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Cleanliness Testing to ISO 16232 and OEM Specifications
Lessons from the Cleanliness Testing Laboratory
by
Jack Griffes
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So why bother with cleanliness testing?
Doesn’t it take time and add cost? Doesn’t it have potential to delay shipment?
Doesn’t a failed cleanliness test cause:
Product on hold Rewash potentialRetest after rewash
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So why bother with cleanliness testing?
Doesn’t it take time and add cost? YESDoesn’t it have potential to delay shipment? YES
Doesn’t failed cleanliness test cause:
Product on hold YESRewash potential YESRetest after rewash YES
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So why bother with cleanliness testing?
Reducing early warranty failure costs
Increasing reliability
Increasing longevity
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So why bother with cleanliness testing?
Reducing early warranty failure costsBenefits both Manufacturers & Consumers
Increasing reliability Benefits both Manufacturers & Consumers
Increasing longevityBenefits both Manufacturers & Consumers
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So what is cleanliness testing?
Extracting 90+% of residual contamination from part and transferring it to a filter patch/membrane for further analysis.
Further analysis could be:Gravimetric (mass of contamination)Maximum Particle Size (length or multi-axis)Particle Count / Particle DistributionParticle Identification
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Gravimetric Testing Contamination is extracted from part
– Pressure Rinse– Agitation– Ultrasonic– Functional Test Bed
Extraction fluid is vacuum filtered through a pre-weighed filter patch/membrane with specified micron rating.
Membrane is dried and weighed. Net weight = overall contaminant on part.
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Maximum Particle Size Generally in addition to Gravimetric Limit Typically X-axis (longest axis) only
– Less common multi-axis limits (X & Y, or X & Y & Z)– Can be “any particle” or a specific type like “Metallic”– Should be directly related to a known failure mode
• Margins of Safety (Limits set lower than what can cause failure) or Limits extended to particle types not able to cause a failure can exponentially increase cost of meeting the Limit
Often measured in microns
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Pop QuizHow big is a micron?
A. 1 millionth of a meterB. 1 thousandth of a millimeterC. Smaller than the diameter of a grain of sand?D. 0.000039 of an inchE. All of the above
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Perspective on Particle Size
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Particle Counting Filter patch from Gravimetric testing is
sandwiched between glass slides. Automated Optical Microscope (AOM) takes
hundreds of photos of filtered area Visual analysis is used to count & size particles
inside entire filtered area Particles can be sorted based on optical
properties – Ex. Metallic based on luster & intensity
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Particle Counting Strengths:
– Measures all particles on patch– Categorizes particles within size ranges.– Allows photos of particles to be included in report along
with x & y-axis measurements Weakness:
– Equipment expensive – Technician training is vital– Time consuming
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So what is ISO 16232 all about?• Spells out principles of cleanliness testing• Spells out 90+% extraction efficiency• Spells out blank value under 10% of limits• Spells out principles for 4 methods of extraction
• Pressure Rinse• Ultrasonic• Agitation• Functional Test Bed
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So what is ISO 16232 all about?• Spells out principles of Particle Counting• Presents a uniform cleanliness code for
particle count limits and reporting• Examples:
• CCC = A(B15/C14/D13/E12/F11/G10/H8/I4/K0)• CCC = V(B15/C14/D13/E12/F11/G10/H8/I4/K0)• CCC = N(E1500/F250/G130/H64/I16/K1)
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Understanding ISO 16232 code• CCC = Component Cleanliness Code• A = Standard Area = 1,000cm^2• V = Standard Volume = 100cm^3• N = Numbers of particles per component
• Examples:• CCC = A(B15/C14/D13/E12/F11/G10/H8/I4/K0)• CCC = V(B15/C14/D13/E12/F11/G10/H8/I4/K0)• CCC = N(E1500/F250/G130/H64/I16/K1)
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ISO 16232 code for A or V reporting• B = 5µm ≤ x < 15µm • C = 15µm ≤ x < 25µm • D = 25µm ≤ x < 50µm • E = 50µm ≤ x < 100µm• F = 100µm ≤ x < 150µm• G = 150µm ≤ x < 200µm• H = 200µm ≤ x < 400µm• I = 400µm ≤ x < 600µm• J = 600µm ≤ x < 1,000µm• K = 1,000µm ≤ x
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ISO 16232 code for N reporting• N = Numbers of particles per component
• Contamination Level Code is NOT used• Actual numbers of particles are listed after size
class Letter• Example:
• CCC = N(E1500/F250/G130/H64/I16/K1)
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Crown Cleanliness Testing Laboratory2070 Brooklyn Rd; Jackson, MI 49203 USA (517) 905-5328 or 5304 or 5329
Benefits of using a 3rd party Lab• Capital equipment cost borne by Lab• Skilled Lab Technicians hired by Lab• Calibrations, record keeping, etc.
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Crown Cleanliness Testing Laboratory Capabilities
Class 100,000 Clean Room Extraction Area
Gravimetric Testing per ISO 16232 & VDA 19 plus many OEM standards
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Crown Cleanliness Testing Laboratory Capabilities
Two systems with fully ISO 16232 compliant
calibration factors
We test to ISO 16232, VDA 19And many OEM specifications
Particle Counting & Sizing
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Crown Cleanliness Testing Laboratory Capabilities
Liquid Particle Count Testing – is done according to ISO 16232 or other similar
standards using Automated Optical Microscope (AOM) systems
– rather than count the particles suspended in the liquid the particles are counted on a filter membrane which allows multi-dimensional measurements and photos of the largest particles
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Crown Cleanliness Testing Laboratory2070 Brooklyn Rd; Jackson, MI 49203 USA
Jack Griffes (517) 905-5328 [email protected]
Allen Zubke (517) 905-5304 [email protected]
