CASE STUDY:
validating AeroTron-AV & Reducing Cycle Times
Introduction
Reliance Specialty Products was approached by a large Aerospace company to help validate if the AeroTron-AV solvent would effectively remove/clean a heavy wax used in the Aerospace company’s landing gear. The Aerospace company currently uses TCE solvent in their vapor degreaser – where they spray the coupon with solvent remove the wax. As part of the validation testing, the company asked Reliance to clean the coupon as it is currently cleaned (in vapor with spray). Additionally, Reliance was asked to process the coupons using alternative means to assess if there is a more efficient, effective cleaning approach.
Reliance tested 3 different processing approaches: 1. Spray, 2. immersion, and 3. Ultrasonic immersion
OBJECTIVES:
Assess the effectiveness of AeroTron-AV solvent to remove the heavy wax contaminant and therefore be considered a viable replacement for the TCE currently used in the company vapor degreaser.
Determine if there is an optimal way to clean the wax from the part coupons.
Validation Methodology
STEP 1: As part of Reliance’s transition validation process, Reliance conducts a free initial consultation with the client company to assess what the need/problem to be addressed is, while garnering a comprehensive understanding of the current application and what the client company is interested in achieving. Once the initial consultation is completed, Reliance proposes a plan for achieving the goals and objectives, lending the expertise ad wisdom from years of vapor degreasing thousands of different kinds of parts with a multitude of contaminants.
In this case the aerospace client is interested in evaluating the effectiveness of the AeroTron-AV to replace the TCE solvent that they are currently using in their vapor degreaser.
They also would like Reliance to try various other cleaning processes: ultrasonic immersion, immersion only and spray only (their current cleaning method) to assess if there is a faster more effective processing method.
STEP 2: Clean the Parts in AeroTron-AV using spray.
The next step is for the client to send in sample test parts to be cleaned at Reliance where our lab has fully equipped ULTRA vapor degreasers running a variety of solvents for part cleaning validation. This is also a complimentary offering as part of the validation process.
In this case, the aerospace client sent coupons covered with heavy wax. The reliance team planned the cleaning strategy in the validation process - first to clean as the client currently processes the parts.
Clean the coupon in vapor and spray (as the client currently does) and assess if the AeroTron-AV solvent works and how long the removal takes.
Note: the client currently cleans the part with spray - no immersion - so the cleaning takes around 50 minutes.
RESULTS: The AeroTron-AV successfully removed the heavy wax after 50 minutes of spray in the vapor zone.
Objective 1 - success
Step 3 - PROCESS OPTIMIZATION using Immersion
Immersion In AeroTron-AV. Now instead of just spraying the coupon, the Reliance team immerses another set of coupons in AeroTron-AV and asseses if the wax can be removed faster & log how long the removal process takes.
RESULT of Step 3 immersion: The AeroTron-AV successfully removed the heavy wax after 50 minutes of immersion in the solvent.
Step 4 - PROCESS OPTIMIZATION using Ultrasonic Immersion
Ultrasonic Immersion In AeroTron-AV solvent. Now instead of just immersing the wax covered coupon, the Reliance team immerses another set of coupons in AeroTron-AV with ultrasonics applied. Again, asses if the wax can be removed faster & log how long the removal process takes.
After 2.5 minutes in ultrasonic immersion
After 4 minutes in ultrasonic immersion
RESULT of Step 4 immersion: The AeroTron-AV successfully removed the heavy wax after only 4 minutes of ULTRASONIC immersion in the solvent.
SUPRISING OUTCOME & GENERAL OBSERVATIONS
Cycle time is significantly reduced with application of ultrasonics. The wax is soluble in AeroTron-AV but not aggressively soluble. In addition to immersion and spray steps, the batch of parts with "Heavy Wax" cleaned by ultrasonic immersion, the cycle time was significantly shortened. The immersion with spray cycle for the heavy wax part without ultrasonics was 50 minutes, with the ultrasonics applied, the cycle time was reduced to 4 minutes.
RECOMMONDATION:
Incorporate Ultrasonic Immersion Into the Cleaning Cycle.
To significantly reduce cycle times, incorporate ultrasonic immersion into the cleaning cycle. Thus reducing the cycle time from 50 minutes to 4 minutes - a 92% reduction in processing time.
EQUIPMENT USE FOR THE CLEANING:
Reliance ULTRA 2012LE Vapor, Immersion, Ultrasonic Immersion & Distillate Spray Vapor Degreasing System.
Excellent for Vapor Degreasing and Ultrasonic Cleaning
SOLVENT TESTED
AeroTron-AV is manufactured by Reliance and specifically designed to replace Trichloroethylene (TCE) in vapor degreasing with improved health, safety, regulatory, permitting and environmental benefits. We can assist you every step of the way!
Excellent soil loading
Extensive bath life and stability
Manufacturer's expertise and product support
Distillable
