26 ss\ ,PbF

CONTENTS

CLEANING METHODS
Wetting
Emulsification
Solubilization
Saponification
Deflocculation
Displacement
Sequestration

SELECTING A CLEANING METHOD

CLEANER CHEMISTRY
Organic Solvents
Emulsion Cleaners
Alkaline Cleaners

RINSING AND DRYING

TESTS FOR CLEANLINESS

SUGGESTED ALKALINE CLEANING PROCESSES

COMPARISON OF PHYSICAL AND CHEMICAL PROPERTIES

DARACLEAP METAL WORKING FLUIDS

Steps for Successful Cleaning
Equipment *
 CLEANING HANDBOOK

CLEANING METHODS

Cleaning is defined as the removal of soil or unwanted matter from a

surface to which it clings. The cleaning process can be accomplished by one
or more of the following cleaning mechanisms:
\I & 1 WETTING
Through the use of surface active agents, the cleaning penetrates and
loosens the substrate-soil bond by lowering surface and interfacial tension.

Wetting EMULSIFICATION Wetting

Once wetting occurs, two mutually-immiscibleliquids are dispersed. Oil
droplets are coated with a thin film of surfactant, therefore prevented from
recombining and floating to the surface.

SOLUBILIZATION
The process by which the solubility of a substance is increased in a certain
medium.
SAPONIFICATlON
The reaction between any organic oil containing reactive fatty acids with
free alkalies to form soaps. Emulsification
Solubilization
Insoluble Fatty Acid t Alkali = Water Soluble

DEFLOCCULATlON
The process of breaking the soil into very fine particles and dispersing them
in the cleaning media. The soil is then maintained as a dispersion and prevented
from agglomerating.

DISPLACEMENT
Soil is displaced by mechanical action. Movement of the workpiece or fluid en- Deflocculation
hances the speed and efficiency of soil removal.

SEQUESTRATION
Displacement
Undesirable ions such as calcium, magnesium, or heavy metals are deacti-
vated, thus preventing them from reacting with material that would form insoluble
products, (i.e., hard water soap scum).

Sequestration
 SELECTING A CLEANING METHOD

The nature of the soil, the substrate involved, and the degree of cleanliness
required are all factors to consider when selecting the cleaning process to use.
When selecting a cleaning method, one must consider the size, shape, and
surface of the part to be cleaned, the soils involved, and the rate of production
needed to ensure that the end results desired are obtained. As a general rule:

Concentration x Temperature x Time x Mechanics = Clean

Types of cleaning methods include: manual (hand wipe, brush, mop, etc.),
Immersion (soak, agitation, electrolytic, ultrasonic), vibratory/tumbling, spray,
and vapor degreasing.

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 CLEANER CHEMISTRY

Cleaners generally fall into three categories: organic solvents, emulsion

cleaners, or aqueous alkaline cleaners.

ORGANIC SOL VENTS

Can be used in manual, immersion, spray, or vapor applications. They can
be made from the following solvents:

Aliphatic Naptha, Stoddard solvent, kerosene, mineral spirits

Aromatic Toluene, xylene, hi-flash naptha

Chlorinated Perchloroethylene, trichloroethylene, 1,1,1-trichlo-

roethane, dichlorodifluoromethane,methylene
chloride

Glycol Ether Solvents Butyl Cellosolve, Butyl Carbitol, Cellosolve Acetate,

hexylene glycol

Oxygenated Methanol, ethanol, isopropyl alcohol

All solvent cleaners have high Volatile Organic Content (VOC). The United
States Environmental Protection Agency (EPA) regulates the amount of VOCs
which can be released into the atmosphere.
Virtually all solvents also have worker vapor exposure limits defined by the
Occupational Safety and Health Administration (OSHA). In addition, solvent-
based cleaners are virtually all hazardous wastes as defined by the US. EPA.
Although solvents can be reclaimed, it is expensive and the sludge andlor
used solvent must still be treated as a hazardous waste.

EMULSlON CLEANERS
Some water-based cleaners use non-chlorinated solvents as part of their
package. A typical composition might include an organic solvent, a metallic or
amine soap, and surface active agents.
These emulsion cleaners function by emulsifying the soils and keeping them
dispersed throughout the fluid. As the emulsion cleaner is used, the entire bath
becomes contaminated. The spent bath, including the water, must then be
treated as a hydrocarbon waste.

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 ALKALINE CLEANERS
These cleaners are generally composed of water, an alkali source, se-
questrant, a surfactant package, and corrosion inhibitors.
Daraclean cleaners are designed to be self-cleaning. Since the cleaner has
a greater affinity for the part surface than the soil does, it undercuts the soil and
pops it from the part surface. Light oils float to the bath surface where they can
be skimmed or filtered off. Heavy soils settle to the bottom where they can be
filtered off or collected as sludge.
Only the contaminants need be hauled away as waste. The liquid can be
recycled indefinitely. Concentration is replenished and cleaning continues.
Soils readily removed with alkaline cleaners include:
cutting oils
shop dirt
low melt waxes
rust preventatives
finger prints
grease
mill markings
carbon
road soils
coolants
* some water-based paints
Alkaline cleaners are successfully used:
prior to painting
prior to plating
* prior to anodizing
in-process cleaning
sump cleaning
as the finish process prior to packaging
Unlike solvent cleaning, emulsion and alkaline cleaners may require rinsing.

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 RINSING AND DRYING

Although not always required, rinsing can be an important step in the

aqueous cleaning process. Hints to remember concerning rinsing include:

Rinse Water Keep it clean! Hard water salts can cause spots.
Chlorinated water can promote rust. Dirty water can
recontaminate parts.

Rinse Tank Clean thoroughly and often. This stage should be

constructed of 304 or 316 stainless steel. If a mild
steel tank is used, it should be coated with a two-part
epoxy paint or an inhibitor should be put into the rinse
water to retard corrosion of the tank.

Rinsing Soap or Silicates Rinse immediately. Use a warm overflowing rinse for
soaps. Use an abundant rinse for silicates.

Rinsing Copper Rinse cold. Not all alkalies rinse the same. Soda ash
and liquid silicate are generally easier to rinse than
are other silicates, phosphates, or sodium hydroxide.

Unlike vapor degreased parts which come out dry, aqueous cleaned parts
are wet. Drying can be facilitated by a number of methods depending on part
configuration and the speed required.
These methods include:
air evaporation
compressed air blow off
warm air circulating fan
drying oven
infrared lamp bank
* solvent displacement
sawdust tumble
cloth wipe
* centrifuge
Cleaner chemistry can also affect drying characteristics. Cleaners with low
surface tension tend to have reduced drag-off and subsequently dry faster.

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 TESTS FOR CLEANLINESS

One question which must be asked is “How clean is clean?” The degree
of cleanliness varies depending on subsequent processes. It is reasonable to
expect that a printed circuit board must be cleaner than a rebuilt carburetor.
Cleanliness can be measured by any number of different methods such as:

Visual Does the part look clean?

Water-break-free Will water sheet off the part rather than bead?

White tissue Will a white cloth stay white after being rubbed on a
cleaned, dried surface?

Scotch transparent tape Will a piece of tape lift soils from the part surface?

Black lightlfluorescence Can you see dye sticking to soils using a black light?

Solvent extraction This is used primarily for organically soiled parts

which must be ultra clean.

Scanning Electron Visually examine a magnified surface for cleanliness.

Microscopy (SEM)

AugerlESCA Identify and quantify surface contaminants.

Conductivity Measure the residual electricity-conducting compo-

nents.

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 SUGGESTED ALKALINE CLEANING PROCESSES

In-process cleaning: 1 Stage: or 2 Stage:

CLEAN RINSE
3-25% 60-160°F
60-160°F

RINSE PLATE
> 60-160°F ) ANODIZE

or:
CLEAN CLEAN RINSE PLATE
3-2570 3-2S0/o -”’? 60-160°F 3 ANODIZE
60-160°F 60-160°F L

or:
CLEAN RINSE RINSE PLATE
3-25% 60-160°F 3 60-160°F 3 ANODIZE
60-160°F

Cleaning prior to painting:

CLEAN
3-25% ) DRY ) PAINT
60-160°F

or:

CLEAN RINSE
3-25% 60-160°F DRY PAINT
60-160°F

CLEAN RINSE RINSE

3-25Yo ) 60-160°F PHOSPHATIZE 3 60-160°F \
/ DRY \
/ PAINT
60-160°F

CLEAN RINSE RINSE

3-25% 60-160°F 3PHOSPHATlZE 3 60-160°F 3 SEAL 7
\
DRY
60-160°F

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 COMPARISON OF PHYSICAL AND CHEMICAL PROPERTIES

The properties of commonly used vapor cleaners are compared to commer-

cially available aqueous alkaline cleaners.
Parameter Vapor Cleaners Aqueous Cleaners
1,7,1-Tri- dichlorodi-
chloroethane fluoromethane Daraclean 282 Daraclean 283

Specific gravity 1.322 1.305 1.02 1.07

Flash point (TOC) none none none none

Boiling point, "C 74.1 -29.8 100 100

VOC, pounds/gallon 10.9 10.9 <.35 <.35

Surface tension,
dynes/cm 28 19 29 29

pH 100% - - 11.5 13.0

pH 10% - - 10.5 12.0

5 day
BOD, 10% (ppm) - - 7,250 1,420
COD, 10% (ppm) - - 25,022 15,800

Freon extractibles
(PPW _. - 1,124 231

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 DARACLEAN METAL WORKINGFLUIDS , ..

Grace Metalworking Fluids has commercially available alkaline cleaners under

the Daraclean label.
The Daraclean cleaners are safe on ferrous, cuprous, and most aluminum
substrates as well as on plastic and glass. They are all-temperaturecleaners de-
signed to be low foaming (at temperature above 100°F) so they can be used in
foam, tank, or spray applications.
Special features of Daraclean cleaners include:
Self-cleaning
* Recyclable
Hard water stable
In-process rust protection
Formulatedwith people and the environment in mind.
Custom formulations and cooperative customer relationshipsare also part of
the Daraclean Metalworking Fluids program.

STEPS FOR SUCCESSFUL CLEANING

Whether you are setting up a trial, a new production cleaning line, or are
modifying an existing cleaning system, several steps should be followed to ensure
success.
1. Determinetank volume. Allowing for several inches of free-board, multiply
Length x Width x Height in feet x 7.5 x 0.66 = Gallons
2. Select the proper product. Your Grace sales engineer can help you.
3. Charge the tank at the recommendedproduct concentration. For trials, use
the highest concentration practical; it’s easier to reduce concentration after
successful results are achieved. A starting range of 3-6% is suggested for
spraywash applications while a 10-20% starting range is suggested for im-
mersion applications.
4. Operate at the prescribed temperature. Trials should be run at 120-140°F
when possible. Temperature can be reduced gradually once desired
cleaning results are obtained.
5. Allow the work to remain in the cleaning bath the proper length of time, as
required for cleaning or as the process will allow.
6. Provide adequate rinsing when needed.
7. Check and replenish the bath on a regular basis to maintain the proper
concentration. Your Grace Metalworking Fluids sales engineer can provide
you with a Titration Test Kit to measure product concentration in your tank.
Laboratory burette test methods are also available upon request.
8. Skim and filter contaminantsfrom the bath on a routine basis for extended
tank life. If skimming and filtration is unavailablethen dump spent solutions
when chemical makeup equals or exceeds the initial charge.
9. Before filling the tank with a fresh solution, clean the tank, check the
heating coils to ensure they are free of scale and debris, and make sure
the drain valve is closed.

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 EQUIPMENT
Daraclean Metalworking cleaners can be used to replace chlorinated vapor
degreasers without major capital equipment expenditures. Shown below are stan-
dard vapor degreasers before and after modification for use with aqueous clean-
ers. To modify an exisiting vapor degreaser, disconnect the chiller coils and raise
the liquid level. To facilitate agitation, a PVC tube with drilled holes can be inserted
and attached to an air source.
Daraclean cleaners are formulated to reject soils. For maximum sump life,
filtration is recommended. Oils should be skimmed or overflowed off the top of the
bath surface. Heavy soils and particulates should be filtered via media, cyclone,
centrifuge, or diatomaceous earth.
Your Grace Metalworking Fluids sales engineer will assist you with your
chemical and equipment needs.

Refri erated
con fensing-I
Coils

Freeboard Zone
Refrigerated
Water
Separator
Vapor Zone
-Refrigerated
Cooling
Coils

Solvent
-Solvent
Filter

I Pump

Vapor Degreaser Without Modification

Refrigerated
Coils

1 Refrigerated
Water
Separator

- Refrigerated
Cooling
Coils

-Solvent
Filter

Modified Vapor Degreaser For Immersion Cleaning

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