultrasonic Cleaners: Sometimes called immersible cleaners, immersible ultrasonic cleaners are machines that consist of only two parts: an ultrasonic generator and a transducer. The transducer is connected to the generator by a cable and is immersed in the cleaning bath. Any container will do as long as it can hold a sufficient amount of solution. These types are designed to be portable. However, this advantage is offset by the machine’s poor cleaning quality.
Section 4: Ultrasonic Cleaning Solutions
The quality of cleaning depends not only on the power and precision of the ultrasonic machine, but also on the type of cleaning solution usedUsing water alone will not aid in the cleaning process. The use of cleaning solutions is important:
Do not damage the material being cleaned
Do not over-foam
Can easily facilitate cavitation
Can effectively wet all submerged surfaces
Rinse easily
Ultrasonic cleaning solutions typically consist of alkaline detergents, surfactants, acids and enzymes diluted in deionized water. The composition of the cleaning solution depends on the type of debris to be removed. or the type of contaminant.
Deionized Water: Deionized water is the main solvent into which all other ultrasonic cleaning compounds are diluted. It is made from ordinary water that has been purified through ultrafiltration and softening to remove almost all minerals, salts, metals and other contaminants. Due to its purity, it can easily absorb contaminants, making the cleaning process fast and effective.
Alkaline Detergents: Alkaline detergents are used to remove organic and petroleum-based contaminants such as oil, grease and waxes. It generally has a pH value of 10 and above. Alkaline detergents are almost synonymous with caustic solutions and surfactants. Their main action is to reduce the surface tension of water. This allows oils to dissolve easily in the solution. Furthermore, reducing surface tension increases the wettability of the particle, which helps it sink into the solution.
Acids: Acids are used to aggressively remove mineral deposits, scale, dirt, rust, and small metal chips and tarnish. Compared to alkaline detergents, they are on the opposite side of the pH spectrum, at or below. The automotive, aerospace, and metal fabrication industries often use acid solutions for ultrasonic cleaning. Acid residue will continue to react with the surface of the part, causing damage, tarnish, and corrosion, so a rinse or corrosion treatment follows.
Enzymes: Enzymes are used primarily in medical and dental ultrasonic cleaners. They are catalysts made from active protein sequences that break down biological matter. They are safe to use because they are biodegradable and pH neutral. They are used to remove blood, bone, tissue, fat and other soils that cannot be easily cleaned with typical detergents. Enzymatic cleaners are available as concentrated solutions or soluble powders and tablets.
EDTA (Ethylene Diamine Tetra Acetic Acid): EDTA is a chemical compound used to remove or neutralize metal ions in cleaning solutions. This prevents metal ion contaminants from discoloring the material being cleaned. It also stabilizes the solution, allowing it to withstand more cleaning cycles.
Corrosion Inhibitors: Corrosion inhibitors are chemical additives that significantly reduce oxidative attack on the material. They are commonly used in the cleaning of metallic objects such as jewelry, electronics, automotive and aerospace parts. Since some ultrasonic cleaning solutions contain acids, a corrosion inhibitor rinse bath can be applied to protect the material. These added chemicals also protect and preserve the cleaning tank against corrosion.
Ammonia: Ammonia is a popular compound used in many homemade cleaning solutions. It acts similarly to detergents, removing most dirt, grime and oil-based residues. It is less expensive because only a very small amount of a cleaning solution is required. Ammonia is often used to clean jewelry pieces.
Section 5: Ultrasonic Cleaning Process
Ultrasonic cleaning is a very simple process that mainly involves preparing the cleaning bath and the machine. the washing process is performed without much intervention from the operator. Additional processes can be performed after washing. The general procedure for performing ultrasonic cleaning is given below.
ÖPre-Rinse: Before a part is placed in the ultrasonic cleaner, loose dirt, soil and large particles should be removed. It is recommended that a component be washed or brushed to increase the efficiency of the ultrasonic cleaner. This step is important when there are many contaminants to be removed. The process can be completed using warm water. Immersing the parts in a pre-rinse can be helpful and can increase efficiency.
Ç Preparing the Solution: This step covers all the initial work of formulating the cleaning solution and transferring it to the cleaning tank. Ready-to-use ultrasonic cleaning formulations are widely available on the market, eliminating the need for trial and error. Keep in mind the type of contaminant to be removed. Different types of contaminants require specific cleaning solution components and additives. Also check that the solution is compatible with the material being cleaned. An acidic solution can etch metallic objects without proper rinsing or corrosion prevention.
Adjusting Bath Temperature: Most ultrasonic cleaners, especially in industrial installations, have a heater installed to control temperature. Temperature directly affects the cavitation efficiency of the machine. Furthermore, other fluid properties such as surface tension, viscosity, and density are affected by temperature. Higher temperatures also cause more chemical activity in the solution.
Setting the Generator Parameters: This step is usually performed when working with industrial ultrasonic cleaners. Changing the generator parameters allows the operator to control the intensity of the cavitation. This is important when cleaning parts with different sizes and weights. Common desktop ultrasonic cleaners do not have this function and have preset generator values.
Solution Degassing: Dissolved gases in the cleaning solution reduce the intensity of cavitation. Gases are dissolved in the solution by means of small bubbles. Upon application of positive and negative pressure stages, cavitation cavities move towards the gas bubbles. The extra volume prevents the voids from collapsing, which significantly dampens the shock waves generated by cavitation.
To degas the solution, the ultrasonic cleaner is first run at low power for a few minutes. Most of the dissolved gases will eventually rise to the surface of the liquid. The rise of the gases can be observed with the naked eye as the gases collect at the surface and form larger bubbles.
Ultrasonic Washing: Once the machine is fully set up, it is time to begin the washing process. Ultrasonic washing involves submerging the part in the cleaning solution. Strainer baskets are placed to hold the part and float approximately two or more inches from the walls of the tank.It is used to provide a clearance of up to 10 minutes. The washing time can last up to 10 minutes, more or less. This depends on the quantity and nature of the contaminants to be removed.
Rinsing: Rinsing is an optional process in which the cleaning solution is removed from the surface of the part. This is an important step when working with acidic solutions. Rinsing baths use pure, deionized water or deionized water containing additives such as corrosion inhibitors.
Secondary Processes: Secondary processes are optional steps that can include polishing and oiling. These processes use different solvents that add the desired surface properties to the material. The additional polishing step is usually done in the cleaning of jewelry pieces, while the oiling step is done in the maintenance of firearms.
Drying: This process involves exposing the piece to warm air or normal room air. A fan or blower is used to speed up this process and is usually seen in production lines that require short drying times.
Ultrasonic Cleaner Maintenance
The importance of ultrasonic cleaners requires procedures that preserve their integrity. Proper maintenance increases the efficiency of the system and ensures cleaning operations. Here are some recommendations for successful maintenance.
The system should be started when there is a sufficient amount of solution. This will prevent damage to the transducers.
The solution must be level to prevent it from entering the ultrasonic cleaner.
The ultrasonic cleaner should not touch the bottom of the tank, which could scratch or corrode the machine.
Avoid using solutions that are highly alkaline or highly acidic.
Ultrasonic cleaners should not be placed on wet surfaces, damp towels or wet should not be placed in clothing.
Results
An ultrasonic cleaner is a type of sonic cleaner or sonic cleaning machine that uses cavitation to remove unwanted materials. The term ultrasonic refers to the pressure generated by cavitation oscillating at extremely high frequencies (above 20 kHz). waves.
Ultrasonic cleaners are used because of their precision and accuracy, high cleaning speed, flexibility, efficiency and simplicity.
An ultrasonic cleaner consists of a generator, transducer and tank. Secondary components may include a strainer basket and heating elements.
Another important aspect of ultrasonic cleaning is the cleaning solution. The formulation of the cleaning solution depends on the contaminant to be removed.
Source: https://www.iqsdirectory.com/