CASE STUDY:
NDT Dye Penetrant REMOVAL
Aerospace MRO company requires complete removal of NDT Liquid Dye Penetrant. Reliance helped evaluate if Dye Penetrant could be completely removed by Vapor Cleaning only, or would immersion and/or ultrasonics be required for complete cleaning in AeroTron AV-5408 solvent and the ULTRA vapor degreasing system.
The Objective & Challenge:
An Aerospace MRO (Maintenance, Repair & Overhaul) company asked Reliance to conduct an NDT (Non-Destructive Testing) dye penetrant removal testing to help assess if AeroTron-AV-5408 Boeing approved solvent could completely clean the aircraft parts in vapor only or would additional immersion and/or ultrasonics be required for complete cleaning?
Key challenge:
Complete removal of liquid NDT dye penetrant from all surfaces including ID & OD of part.
Results
Conclusion: Vapor degreasing with immersion completely cleaned the aircraft part of baked on NDT dye penetrant - ultrasonics not required, vapor cleaning left some dye penetrant residue.
Processing Time: 35 seconds with multi-dip. AeroTron-AV-5408 Solvent in the ULTRA 2012LE vapor degreaser delivered efficient cleaning.
Key outcomes:
Effective removal of dye penetrant in 35 seconds of processing
Entire part clean & dry ready for next process step.
Equipment & Solvent Used:
Solvent: The parts were cleaned in AeroTron-AV-5408 which is a Boeing BAC5408 approved
non-flammable vapor degreasing solvent manufactured by Reliance.Equipment Utilized: The sample aircraft parts were cleaned in a Reliance ULTRA 2012LE Ultrasonic Vapor Degreaser equipped with1000 watts of ultrasonics and the BHE Automated Basket Elevator System. The ultrasonic immersion chamber in the ULTRA 2012LE is 20"L x 12"W x 12" deep.
Cleaning Process
The cleaning process was designed to evaluate which of 3 processes would ensure complete cleaning in the shortest time. Three processes were utilized:
1.VAPOR ONLY Cleaning- parts held in vapor zone for 1 minute.
RESULT: Vapor only cleaning left a bit of dye penetrant on the part.
Note: The vapor condensing time is relatively short from a typical ambient room temperature of "say" 75F to 116/118F (solvent vapor of AeroTron AV 5408) because once the part temperature equals the solvent vapor temperature all condensing (vapor cleaning) stops and
a. part is finished cleaning and moved into the refrigeration zone for solvent flash off
b. or the part can be sprayed for additional removal using clean distillate from the spray wand/spray tank reservoir or use an automatic spray manifold then removed after refrigeration flash off
c. or, if immersion is available, the parts are dipped into the immersion tank
** NOTE: Our BHS/BHE automation has the full capability of performing all cleaning steps above.
Total processing Time:90 seconds (1 minute + Refrigeration for 30 seconds for flash off )
2 IMMERSION Cleaning - a second set of parts were immersed into the clean solvent tank for 25 seconds.
RESULT: Immersion cleaning resulted in complete cleaning.
Total processing Time: 35 seconds (25 seconds immersion + Refrigeration for 10 seconds for flash off )
3.ULTRASONIC IMMERSION Cleaning- a third round of parts were immersed into clean solvent tank and 1000 watts of ultrasonics were applied.
RESULT: Immersion cleaning with ultrasonics resulted in complete cleaning.
Total processing Time: 105 seconds (Vapor cleaning 30 seconds + 45 seconds ultrasonic liquid immersion + Refrigeration 30 seconds for flash off)
Process Highlights
Immersion and Ultrasonics remove dye penetrant from ID, OD and crevices.
Refrigeration Zone drying delivered residue-free finishing
VAPOR DEGREASING
EQUIPMENT USED FOR THE CLEANING:
Reliance ULTRA 2012LE Vapor, Ultrasonic Immersion & Distillate Spray Vapor Degreasing System with Automated Basket Handling. Larger systems are available.
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SOLVENT USED:
AeroTron-AV-5408: BAC 5408 Boeing Approved Solvent.
AeroTron-AV-5408 is specially formulated for metal, plastic and elastomer compatibility in aerospace cleaning and can be used to clean titanium with improved health, safety, regulatory, permitting and environmental benefits.
