Parts Cleaning and Rust Prevention
Corrosion on parts can cause a wide range of problems before, during and after production. Corrosion can lead to problems with paint or other coating adhesion, misfit for assembly, and can reduce visual appeal. This is a common concern and one that can cause expensive disruptions in the supply chain if not properly prevented.
Corrosion on metal occurs in many forms and can be categorized into localized and general forms. Corrosion is the result of the oxidation of metal or in layman’s terms, the result of a chemical reaction between metal and its surrounding environment which leads to the deterioration of the metal.
Localized corrosion includes pitting, crevice corrosion and filiform corrosion. Pitting is the occurrence of small holes or cavities appearing on metal surfaces. Crevice corrosion forms in shielded areas such as under washers, gaskets, fastener heads, etc. Filiform corrosion happens when water gets underneath a coating such as paint.
A general form of corrosion that most people are aware of is rust. Rust is an electrochemical event that occurs when metal is exposed to water. Some action, such as applying a preventive coating must disrupt this sequence in order to prevent rust from forming. Corrosion on parts can cause a wide range of serious problems for manufacturers. If you work with metals, prevention is the key to ensuring quality finishes and satisfied customers.
Scott Fouts, Regional Manager for Kyzen, Chemical Company highlights a few common causes of corrosion:
• High humidity conditions in the factory
• Shipping to high humidity locations
• Not using the proper shipping containers
• Washing multiple metals with different chemistry packages within the same wash cycle
The picture below depicts flash corrosion which can happen when a steel part dries completely after being cleaned without corrosion prevention. One method to combat this is to have a corrosion package built into the cleaning chemistry.
(Photos courtesy of Kyzen Chemical Company)
Three common mistakes that Scott see’s in the field are:
- Not identifying the specific metal with the proper corrosion inhibitor.
- Not identifying the proper percentage of concentration needed for a specific metal.
- Not maintaining the proper concentration.
Humidity testing is one method that aids in determining the effectiveness of a corrosion inhibitor. Parts can be placed in a climate controlled humidity chamber for various duration’s of time, typically 30, 60 or 90 days. The chamber creates a harsh environment that speeds up the corrosion process. Parts can be checked periodically to determine the approximate shelf life of the inhibitor on the customer’s shelf.
Once the proper inhibitor has been identified, maintaining a consistent application process is critical. Routine checks of the effectiveness of the cleaning chemistries and inhibitors will insure that the inhibitor is performing to the required shelf life.
Three common methods for monitoring chemical effectiveness are conductivity, titration and testing with a refractometer. Water based parts washers will lose water through evaporation. Chemical injection systems help to automate the chemical addition process by metering chemical when water is automatically introduced to the machine. Automated chemical injection removes the need to manually add chemical but routine testing is critical to insure the best result.
In order to prevent corrosion on metal parts several factors need to be considered. What is the best inhibitor for the type of metal I am working with? How will the parts be cleaned to prepare the surface and how will the corrosion inhibitor be applied? How long do I need the corrosion inhibitor to last? The sales team at Alliance can help in answering your questions concerning, parts cleaning, corrosion inhibitors and determining the proper equipment for your application.
Scott has more great insights on corrosion in his video “Fighting Corrosion, A Global Problem” which can be seen at: http://www.kyzen.com/fighting-corrosion-global-problem/. Scott will also be presenting at PMTS/PCx. To learn more and attend his educational session please visit http://www.kyzen.com/visit-pmts-pcx2017/.
A study by NACE International (The International Association of Corrosion Engineers) cites that the direct cost of corrosion in the U.S. is 3.1% of Gross Domestic Product or ?
A) 153 billion B) 209 billion C) 252 billion D) 276 billion
(Answer at bottom)
Weimer Bearing and Transmission
Alliance would like to extend a special thank you to Ryan Wettstein of Weimer Bearing and Transmission. Weimer Bearing is a distributor of bearing and drive components. On a recent project, Alliance was working under a tight schedule to complete a custom indexing parts cleaning system for a very important customer cleaning aluminum front engine covers. The machine utilizes a matched set chain with attachments placed on precise centers for conveying the part fixtures through the cleaning system.
The chain manufacturer was running slightly behind on the delivery and when the chain arrived it was discovered that the spacing on the attachments was incorrect. This was huge problem since the machine due date was quickly approaching. We contacted Ryan and described the problem that we were experiencing. Ryan got on the problem ASAP. He contacted the chain manufacturer and pulled out all the stops to get us the correct chain in 2 days.
We really appreciated Ryan’s help and the efforts of the chain manufacturer on this and as a result we were able to keep the machine on schedule.
Oil Dipping Automotive Parts For Rust Prevention
Machine model: Aquamaster CB-1200E
Part to clean: Automotive transmission parts
Machine type: Conveyorized Belt
Most water based cleaning chemistries when dried down provide short term rust protection. This application required long term rust protection. A pneumatic pump is used to rain oil down on parts. No pressure was used as we didn’t want to atomize the oil since this could cause fumes and a potential for ignition.
View full application here
CAN YOUR COMPANY BENEFIT FROM A PARTS CLEANING SYSTEM?
If you have dirty parts, the answer is yes. Alliance parts cleaning systems are used for a wide variety of applications. Finding the right machine for a cleaning application can be determined by gathering pertinent information. Questions such as: What is the production rate? What is the part size and configuration? What contaminates am I removing? What are the cleanliness requirements? Do I need a spot free finish? How dry do I need my parts? are all determinants of quoting the proper machine.
If you have an application and need help in determining the best parts cleaning system for your needs, complete our Parts Cleaning Survey form today (Request Quote) for a free parts cleaning evaluation.
Alliance Manufacturing, Inc. specializes in the engineering and manufacturing of water-based (aqueous) parts cleaning equipment for the industrial products market. Our engineers have developed a full line of aqueous parts cleaning systems, including belt, chain, monorail, front/top loading cabinet, indexing, return-to-operator, compact cell, rotary drum, and customized machines engineered for specific cleaning applications. Alliance holds a patent for the only split-style, removable “Full Access” canopy, which allows for easy interior access for maintenance and process adjustment. Our machines are designed with corrosion-resistant materials for lasting quality and customer satisfaction. Aqueous parts cleaning equipment was developed as an environmentally safe alternative to solvent-based systems. Alliance Manufacturing, Inc. was established in 1994 in Fond du Lac, WI.
We offer parts cleaning solutions for many applications!
Trivia Answer: D