Autoliv Inc.

Manufacturing Process Specification

Inflator / Micro Gas Generator Component Washing –
MPS 143

AUTOLIV INC.
MANUFACTURING PROCESS SPECIFICATION

Inflator / Micro Gas Generator

Component Washing

MPS 143

PLM No: E2190982

Process: Component Washing

Product Area: Inflators, Initiators

Owner: Brian Kwant Approved by: Brian Snyder

Svante Mogefors
Version: 1.0 Release date: 16-Nov-2018 Pages: 13

MPS 143 version 1.0 / 16-Nov-2018 Page 1 of 13

Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143

Table of Contents
MPS 143

1 SCOPE........................................................................................................................................................ 3

2 PRODUCT SPECIFICATION ..................................................................................................................... 3

2.1 COMPONENT CLASSES AND ACCEPTANCE CRITERIA ................................................................................ 4
2.2 INSPECTION METHOD ............................................................................................................................ 5
2.3 PROCESSING FLUIDS ............................................................................................................................ 5
2.3.1 Phosphatation duration .................................................................................................................. 5
2.3.2 Stamping: the use of Chlorinated paraffin (foil/label adhesion consideration) .............................. 6
2.3.3 Stamping: the use of Amino alcohols (foil/label adhesion consideration) ..................................... 6
3 PROCESS DESCRIPTION ......................................................................................................................... 7
3.1 PROCESS FLOW .................................................................................................................................... 7
3.2 MACHINE AND TOOLING SPECIFICATION .................................................................................................. 8
3.2.1 Component Traceability ................................................................................................................. 9
3.2.2 Wash and Rinse Temperature Controls ...................................................................................... 10
3.2.3 Separation of Oils ........................................................................................................................ 10
3.2.4 Wash Solution Cleanliness .......................................................................................................... 10
3.2.5 Wash System Cleaning................................................................................................................ 10
3.2.6 Part orientation ............................................................................................................................. 10
3.2.7 Drying ........................................................................................................................................... 10
3.2.8 Daily Inspection ............................................................................................................................ 11
3.3 PROCESS PARAMETERS – INPUT .......................................................................................................... 12
3.4 PROCESS PARAMETERS – OUTPUT ...................................................................................................... 12
3.5 OTHER ............................................................................................................................................... 13
4 REFERENCES AND APPENDICES ........................................................................................................ 13
4.1 MANDATORY REFERENCES .................................................................................................................. 13
4.2 GUIDELINES ....................................................................................................................................... 13
4.3 CHECKLIST ......................................................................................................................................... 13
5 MODIFICATION INDEX ............................................................................................................................ 13

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143

1 Scope
This MPS shall be applied according to AS405.

In this document, the term “wash process” refers to the entire combined washing,
rinsing, application of rust preventive (RP) as needed, and drying processes of metal
components. This MPS defines the wash process for these component parts. The
purpose of this MPS is to drive each inflator facility that has an internal washing
process to have in place repeatable, in-control wash processes for those
components requiring consistent and predictable surface conditions.

2 Product Specification
A defined wash process shall be applied on each component requiring a consistent
and predictable surface cleanliness. Controlled surface cleanliness may be required
for such operations as welding, press-fitting, gas filling (contamination
incompatibility with gases), label or foil barrier apply (adhesion), leak check
(contamination out-gassing), electric checking (faulty resistance readings), or others.
These requirements could come from product specifications, PFMEA, plant
experience, or specific customer requests, and shall be called-out on component
drawings (see Figure 1)
Cleanliness for washed parts can be difficult to quantify so it is important that
process inputs be defined by testing and validation to component requirements and
followed-up with maintaining a controlled and closely monitored wash process (this
could be supplier-based or in-house wash process).

Figure 1: Examples of surface condition callouts on component drawing

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
2.1 Component classes and acceptance criteria

The requirements can vary significantly depending on the component class and how it
is used in the inflator manufacturing process. For example, the component surface
cleanliness can have impact on the following processes:
• Component Weldability (including weld strength and porosity)
• Label Adhesion
• Barrier Foil Adhesion and Hermeticity
• Performance of Press-Fitting
• Surface Contamination (customer dissatisfaction)

Each of the aspects of the wash process (washing, rinsing, RP application, and drying)
all play a collective part in the post-wash process surface cleanliness. All must be
considered based on each contribution.

It is important that all potential impacts of the complete wash process be understood
and the wash process be defined and controlled to mitigate the potential negative
impacts.

Below table shown in Figure 2 defines the different classes and surface
condition criteria for each.
Component Definition : Criteria Example
Class
Critical components are Surface Condition: Laser weld: stored gas
parts that become part Absent of grease, oil, inflator chambers
of a hermetic weld joint particulate, rust, or Resistance weld: adapters,
performed by a laser excess of rust bases of metal adapter pyro
weld, resistance weld, inhibitor. Part to part inflators
foil bonding Gas-Metal adhesion; due to oils, Foil bonding: diffusers of
Arc (MIG, MAG, TIG), washing fluids, etc., is pyro inflators.
Critical
Inertia Weld, injection not permitted. MAG weld: APG chambers
molding process. Dyne test ≥ 36 Inertia weld: Top hat, dome,
chamber of ACH inertia
welded inflators
Injection molding: bases of
Molded In Base pyro
inflators

Standard components Surface Condition: Crimp: crimped studs,

are those parts not Absent of grease, oil, crimped diffusers
used to form a hermetic and particulate. Press-fit: Press-fitted igniter
weld joint, are Surfaces shall be cup, pellets holder, filter
mechanically fastened, uniform in color. Rust
Standard or crimped or Press-fit. allowed on minor
surfaces but not in the
join region or visible
region for the
customer.
Dyne test ≥ 36
Figure 2: Component Classes

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143

2.2 Inspection Method

The following inspection method can be used for initial development of a wash
process and for quality verification / problem solving.
- Measure the surface tension, on the component by ink test: 36 mN/ m minimum
or as defined in the drawing (ex: ink test by Dyne). Test areas must be agreed by
Autoliv.
The ink test serves well to distinguish the quality of a cleaning process. The
ink line shall remain unchanged for at least 2 seconds on the material’s
surface without turning into drops. See the example Figure 3.

The document E3311640 available in PLM describe the recommended

method to evaluate cleanliness of Metals using the Dyne Test.

Figure 3: Ink test example at different Dyne levels

2.3 Processing Fluids

All fluids used in the machining, grinding, drawing, stamping or other processing during
the manufacturing of those components requiring a consistent and predictable end use
surface condition, shall be removable by the defined wash process for those
components.

2.3.1 Phosphatation duration

Phosphate crystallization must be minimized. The larger the crystal size, the more
difficulty Autoliv has sticking foil or label. Crystals damaged during handling and
transportation (part-to-part contact) form fine particles on the surface that are difficult
to remove during washing. These particles form a dry powdery film on the
component that doesn’t allow the labels to adhere properly.

If components are phosphatized before drawing, a maximum duration inside the

phosphatizing bath must be defined. The objective is to deposit the lowest needed
quantity on the component surface. The phosphate coating weight must be defined
by the supplier and validated by Autoliv during SEM Testing.

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
2.3.2 Stamping: the use of Chlorinated paraffin (foil/label adhesion consideration)
Chlorinated paraffin can be difficult to remove from component surfaces.
The chlorinated paraffin may also react with the metal, causing other compounds to
form on the surface. These aspects reduce adhesion of label or foil to the steel.

The choice of a coolant without chlorinated paraffin is preferred. If chlorinated

paraffin elimination is not possible, chlorinated paraffin concentration must not
exceed 40%.

2.3.3 Stamping: the use of Amino alcohols (foil/label adhesion consideration)

Amino alcohols, such as ethanolamine or diethanolamine, can react with or absorb
water. Such compounds, along with moisture, reduce adhesion. Amino alcohols,
therefore, are forbidden in the coolant composition.

Note : ethanolamine or diethanolamine can be present in the Volatile Corrosion

Inhibitor (VCI) products (bag, paper or chip).

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
3 Process Description
Production component parts are processed through a controlled wash, rinse, rust
preventive application (as needed), and drying system. The water temperature, as well
as soap and rust preventative (RP) concentration percentages, and drying temperature
and duration, shall be monitored and controlled through the wash process. The
frequency of monitoring shall be time based (example: every four hours), and the
maintenance of the system be established such that the wash system is optimized for
both wash process effectiveness as well as sensitivity to environmental impact.

3.1 Process flow

Figure 4 shows the component washing process flow.

Scan the component AIAG label

Load the components into the

washing machine Perform hot air drying

Perform hot water wash Off-load components from the

wash machine

Perform 1st hot water rinse

with intermediate rust
preventive application Inspect some
Reject
samples from the lot

Perform 2nd hot water rinse Accept

with final rust preventive
application
Reconcile component lot
Scrap / Rewash the lot
traceability

Figure 4: Component Wash Process Flow

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
3.2 Machine and tooling specification

Figure 5 shows a sketch of a washing machines using 2 rinse tanks.

Figure 5: Example of 2 tanks rinse system

Guidelines:
• The use of demineralized water for rinsing is recommended
• Design wash system tanks to include sloped bottom of the tank with a sediment
collection feature (sump) which allows for easy cleaning of sediment without
emptying the entire tank. This could increase the interval at which total draining
and cleaning of tank may be required (consider environmental impact).
• The best practice is to have a 2-tank rinse system. This is reflected in the
process flow above (see Figure 4). Also, adding a small amount of rust-
preventive to the first rinse tank inhibits surface oxidation from forming between
the intermediate and final rinse.
• Standardizing wash, rinse and drying process temperatures (water and air) with
visible indicators is recommended for quick glance verification of normal
condition.

Some washing machines can use ultrasonic systems (see Figure 6).

Figure 6 : washing machine using ultrasound

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
3.2.1 Component Traceability
Traceability of component lot information shall be maintained as each lot of
component parts transfers through the wash process: scan each tote, print a label,
placed in a FIFO system, go through the wash process, repack in a tote with the
new label. The wash process shall be recorded in the traceability system.

The process shall ensure that no mixes can occur between component part
numbers and component lots.

Guideline:
Lot separation can be accomplished by scanning and monitoring and the
basket number and the component label when going in and going out of
the machine (see Figure 7).

Any component which is found out of a basket/tray shall be scrapped.

Figure 7: example of scanning sequence to ensure traceability

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
3.2.2 Wash and Rinse Temperature Controls
The wash process equipment shall have controls to maintain water temperature for
the wash and rinse processes.

3.2.3 Separation of Oils

Wash process equipment shall have a method for coalescence and removal of oils
that are removed during the wash process. The preventive maintenance of the
coalescence system shall be based on a time frequency defined in the Standard
Work Instruction. Also, the filter system shall be monitored using pressure.

3.2.4 Wash Solution Cleanliness

Wash water cleanliness shall be monitored at a defined frequency, as per
recommendations by Wash chemical suppliers.

The frequency at which the wash solutions are changed shall be defined to prevent
build-up of undesirable compounds in the wash and rinse baths.

3.2.5 Wash System Cleaning

At a defined frequency, wash process equipment tanks that are subject to collection
of debris and sediment shall be drained of all water and the debris and sediment
cleaned from the tanks. This cleaning procedure shall be described in the SWI.

3.2.6 Part orientation

Orientation of parts or part tumbling during the drying process shall be done to avoid
water or residues remaining on or inside the component. See Figure 8.

Figure 8: Part orientation - Baskets

3.2.7 Drying
The wash process equipment shall have controls to maintain hot air
temperature for the drying processes.

Some component designs might need an additional drying process. A

spinning dryer can be used (see Figure 10). In this case, speed or frequency,
time and temperature shall be controlled

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143

Figure 9: Example of a spinning dryer for Tophat component

3.2.8 Daily Inspection

Daily inspection shall include:

• Wash water titration, also described in the SWI, to verify the
concentration of soap.
• Rinse water (1 and 2 as applicable), also described in the SWI, to
verify the concentration of RP.
• It is required to record titration results as well as wash, rinse and drying
temperatures as shown on Figure 10.

Figure 10: Example of scheduled DIS for process input verification

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
3.3 Process parameters – Input
Wash input parameters
• Wash water temperature °C (°F)
• Wash water pressure (as applicable) bars (psi)
• Soap type
• Percentage of soap concentrate %
• Wash time s
• Current Frequency for Ultrasonic Washer Hz
Rinse input parameters s
• Rinse water temperature °C (°F)
• Rinse water pressure (as applicable) bars (psi)
• Rust Preventive type (RP)
• Percentage of RP concentrate %
• Rinse time s
• Current Frequency for Ultrasonic Rinser Hz
Dry input parameters
• Dryer air temperature °C (°F)
• Drying air flow m3/min
• Drying time s
• Speed for spinning dryer RPM

3.4 Process parameters – Output

The wash process output is the cleanliness of the component surface after the full
wash process has been applied.

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Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
3.5 Other
For safety reasons as well as to avoid post wash component contamination, operators
shall wear gloves and safety glasses.

Discharge water containing soap and rust preventive can be governed by City, State,
Regional, or National guidelines. Consult with appropriate regional authorities to
comply with regulations.

4 References and Appendices

4.1 Mandatory references

• AS405 Manufacturing Process Specification
• AS5 Substance Use Restrictions
• PLM E3099055 PLI Applicable Global Lessons Learned

4.2 Guidelines
• E1068195 Component Specification for Foil or Label Sticking
• E1068189 Component Specifications for Components to be Laser/Drawn Arc
Welded – Washing
• E1264407 Component specification for machined drawned stamped components
to be overmolded
• E688419 Requirement Specification for cleaning piece parts for APG-1
• E3311640 Dyne Test Method

4.3 Checklist
• Appendix A MPS Compliance Checklist

5 Modification Index
Version # Date / Team Modification
1.0 16-Nov-2018 First version
Brian Kwant
Lane Henderson
Bowdie Holmes
Yaqing Xu
Jerry Zheng
Yann Le Gall

MPS 143 version 1.0 / 16-Nov-2018 Page 13 of 13

Autoliv Inc. Manufacturing Process Specification
Inflator / Micro Gas Generator Component Washing –
MPS 143
Appendix A: Checklist

MPS: MPS 143 - Inflator / Micro Gas Generator Component Washing (Version 1.0) Audit date:
Site: Audited by:

Cell:
Result
Audit

Compliance verified: Yes No Signature:

Please observe - Auditing the process the MPS Checklist shall be accompanied by the General MPS 0-2 Checklist added as a 2nd page
MPS 143 - Inflator Component Washing - Compliance Audit Checklist
Standard
Item

Requirement Reference Result

1 Is the traceability of component lot maintained through the wash process ? 3.2.1 Yes No

2 Is the water temperature controlled and maintained for the wash and rinse steps ? 3.2.2 Yes No

Is there a method for coalescence and removal of oils that are removed during the wash process with
3 3.2.3 Yes No ahomps
preventive maintenance at a defined frequency ?

4 Is the filtering system monitored using pressure ? 3.2.3 Yes No

5 Is the water cleanliness monitored at a defined frequency ? 3.2.4 Yes No

6 Is the wash equipment drained and cleaned at a defined frequency ? 3.2.5 Yes No

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