Changing the Game Rules with CO2 · 2011-01-28 · Advantages of CO2 cleantech… “Clean” Processing… Clean without producing environmental wastes such as air pollution, spent

IDEMA RELIABILITY SYMPOSIUM 2008

Changing the Game Changing the Game Rules with CORules with CO22

Clean Manufacturing Clean Manufacturing Solutions for the HDD Solutions for the HDD

IndustryIndustry

David JacksonDavid Jackson

May 15, 2008


CO2 technology offers robust methods for precision cleaning surfaces for high-tech products such as aerospace parts, optical devices, sensors, integrated circuits, air bags, medical devices, and disk drive components.

A diversity of dry treatment schemes:

• Selective Spray• Immersion Solvent • Extraction Solvent• Atmospheric Plasma• Low Pressure Plasma• UV-Ozone Treatment• Microabrasive-Snow

CombinationalTreatments

COCO2 2 CleantechCleantech……


Advantages of COAdvantages of CO2 2 cleantechcleantech……

““CleanClean”” ProcessingProcessing……Clean without producing environmentalwastes such as air pollution, spent solvents,rinse water, sludge and filters.

““LeanLean”” ProcessingProcessing……Reduce manufacturing wastes such as energy,space, time and manpower by modifying theproduction process.

““DryDry”” ProcessingProcessing……CO2 processes are similar to Freon 113 cleaning;parts remain dry during the cleaning process.


COCO22 is abundantis abundant……

South Pole - MarsA by-product of industrial and naturalprocesses such as refineries, CaCO3

wells, and bakeries.

A recyclable and renewable resource.

Major commercial uses include beveragecarbonation, fire extinguishing and welding.

MarsNASA Hubble

Space Telescope


Health and safetyHealth and safety……

Solvent Ozone DepletingPotential (ODP) OSHA PEL VOC

Carbon Dioxide None 5,000 ppm No

Perchloroethylene ~0 25 ppm YesCarbon Tetrachloride 1.10 2 ppm YesMethylene Chloride ~0 500 ppm YesTrichloroethylene ~0 50 ppm Yes

1,1,1-Trichloroethane 0.15 350 ppm Yesn-Propyl Bromide (nPB) ~0 100 ppm Yes

PEL – Permissible Exposure Limit

CO2 is non-corrosive and non-toxicRecycled CO2 is not regulated by EPA


PR

ES

SU

RE

TEMPERATURE

CO2 (l)

CO2 (g)

CO2 (s)CRITICAL POINT73 atm, 31.1 C

TRIPLE POINT5.11 atm, -56.4 C

1 atm

-78.5 C

PHASE DIAGRAMFOR CO2

SUPERCRITICALREGION

DRY ICE

30 C

70 atm

5b ATMOSPHERICPLASMA

CLEANINGThe 4th StateCO2(p)

1a

4 EXTRACTIVECLEANING

SPRAY ORIMMERSIONCLEANING2

The many faces of COThe many faces of CO22……

SPRAY, JETCLEANING

3a

3bCDA

VACUUMPLASMA

CLEANING

5a

1b


Composite COComposite CO22 spray cleaningspray cleaning……

Cleaning process and chemistry similar to spray cleaning with Freon 113.

Composite spray technology provides superior process control, cleaning performance and economy as compared to conventional “Snow”technology.


0

50

100

0 50 100

0

50

100

30%

70% 0%

CLEA

N DR

Y AI

R

ADDITIVE

CO2(s)

LEAN/FINEPARTICLECLEANING

COMPOSITION

P - 8

0 PS

IT-

150

DEG

. C

FINE PARTICLES

Technology differentiationTechnology differentiation……

Mass/Flow Control

Fractional Composition ControlComposite CO2 Spray

Snow Spray


CO2 Crystals

• Structure - molecular crystal, angular, octahedron• Solvency - hydrocarbon-like chemistry• Impact Phenomenon - ablation and phase change (solid->liquid->gas)• Additives - can be modified with liquids, solids, vapor-phase additives• Compressibility - practically incompressible• Hardness - 0.3 Hm (8 Hv)• Particle Size - < 0.5 microns to > 500 microns, range adjustable (coarse/fine)• Impact Stress - up to 60 MPa, pressure/particle size/distance dependent

Composite COComposite CO22 cleaning spraycleaning spray……

SEMPhotomicrograph

1 μm Dilute CO2-CDA-(additive)Compositions


Fd = (C) (ρ) (V2/2) (A)

Shear stress for particle removalShear stress for particle removal……

Goal: Maximize Drag Force

Drag Coefficient (particle shape/roughness)

Fluid DensityFluid Velocity

Frontal Area(Particle)

Adapted from Musselman et al14th Space Simulation Conference, Nov. 3-6 1986


DENSITYg/ml

VISCOSITYmN-s/m2

SURFACETENSIONdynes/cm

SOLUBILITYMPa1/2

Freon 113Carbon Dioxide

1.6 1.6

0.07 0.68

3 19.6

22 15

COCO22 (spray) compared to Freon 113(spray) compared to Freon 113……

Hydrocarbon Cohesion Energy

Shear Stress Energy


Coaxial sprayCoaxial spray……

Coaxial

Atmosphere

• Short spray trajectories• Numerous mixing nozzle configurations• Unlimited capillary configurations• Limited additive compositions


AtmosphereCoanda

Coaxial

Coanda surface

CoaxialCoaxial--Coanda sprayCoanda spray……• Long spray trajectories• Limited mixing nozzle configurations• Unlimited capillary configurations• Unlimited additive compositions


Spray Spray composition controlcomposition control……

Inert Gas

Particle SizeChemistry

Spray DensityTemperature

PressureDistance/Angle

Time

(Propulsion/Heating)

Additive(Chemical/Physical)

CO2

CleaningEnergy


CO2 COMPOSITE SPRAYCLEANING ENERGY

FINE

MEDIUM

COARSE

IMPACT SHEAR STRESS(MPa)

0.1 1 60

Shaved Ice andPellets

(100 - 500 MPa)

500

100

10

ULTRAFINE1

10

PAR

TIC

LE R

AN

GE

(mic

rons

)

CO2 Composite Sprays(0.01 - 60 MPa)

SnowSprays

(0.01 - 2 MPa)

Control ParametersCO2 Particle Size

CO2 Particle DensityPropellant Pressure

Propellant Temperature

Composite COComposite CO22 spray (mechanical) energyspray (mechanical) energy……


HDD applications for composite COHDD applications for composite CO22 sprayspray……

• Motors• Heads• Magnets• Bases• Covers• Spacers• Flexures• Latches• Assembled Devices• Tool Blocks• Fixtures

Build-CleanRework/Reclaim Operations

Production Tooling

HSA

Spacers

MBA


HDD TEST FAILURE

CLEAN COMPONENTS

ASSEMBLY

HDD TEST

Build-Clean Process Flowchart

PARTIAL DISASSEMBLY

Application exampleApplication example……Reclaiming MBAs, Covers, MagnetsReclaiming MBAs, Covers, Magnets

• Dry cleaning partially assembled devices• High-volume capacity• Repeatable process• Smaller space• Less energy

Composite CO2 Spray Value:

HDD Covers


Magnetic Latches

Before After

Application exampleApplication example……Magnetic Particle RemovalMagnetic Particle Removal

SEM 500x SEM 500x


Significant reject (dent) reduction and cost savings

CompositeCO2

Spray

1stStamp

2ndStamp

3rdStamp

nthStamp

Blank

Application exampleApplication example……Suspension Cleaning During FormingSuspension Cleaning During Forming

CompositeCO2

Spray

CompositeCO2

Spray

Integrated into progressivestamping machine

Suspensions


Production DayHours per day 8Days per week 5Weeks per year 50

Cleaning ProcessCleaning cycle on (sec) 2Cleaning cycle off (sec) 2Duty cycle 50%Cleans per day 14,400Cleans per week 72,000Cleans per year 3,600,000

Carbon Dioxide UsageMachine setting (lbs/cleaning hour) 12Usage @ duty cycle (lbs/hour) 6Usage per production day (lbs/day) 48Usage per production year (lbs/year) 12,000

Consumables CostCommercial Grade Liquid CO2 $3,000

Cost per Clean (CpC): $0.001

Case Study Information:Application: Disk Drive Manufacturing, Build-CleanEquipment: PowerSno XP PS8000 Spray Cleaner

Cost per Clean ModelSnowShear Composite Spray Cleaning

Robotic pick-clean-placesystem for MBA reclaimcleaning operations.

Low costLow cost--perper--cleanclean……


Cleaning cost comparisonCleaning cost comparison……

Robotic high capacity spray cleaning systems for MBA, cover and magnet reclaim operations.

Deionized Water(Immersion/Drying)

$0.12-$0.13/part

76% cost reduction (fully burdened)

Composite CO2 Spray(Selective Spray)

$0.01-$0.03/part


Cleaning performance comparisonCleaning performance comparison……

MBA Rework

LPC result of Motor Base Assembly (MBA )0.5 Micron Particles

MBA Prime (Build-Clean)

Before cleaning(Rew ork Disassembly)

After CO2 cleaning(normal condition)

IPA w ipe cleaning Double CO2 automationcleaning (normal

condition)

CO2 automationcleaning w ith

parameter changing

LPC

(cou

nt/c

m2)

Proprietary data removed


Cleaning consistencyCleaning consistency……

MBA Rework

Proprietary data removed


COCO22 spray cleaning solutionsspray cleaning solutions……

Automation/Capacity

Mobility/Clean-in-Place

Modules/Clean Integration

Tools/Workbench


• Adaptable – able to adapt uniquely to manufacturing processes and tools

• Consistent – a process with known and stable process input variables

• Safe – no VOCs, no toxics, and no worker health hazards

• Clean – clean and dry treatment chemistry

• Lean – no waste, cellular, compact and efficient

Changing the Game Rules with COChanging the Game Rules with CO22

WrapWrap--upup……


http://[email protected]

Precision Cleaning Division27636 Avenue Scott Unit CValencia, CA USA 91355

+1.661.775.5964

QuestionsQuestions……

David Jackson

PurCO2Clean…Pure & Simple.

Centrifugal Liquid and Supercritical, Composite Spray and Plasma CO2 Cleaning TechnologyLicensed from DEFLEX/Raytheon

Documents

Changing the Game Rules with CO2 · 2011-01-28 · Advantages of CO2 cleantech… “Clean” Processing… Clean without producing environmental wastes such as air pollution, spent