Agitator Redesign for Corrosive Environment P13656 Luigi Abbate, - - PowerPoint PPT Presentation

Agitator Redesign for Corrosive Environment

P13656 Luigi Abbate, William Fritzinger, Peter Torab, Kate Karauda Sponsor:

Project Description

The goal of this project is to select, optimize, and implement and off-the-shelf ultrasonic cleaning unit to replace a mechanical agitation system at Coating Technology Inc. The new system will significantly reduce the time required to complete a coating removal process, and will be more reliable than a mechanical agitator. Our team will determine the optimal operating conditions for the unit prior to its implementation.

Customer Specifications

Customer Specifications

System Information

• Current mechanical agitation system:

System Information

• Design is prone to mechanical failure and

vulnerable to corrosion

System Information

• Ultrasonic cleaning was selected

○ Increase coating removal rate ○ No moving parts ○ No components are exposed to vapors ○ No maintenance necessary ○ Reduce risk of damage to expensive dies ○ Same unit can be used for many other processes

System Information

• SevereClean SC-11 Ultrasonic Cleaner

Testing Performed

• Variable testing
• Validation testing
• Solution conductivity & absorbance
• Residual coating testing
• Peroxide titration testing

Variable Testing

• Performed at different

starting temperatures

• Samples were

submerged for 1.5-6 hours

• Used CTI hydrogen

peroxide solution

• Coating removal was

visible

Increase in Temp Increase in Time

Surface Coating Removal

• 1” x 1” 304 SS test tabs (x20)
• 6μm TiCN coating

Group Samples Power Level Set Temperature 1 1-4 50% 100F 2 5-8 50% 140F 3 9-12 100% 100F 4 13-16 100% 140F 5 (Control) 17-20 0% (SONICS OFF) 140F

Surface Coating Removal

• The unit was tested at the 50% power

setting to determine if a lower setting could be effective

Surface Coating Removal

• Removal rate significantly increased at

100% power

• 140F is the optimal bath temperature

Surface Coating Removal

• At optimum conditions, the addition of sonics

provides a significant increase in removal rate

Mock Die Coating Removal

• 1”x1”x2” 316 SS bar stock (x4)
• Nine 1/2” deep, 1/16” ID blind holes
• 6μm TiCN coating

Samples Orientation Power Level Set Temperature 21 holes down 100% 140F 22 holes to the side 100% 140F 23 holes up 100% 140F 24 holes down 0% 140F

Mock Die Coating Removal

Starting Point:

Mock Die Coating Removal

Setup:

60 Minutes:

Mock Die Coating Removal

Down Still Side Up

Mock Die Coating Removal

90 Minutes:

Down Side Up Still

Mock Die Coating Removal

Mock Die Coating Removal

Conclusion:

• Mass does not appear to affect surface

coating removal rate

• Sonics are powerful enough to clean inside

blind holes Concerns:

• Hole diameter very large compared to dies
• Mass is much lower than dies

Recommendations

• Heating - Cooling Unit:

○ Used to maintain constant temperature in the unit ○ Prevents from overheating

• Indirect Method:

○ Tank filled with water ○ Glass container with peroxide solution submerged in the tank ○ Parts submerged in the glass container ○ Saves solution & prevents the corrosive effects of the bath on the tank

Project Evaluation

• Successful implementation of the ultrasonic

unit

• Testing yielded expected results
• Successful removal of the coating from

various test specimens

• Determined optimal operating conditions:

○ Temperature ○ Ultrasonic power

Future Steps

• Test the cleaner on dies or mock dies

○ Determine cleaning performance in small through holes ○ Determine effects of increased object mass

• Test rate of removal of base material

○ No measurable results in our testing