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EMULSION CLEANING FEASIBILITY STUDY
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Pee k Bruce MR&D Chemical Processes
Boeing Commercial Airplane Group Wichita, ICS 67277
ABSTRACT
In seeking a n alternative to vapor degreasing, Boeing Wichita MRQD has been performing a feasibility study on emulsion cleaning since January 1990. The evaluation was designed to determine t h e ability of Daraclean 282 to clean details contaminated with soils and forming lubricants commonly found in aerospace manufacture.
During the manufacturing feasibility study, MRQD developed methods of testing, maintenance, regeneration of solution, and established equipment requirements. Testing indicates t h a t t h e emulsion cleaning process, when used as specified, does offer an alternative to vapor degreasing. The emulsion cleaning process has been scheduled for implementation in t h e aluminum precleaning lines for penetrant inspection, alodine, and anodize processing.
KEY WORDS: Emulsion Cleaning; TCA; TCE; Vapor Degreasing.
Mention of trade names of commercial products does not consti tute endorsement o r recommendation for use.
ABSTRACT
In seeking a n alternative to vapor degreasing, Boeing Wichita MRQD has been performing a feasibility study on emulsion cleaning since January 1990. The evaluation was designed t o determine the ability of Daraclean 282 to clean details contaminated with commonly encountered soils.
During the manufacturing feasibility study, MRBD developed methods of testing, maintenance, regeneration of solution, and equipment requirement. Testing indicates that the emulsion cleaning process, when used as specified, does offer an al ternat ive to vapor degreasing of details. The emulsion cleaning process has been scheduled for implementation in t h e aluminum precleaning lines for penetrant inspection, alodine, and anodize processing.
1.0 INTRODUCTION
There a r e nine vapor degrease tanks in operation at Boeing Wichita using tri- chlorethylene (TCE) as the solvent degreaser. The solvent emission from t h e vapor degreasing was 1.01 million Kg and 0.98 million Kg in 1987 and 1988 respectively. In 1989, Boeing Wichita established a plan to replace or modify all of t h e aging degrease tanks as a short-term solution to reduction of t h e TCE solvent emission. In t h e meantime, all Boeing technical groups were focusing their attentions on water-based cleaners as candidates to replace vapor degreasing. The Boeing Material Technology Group (BMT) released a specification, BAC 5763 , PSD 6-1 1, with three qualified aqueous cleaners. Since t h e aqueous cleaning was new to t h e Boeing Company and t h e aerospace industry, the Boeing Wichita MRQD started a full manufacturing feasibility study on aqueous cleaning in January 1990. The aqueous cleaning process shall meet ratejproduction requirements as well as all currently identifiable environ- mental considerations.
2.0 MATERIAL
2.1 Cleaner Daraclean 282, from W. R. Grace, was used in t h e pilot study. The cleaner has been qualified in BAC 5763, PSD 6-11. Daraclean 282 has also been qualified by Boeing Wichita Industrial Hygiene as a nontoxic, nonflam- mable, and nonhazardous material.
2.2 Soils Eleven soils a r e regularly cleaned on Boeing's Wichita vapor degreasing line. These soils are: mineral spirits, Macco 472, Cimcool 5-Star 40, 910G CS Coolant, Mobilment Omicron, Boelube Paste (Blue), Boelube (Red), Exxon Spinnestic 22, Houghton ASO, Trim-Sol Coolant, and Magna-Glo 14 AM. These eleven soils were studies in this feasibility study.
3.0 FACILITY
3.1 Process Tank A mild steel tank, 1.4m wide x 3.7m long x 1.8m deep, with s team coils sized to maintain t h e solution at 60 to 66 degrees Centigrade was used. The configuration of this tank, with oil skimmer and two pump locations, is shown in Figure 1. The small pump was dedicated to t h e skimmer and served to transport skimmed cleaner solution from the overflow weir and skimmer back to the emulsion tank. Mechanical agitation was provided by t h e large recirculating pumping system with in-line polypropylene filters. The pumping system fed fi l tered solution back to t h e tank through piping located at the bottom of the tank. The system was able t o move t h e solution up and rolled back from top t o bottom.
3.2 Solution Regeneration Device A four-sided weir, gravity-fed to an oil skimmer with three cavities, is shown in Figure 2. The f i rs t plate was welded about one inch above the bottom of the skimmer t o separate cavity one and
.. I
. two. The oil absorbent pads were placed in cavity one for removing t h e floating oil. The second plate was welded to t h e bottom. Solution was accumulated in cavity two until it overflowed into cavity three, and then was pumped back to t h e emulsion tank. The Hyde t ramp oil collector/coa~escer/u~trafiltration unit was evaluated parallel with the homemade oil skimmer in this pilot study.
3.3 Rinse Tank A heated (40-46OC.) overflow rinsing tank, 1.4m wide x 3.7" long x 1.8m deep, with a i r agitation was used. The rinse time, at 40-46OF., was five minutes.
4.0 PROCESS CONTROL REQUIREMENTS ,
4.1 Laboratory Testing Different concentrations of Daraclean 282 were studied t o determine their cleaning effectiveness on various degrees of contaminants at one, three, and five percent levels. Contaminates were applied on t h e 3' x 8" test coupons, which were subsequently immersed in t h e Daraclean 282 solutions at three, five, eight, nine, 10 and 11 percent concentrations at 6OOC. for two, five, and 10 minutes, For e a c h testing condition, t h e alkalinity ratio, nonemulsified oil, emulsified oil, alodine salt spray test, and calculated Concen- tration/mixed concentration were observed and are 6UX"rf ied in Tables I through IV.
4.1-1 Alkalinity Ratio The alkalinity ratio (of total-to-free alkalinity) was Used to determine useful solution life. The f r e e alkalinity of t h e solution was determined by titrating with 0,lN HCl to end at pH 5.67. The titration was then continued t o t h e methyl orange end point t o determine total alkalinity.
4.1.2 Nonemulsified Oil The method f o r nonemulsified oil determination was relatively straightforward. One hundred milliliters of cleaner was poured into a graduated cylinder and allowed to stand. The nonemulsified oil is the total amount of oil floating on t o p and t h e amount of oil sediment at t h e bottom of t h e graduated cylinder.
4.1.3 Emulsified Oil The emulsified oil level was determined by t h e acidification of 96 mls cleaning solution, with 4 mls of concentrated sulfuric acid in a separate funnel. This method was reliable and yielded results in less than one hour.
4.2 Pilot Line Testing A full-scale pilot emulsion cleaning process study was performed Xo ensure t h e production readiness. Test panels were evaluated first, and then production parts, in a shop environment with shop oils.
4.2.1 Test Panels Study The eleven Boeing Wichita common soils were brushed onto one Side of 2 ft. x 4 ft. panels of Sheet aluminum. One panel remained unsoiled and was was Used as a reference. All test panels were cleaned with moderate agitation. The test panels wereqcleaned for two, five, and ten minutes. Each cycle was repeated at temperatures of 38O, 49O, and 6OOC. The initial charge of t h e solution was 5% Daraclean 282. Temperature and immersion times were varied at each cleaner concentration of five, eight, nine, and ten percent.
4.2.1.1 The cleaning effectiveness was determined by visual inspection. The degree of cleaning was ranked from 1 as t h e best (water-break-free) to 5 as t h e worst (no oil removed). For each specified soil, t h e cleaning effectiveness was studied with various solution concentrations and immersion t imes, which are summarized in Tables V to VIE.
4.2.2 Production Par t s All production parts were processed at 10% cleaner concentration, 6OOC., for 10 mir?ates. The per= Were rimed et 43OC, fer five minutes. Par t types varied from flat Sheets to channels, extrusions, Skins, ribs, clips, straps, doublers, tees, fittings, shims, stiffeners, panels, forgings,
and castings. Test parameters, requirements, and frequencies were a6 defined in Table VI. In Shop 3255, approximately 30% of all the parts (10,000 production parts), have been cleaned in t h e emulsion solution from September 25, 1990, t o December 21, 1990.
4.2.2.1 Water Break Surface Testing indicated that Daraclean 282, when Used as specified, did clean t h e parts well. As shown in Tables V t o m, certain s o i l i showed water-break f r e e surface through the entire range of testing para- meters. Others consistently defied t h e water-break free condition regardless of immersion time, temperature, and concentration. In all cases, the parts were clean enough to continue processing, even when a water-break free condi- tion was not achieved.
4.2.2.2 Adhesion Test After emulsion cleaning, three panels of 2024, 6062, and 7075 aluminum were processed by either Alodine 1200 or chromic acid anodizing. In t h e first test, t h e panels were primed with BMS 10-11, Type 1 primer, and cured for seven days. In t h e second test, t h e primed panels (with anodize coating) were topcoated with BMS 10-11, Type Il enamel, and cured for seven days. In t h e third test, t h e alodine panels were primed with BMS 10-79, Type III primer, and then topcoated with BMS 10-60, Type 11, BAC 707 enamel. All test panels were soaked in distilled water for seven days prior to the adhesion testing, per BSS 7225, Type6 I and III. The adhesion tests were successful-there was no loss of coatings on any of t h e panels. In addition, specific parts are currently being selected and monitored for long-term paint adhesion in service.
4.2.2.3 Bond Strength The part6 cleaned by the emulsion cleaning process were compared to those cleaned by vapor degreasing. Lap shear panels and T-peel panels were bonded with BMS 5-101 adhesive. The test results are shown in Table W. Similar bond strengths were obtained from both cases.
4.2.3 Solution Evaporation Evaporation effects have been monitored for about three months. With a i r agitation at 6OoC., the water evaporation is approxi- mately 2.56 l/hr, o r 0.49 1 per hr. per m2. Without agitation, at the same temperature, t h e water evaporation is about 1.37 l/hr, or 0.26 1 per hr. per m2. After two months of continuous use, the Daraclean 282 concentration had reduced from 10% to 9.7%. This small drop in concentration has to be due to drag-out and not to t h e loss of evaporation. No reduction in cleaning effectiveness was observed over t h e course of three months of solution use and replenishment.
4.2.4 Sulfur and Total Dissolved Solid Sulfur testing of the rinse was performed on a biweekly basis. No significant amount of sulfur was detected. Trace metal contamination was checked with atomic absorption. No t race amounts of copper, iron, nickel, zinc, or aluminum were found af te r eight weeks of cleaning production parts.
5.0 RECOMMENDATION
From t h e technological point of view, it is feasible t o implement t h e aqueous cleaning process of aluminum cleaning based on the MRQD feasibility study. ln general, t h e pilot tank Study provided adequate data on the successful func- tioning of t h e aqueous cleaning process. l n addition, several recommendations for process improvement are summarized as follows.
5.1 Process Tank A stainless steel tank with steam coils sized t o maintain t h e solution at 60° to 77OC. is recommended. Moderate mechanical agitation with air agitation backup is required. iiuromaticlmanuai controis for i;anir lid and a i r agitation shall be installed to reduce evaporation. In addition t o immersion, spray cleaning with a variable pressure control is highly recommend-
' . 4 .
c. L * '. ed. Automatic water level controls should be included with t h e tank to maintain
the solution levels during and between operations.
a .
5.2 Rinse Tank One rinse tank capable of sustaining a temperature of 71OC. with air agitation controlled by manual t imer is recommend.
5.3 Regeneration Devices Since t h e cleaner had a greater affinity for t h e part surface than the soil did, it undercut t h e soil and popped it from t h e par t surface. Light oils floated to the bath surface, where t h e y were skimmed off. Heavy soils sett led to t h e bottom, where they were filtered off. The skimmer and fi l ters did a very good job of removing the oils and regenerating t h e solution.
A very small amount of water soluble oils are used in Boeing Wichita. The emulsified oil does not accumulate rapidly enough in t h e tank to warrant t h e cost of purchase and operation of an ultrafiltration unit. However, an ultrafil- tration unit would be valuable if water soluble oils are heavily used.
5.4 Racking Techniques Racking techniques were found to be very important to the success of emulsion cleaning. A part spacing distance of two to five centimeters must be maintained. Layering is also critical.. When solution flow is hindered, t h e cleaning ability falls off noticeably.
EMULSION CLEANING MAN U FACTU RI NG FEASl BI LlTY
Dr. Peter H. Wu Manufacturing Research and Development
Boeing Wichita
GS410715.01
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Work Statement: Degreasing Boeing Commercial Airplanes, Wichita Division
Develop alternative processes to vapor
degreasing. Primary emphasis is on aqueous
degreaser. Order of development activities
will be based on substrates aluminum, steel, and titanium.
OS9107 15.03
EMULSION CLEANING
Emulsion Clean I BAC5763
MANUFACTURING RESEARCH AND DWELOPMENT
I Warm Water Rinse 9O-14O0F
Pilot Line Process Flow
Vapor Degrease BAC 5408 .
Boeing Commercial Airplanes, Wichita Division
Alkaline Clean Warm Water BAC 5749 Rinse 90-140°F
Condition 1 (Standard Operation) I i I 3
I i I I Water Break- I Wet Processing H Free Surfaces
Dry or Continue
.- Pre-Cleaning Removes oils and grease to minimize contamination of alkaline cleaning solutions
Emulsion solution - Concentration 3,5,7,9,10,11% - Temperature room temp 100,~110,120,130,
- Immersion time 5-30 minutes
- Immersion time - 5 minutes minimum - Part cleanliness - visually clean
- 140,lSO"F
Emulsion rinse
GS91-0715-027
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Pilot Line Process Flow (Cont'd) Boeing Commercial Airplanes, Wichita Division
Condition 2 (Skip Alkaline Cleaning) *
I
Warm Water I Emulsion BAC5763 Clean H Rinse 90-140°F I I L
Yes Water Break- , Dry or Continue Free Surface Wet Processing
No
GS91-0715028
EMULSlON CLEANING
Vapor Degrease I Alkaline Clean 1
BAC 5408 BAC 5749 - /
MANUFACTURING RESEARCH AND DEVELOPMENT
Warm Water Rinse 00-140°F
Pilot Line Process Flow Boeing Commercial Airplanes, Wichita Division
Condition 1 (Standard Operation) h 1 I . i
I Emulsion Clean I BAC5763
I 1 I
I Water Break- I Wet Processing H Free Surfaces
Dry or Continue c I I
. -
Re-Cleaning Removes oils and grease to minimize contaminatiori of alkaline cleaning solutions
0 Emulsion solution - Concentration 3,5,7,9,10,11% -Temperature ropm temp 100,~110,120,130,
- Immersion time 5-30 minutes
- Immersion time - 5 minutes minimum - Part cleanliness - visually clean
- 140,IWF
0 Emulsion rinse
GS91-0715-027
EMULSION CLEANING
Emulsion Clean BAG 5763
L
MANUFACTURING RESEARCH AND DEVELOPMENT
, Warm Water ' Rinse 90-14OoF _I
Pilot Line Process Flow (Cont'd)
Yes ,
Boeing Commercial Airplanes, Wichita Division
L
Water Break- Dry or Continue Free Surface Wet Processing
Condition 2 (Skip Alkaline Cleaning) *
GS91-0715-020
c
-
Alk" BAC 5749
EMULSION CLEANING
Warm Water Water Break- Free Surfaces hinse 90-l4O0F
4
MANUFACTURING RESEARCH AND DEVELOPMENT
, VaDor Dearease Yes AC 5408
Pilot Line Process Flow (Cont'd)
Alkaline Clean Warm Water BAC 5749 Rinse 90=14O0F
Boeing Commercial Airplanes, Wichita Division
Condition 3 (Salvage Production Parts) Goal
Water Break Surfaces
I
Water Break- I Free Surfaces
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
pH Versus Daraclean 282 Concentration -
Boeing Commercial Airplanes, Wichita Division
11.7
11.6
11.5
11.4
-- 11.3
11.2
11.1
11.0
10.9
10.8
10.7
10.6 1 1 1 1 1 1 1 3 5 7 9 11 13
Percent Daraclean 282 Concentration . GS91071!i. 11
EMU LSlON CLEAN IN G MANUFACTURING RESEARCH AND DEVELOPMENT
Endpoint Determination Boeing Commercial Airplanes, Wichita Division
11
9
I 7 e
5
3 0 2 4
Number of mls 6
GS810715.08
. -
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Alkalinity Ratio Boeing Commercial Airplanes, Wichita Division
1.55
1.5
1-45
1.4
1.35
1.3
1.25
1.2
1-15
1.1 I I I I I
1 3 5 7 9 % Concentration
11 13 GSO10715.10
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Alkalinity Ratio Vs Daraclean 282 Concentration Boeing Commercial Airplanes; Wichita Division
1.44
1.40
0 1.36
a 1.32 a r .= 1.28 L L .I - a 1.24 Y -
1.20
1.16
1.12
5% Contamination
3% Contamination \ - Contaminated with Macco 472
1 3 5 7 9 11 13 Percent. Daraclean 282 Concentration GS010716.12
. -
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Manufacturing Feasibility Study Boeing Commercial Airplanes, Wichita Division
Identify test candidate (Daraclean 282) Cleaner stabilityltank life
1. Solution monitoring PH Oil contaminants level (ml/l) Trace metal concentration
Skimmer Filtration (ultrafiltration) Coalescent unit
2. Solution purification and cleaner regeneration
GSS10715.07
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Emulsion Cleaning Effectivity Matrix -
Boeing Commercial Airplane Group, Wichita Division
Type of Soil to be Cleaned
1. Trim-Sol SF
3. Cimcool 5 Star 90 4. Coolant 9106 CS 5. Boelube Blue 6. Boelube Red 7. Mobilmet Omicron 8. Exxon Spinnestic 22 9. Macco 472
2. Houghton AS0
IO. ,Magnaglo 14 AM 11. Mineral Spirits
General Use of Soil
Coolant for NC Machining Central Collection Coolant Coolant for NC Machining Grinder Coolant Drilling Operation Lubricant Drilling Operation Lubricant Lathe Cutting Oil Spindle Lubrication Stretch Form Parts Release Agent Penetrant Inspection Parts Solvent Cleaner
GS910715.23
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3% I 5%
MANUFACTURING RESEARCH AND DEVELOPMENT
8% 9% I 10% 11% I .
Laboratory Testing Matrix
60°C
Boeing Commercia, Airplanes, Wichita Division
Exxon Terrestic Table I (Cont'd)
n I
60°C 60°C I 60°C I 60°C 1 60°C I
Daraclean Conc. No. mls
Conc. YO mls. Tot1 Alka
Alka Ratio Emuls. Oil
Non-emuls. Oil Temperature
Panels - 2 min Panels - 5 min
Panels - 10 min Cal. Con / Mix Con
1 5% Contaminant
1.2 I 2.2 I 3.6 I 4.15 I 4.6 I 5.3 I 2.76 I 5.06 I 8.28 I 9.54 I 10.58 I . 12.19 I 2.1 I 3.2 I 5.6 I 6.3 I 6.85 I
1.75 I 1.451 1.39 I 1.351 1.36 I 1.29 I I I I I I -I
1*I 1 * I 1*I 1 * I l * l 1 * I
.(140"F) I (140°F) I (140°F) I (140°F) I (140°F) I (140") I
2*1 2*1 2*1 2*1 2 * I 2 " I 92.0% I 101.2% I 103.5% I IO6.OYo IIO5.8Yo I IIO.8Yo I
GS91-0715-003 1 * = Too Small to Detect 2 * = Alodine Salt Spray Panels OK .
3 * .2% 870% 880% 3 * 83%
653°C (150°F)
65.5"c (150°F)
65.5"c (150°F)
65.5"C (150°F)
2 " 2 "
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Laboratory Testing Matrix Boeing Commercial Airp/anes, Wichita Division
Macco 472 Table I I
I YO Contaminant Daraclean Conc.
No. mls Conc. YO
mls. Tot1 Alka Alka Ratio
Non-emuls. Oil Temperature
EmUk oil
3% 5% 8% . 11% 4875
2.89 10.56 1.65 1.26 1.21 1.15
3 *<.I% 3 * .6% I * 1 " l * I I" 1 * I 1 "
I
65.5OC (1 56")
Panels - 2 min Panels - 5 min
Panels - I O min Cal. Con / Mix Con
2 " 2*1 2 " 2 " 2 " 2*1 2 " 2 " I 2 " 2 " 2 "
96.3% 2 "
96.OYo 1 = Too Small to Detect 2 * = Alodine Salt Spray Panels OK 3 = Did Not Agitate Vigorously
GS91-0715-004
EMULSION CLEANING
5.3 1.23
3.6% < .5%
65.5OC (1 50°F)
MANUFACTURING RESEARCH AND DEVELOPMENT
5.8 1 .22
480% < .5%
65.5OC (1 50")
Laboratory Testing Matrix Boeing Commercial Airplanes, Wichita Division
Macco 472 Table I1 (Cont'd)
5% Contaminant 3% 5% 8% 9% 10./,1 11% Daraclean Conc.
No. mls Conc. YO
mls. Tot1 Alka Alka Ratio
Non-emuls. Oil Temperature
Panels - 2 min Panels - 5 min
Panels - 10 min Cal. Con / Mix Con
EmUlS. oil
I
2.2 3,4 3.9 3 4.89 8,67
2.9 4.35 4.85 1841 1.32 1.28 I .24
383% 3.5% 3.3% 3.4% < -5% < .5% < 85%
65.5OC (150°F)
65.5OC (150°F)
65.5OC (150°F)
2 " 2 * 2 * 2 " * 2 * ( 2 * 2 " 2 " I 2 * 2 "
2 " 2 " 2 "
2 " 2 " 2 " 2 * 1 : 2 "
9788% 94.5% 96.3% 95.7% I 96.0% I = Too Small to Detect 2 * = Alodine Salt Spray Panels OK 3 = Did Not Agitate Vigorously
(391-0715-006
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MANUFACTURING RESEARCH AND DEVELOPMENT
183 1.22 i816 .I OO/~ 0% .IOY~
Laboratory Testing Matrix
i818 8 1 oo/o
Boeing Commercial Airplanes, Wichita Division
. Petrochem Microfinish Table 111 (Cont'd)
65m5OC 6585OC (150°F) I (150°F)
3% Contaminant
65.5OC (150°F)
Daraclean Conc. No8 mls
Conc. YO mls. Tot1 Alka
Alka Ratio Emuls, Oil
Non-emuls. Oil Temperature
Panels - 2 min Panels - 5 min
Panels - 10 min Calm Con / Mix Con
3% 5% 9% I OYO I I Y O
183 2.05 384 3885 4825 4875 2889 4856 7 , s 8.56 187 2 5 3.95 4855
9,45 5
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I 0856 5.55 1.17
8 10940 I *
. . 2 "
2*1 2 * l 2 "
65m5OC (150°F)
2 * 2 "
65.5OC (150°F)
65.5OC (1 50')
2 * 2 *
2 *1 2 * l 2*1 2*1 2 * I 2 "
I I I I 1 = Too Small to Detect 2 = Nadine Salt Spray Panels OK 3 * = Did Not Agitate Vigorously
GS91-0715-008
EMULSION CLEANING
1 " c .I% 60°C
(140°F)
MANUFACTURING RESEARCH AND DRlELOPMENT
1 " I" 1 " < .lo/o c .I% < .I0h 60°C 60°C 60°C
(140°F) (140°F) (140°F)
Laboratory Testing Matrix
(140°F) 2 " 2 " 2 "
86.7240
Boeing Commercial Airplanes, Wichita Division
(140") 2 " 2 " 2 "
86.9%
Daraclean Conc. No. mls
Conc. YO mls. Tot1 Alka
Alka Ratio Emuls. Oil
Non-emuls. Oil Temperature
Panels - 2 min Panels - 5 min
Panels - I O min Cal. Con / Mix Con
Simonize Paste Wax Table IV
1 YO Contaminant
I 14.41 1.9 1 3.1 1 3.6 4.22 6.89 8.01 2.35 3.75 4.35
I 1.281 1.23 I 1.21 I I m 2
I 2*1 2 *1 2 * ( 2 " € €
I 2 " I 2 " I 2*1 2*1 2*1 2 * 106.6% 84.4% 96.1 Yo 89.OYo
1 * = Water Sduble Component Invalidates Test 2 * = Did Not 1
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1.18 I 1.21
6OoC I 60°C
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EMULSION CLEANING
2
MANUFACTURING RESEARCH AND DEVELOPMENT
2 2 2
Emulsion Cleaning Effectivity Matrix
L I
1 1 I 1 2 2 2 2 1 1 I 1
Boeing Commercial Airplanes# Wichita Division
I 2
Daraclean 282 Table V (Cont'd)
I I I 2 2 2
Macco 472
Conc. 38°C 2 Min / 100°F Cleaning Ability 49°C 2 Min / I2O0F Cleaning Ability 60°C 2 Min / 140°F Cleaning Ability 38°C 5 Min / IW°F Cleaning Ability 49°C 5 Min / 120°F Cleaning Ability 60°C 5 Min / I4O0F Cleaning Ability 38°C 10 Min / IOOOF Cleaning Ability 49°C 10 Min / 120°F Cleaning Ability 60°C 10 Min / I4O0F Cleaning Ability
I 5% I 8% I 9% I 10% I
I ----2 I 2 I I I 1 I
1 1 1 1 l l 1 1 1 I I I I I
1 1 l 1 1 1 1 1 1 1 = Best Water-Break Free 4 = Worse, Little Soil Removed
2 = Clean, But Not Water-Break Free 5 = Worst, No Sol Removed
3 = Good, Most Sol Removed
GS91-0715-011
EMULSION CLEANING
5% 8% 2 2 2 2 I I 2 2 2 2 1 I 2 2 1 I 1 1
MANUFACTURING RESEARCH AND DEVELOPMENT
9% 10% 2 1 1 I 1 1 I 1 1 1 I 1 I I 1 1 I 1
Emulsion Cleaning Effectivity Matrix Boeing Commercial Airplanes, Wichita Division
Daraclean 282 Table V (Cont'd)
Conc. 38°C 2 Min / 100°F Cleaning Ability 49°C 2 Min / 120°F Cleaning Ability 60°C 2 Min / 140°F Cleaning Ability 38°C 5 Min / 100°F Cleaning Ability 49°C 5 Min / 120°F Cleaning Ability 60°C 5 Min / 140°F Cleaning Ability 38°C 10 Min / 100°F Cleaning Ability 49°C 10 Min / 120°F Cleaning Ability 6OoC 10 Min / 140°F Cleaning Ability
1 = Best Water-Break Free 4 = Worse, Little Soil Removed
2 = Clean, But Not Water-Break Free 5 = Worst, No Soil Removed
3 = Good, Most Soil Removed
GS91-07 15-01 2
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Emulsion Cleaning Effectivity Matrix Boeing Commercial Airplanes, Wichita Division
Daraclean 282 Table V (Cont'd)
Coolant 9106 CS
Conc. 38°C 2 Min / IOOOF Cleaning Ability 49°C 2 Min / 120°F Cleaning Ability 60°C 2 Min / 140°F Cleaning Ability 38°C 5 Min / 100°F Cleaning Ability 49°C 5 Min / 120°F Cleaning Ability 60°C 5 Min / 140°F Cleaning Ability 38°C I O Min / 100°F Cleaning Ability 49°C I O Min / 120°F Cleaning Ability 60°C I O Min / 140°F Cleaning Ability
I 5% I 8% I 9% I 10%
1 I
1 2 1 1 1 2 l l c
l l 1 1 1 1 l l I 1 I I I 1 I I I 1 1 I I I I I 1 I 1 I I I I I
1 = Best Water-Break Free 4 = Worse, Little Soil Removed
2 = Clean, But Not Water-Break Free 5 = Worst, No Soil Removed
3 = Good, Most Soil Removed
GS9i-0715-013
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Emulsion Cleaning Effectivity Matrix Boeing Commercial Airplanes, Wichita Division
Daraclean 282 Table VI
Mobilmet Omicron
Conc. 38°C 2 Min / 100°F Cleaning Ability 49°C .2 Min / 120°F Cleaning Ability 60°C 2 Min 1 140°F Cleaning Ability 38°C 5 Min / W O O F Cleaning Ability 49°C 5 Min / 120°F Cleaning Ability 60°C 5 Min / 14OOF Cleaning Ability 38°C 10 Min / 100°F Cleaning Ability 49°C I O Min / 120°F Cleaning Ability 6OoC 10 Min / 140°F Cleaning Ability
1 = 68St Water-Break Free 4 = Worse, Little Soil Removed
2 = Clean, But Not Water-Break Free 5 = Worst, No Soil Removed
3 = Good, Most Soil Removed
GS91-0715-014
EMULSION CLEANING
Conc.
MANUFACTURING RESEARCH AND DEVELOPMENT
5% 8% 9% 10%
Emulsion Cleaning Effectivity Matrix
38OC 49OC
2 Min / IOOOF Cleaning Ability 2 Min / 120°F Cleaning Ability
Boeing Commercial Airplanes, Wichita Division
Daraclean 282 Table VI (Cont'd)
3 3 2 I 3 3 2 1
Boelube Blue
49°C 68°C
5 Min / 120°F Cleaning Ability 5 Min / 14OOF Cleaning Ability
38OC 10 Min / IOOOF Cleaning Ability 49°C I O Min / 120°F Cleaning Ability 60°C 10 Min / 140°F Cleaning Ability
3 2 I 1 2 2 I I 3 2 1 1 2 2 2 I 2 2 I 1
I I I
60°C 2 Min/ l4O0FCleaningAbility I 3 I 2 I 2 I 1 I 1 I I
38°C 5Min/ IOO°FCleaningAbility I 3 I 2 I 2 I 1
1 = Best Water-Break Free 4 = Worse, Little Soil Removed
2 = Clean, But Not Water-Break Free 5 = Worst, No Soil Removed
3 = Good, Most Soil Removed
GS91-0715-015
EMULSION CLEANING
Conc.
MANUFACTURING RESEARCH AND DEVELOPMENT
I 5% 8% 9% I OYO
Emulsion Cleaning Effectivity Matrix
38°C 49°C
2 Min / IOOOF Cleaning Ability 2 Min / 120°F Cleaning Ability
Boeing Commercial Aiplanes, Wichita Division
Daraclean 282 Table VI (Cont'd)
4 4 3 2 4 4 3 1
Boelube Red
60°C 5 Min / 140°F Cleaning Ability 38°C 10 Min / 100°F Cleaning Ability 49OC 10 Min / I2O0F Cleaning Ability 60°C 10 Min / 140°F Cleaning Ability
2 2 2 1 3 2 2 I 3 2 2 I 2 2 2 1
60°C 2Min/140°FCleaningAbility I 4 I 4 I 3 I 1 I I 1
38°C 5Min/10O0FCIeaningAbility I 3 I 3 I 2 I 2
49°C 5 Min / 120°F Cleaning Ability I 3 I 3 I 2 I I
1 = Best Water-Break Free 4 = Worse, Little Soil Removed
2 = Clean, But Not Water-Break Free 5 = Worst, No Soil Removed
3 = Good, Most Soil Removed
GS91-0715-016
EMULSION CLEANING
~~ -~
2 2 2 2 2 2 2
MANUFACTURING RESEARCH AND DEVELOPMENT
2 2 1 2 1 1 2 1 1 2 1 1 2 2 1 2 1 1 2 21 1
Emulsion Cleaning Effectivity Matrix Boeing Commercial Airplanes, Wichita Division
Daraclean 282 Table VI (Cont'd)
Cone. 38°C 2 Min / 100°F Cleaning Ability 49°C 2 Min / 120°F Cleaning Ability 60°C 2 Min / 140°F Cleaning Ability 38°C t 5 Min / IOOOF Cleaning Ability 49°C 5 Min / 12OOF Cleaning Ability 60°C 5 Min / 14OOF Cleaning Ability 38°C 10 Min / IOOOF Cleaning Ability 49°C 10 Min / 120°F Cleaning Ability 60°C 10 Min / 140°F Cleaning Ability
Exxon Spinnestic 22
1 2 1 2 1 2 - 1 2 1 2 1 2 1 2 1 1
1 E Best Water-Break Free 4 = Worse, Little Soil Removed
2 = Clean, But Not Water-Break Free 5 = Worst, No Soil Removed
3 = Good, Most Soil Removed
GS91-0715-017
EMULSION CLEANING
38OC 10 Min / 100°F Cleaning Ability 49OC 10 Min / 120°F Cleaning Ability 60°C 10 Min / 140°F Cleaning Ability
MANUFACTURING RESEARCH AND DEVELOPMENT
1 I 1 I I I I I 1 I I I
*
Emulsion Cleaning Effectivity Matrix Boeing Commercial Ai~lanes, Wichita Division
Daraclean 282 - _
Table VI1
Houghton AS0
GS91-0715-018
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Emulsion Cleaning Effectivity Matrix Boeing Commercial Airplanes, Wichita Division
Daraclean 202 Table VI1 (Cont’d)
Magnaglo 14 AM
Conc. 5% 8% 9% ” 1 O Y O
38°C 2 Min / 100°F Cleaning Ability 3 2 3 3 I 1
49OC 2 . - Min / 120°F Cleaning Ability 60°C 2 Min / 140°F Cleaning Ability 38OC 5 Min / IOO°F Cleaning Ability 49OC 5 Min / 120°F Cleaning Ability 60°C 5 Min / 140°F Cleaning Ability 38°C 10 Min / 100°F Cleaning AbiIity 49°C 10 Min / 120°F Cleaning Ability 60°C 10 Min / 140°F Cleaning Ability I
1 = Best Water-Break Free 4 = Worse, Little Soil Removed
2 = Clean, But Not Water-Break Free 5 = Worst, No Soil Removed
3 = Good, Most Soil Removed
GS91-0715-020
EMULSION CLEANING
~
5% 2 2 2 2 2 I 2 2 2
MANUFACTURING RESEARCH AND DEVELOPMENT
8% 9% I OYO 2 3 2 2 2 2 1 2 1 2 2 2 1 2 1 I I 1 2 2 2 1 I 1 I I 1
Emulsion Cleaning Effectivity Matrix Boeing Commercial Airplanes, Wichita Division
Daraclean 282 Table VI1 (Cont'd)
Conc. 38°C 2 Min / WOOF Cleaning Ability 49°C 2 Min / 12OOF Cleaning Ability 60°C 2 Min / I4O0F Cleaning Ability 38°C 5 Min / IOO°F Cleaning Ability 49OC 5 Min / 12OOF Cleaning Ability 60°C 5 Min / 14OOF Cleaning Ability 38°C 10 Nlin / IOOOF Cleaning Ability 49°C 10 Min / 120OF Cleaning Ability 60°C 10 Min / 14OOF Cleaning Ability
him-Sol Coolant
1 = Best Water-Break Free 4 = Worse, Uttle Soil Removed
2 =: Clean, But Not Water-Break Free 5 = Worst, No Soil Removed
3 = Good, Most Soil Removed
GS91-0715-019
EMULSION CLEANING
1987 1988 1989
MANUFACTURING RESEARCH AND DEVELOPMENT
. .040 .028 .I02 .777 2.315 .055 .037 .127 .I27 .276 1.847 .062 .069 0.030 0.110 0.089 0.855 1.453 0.055 0.310
hcolon Dihlor FIM Mu( TCE YleK Toluonm
1987 = 1989 Chemical Air Emissions - Boeing Wichita
.I17
.053
0.048
PwchloI
Boeing Commercial Airplanes, Wichita Division
.095 .011 0.000
.018 .012 .001 - -
0.051 0.001 0.010 0.053 0.018 0.012
Xylono C h b h C h ” o KBuIylOH TCA Phonal Ammonia
2.4
1.8
1.2
0.6
0.0
.I17
.053
.095 .011 0.000 I .018 LI .012 .001 I I I I 0.048
PwchloI
0.051 0.001 0.010 0.053 0.018 0.012
Xylono C h b h C h ” o KBuIylOH TCA Phonal Ammonia
GS910715.21
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Process Development Boeing Commercial Airplanes, Wichita Division
Defined manufacturing parameters - lndentified contaminants - Established critical soil concentration - Optimized operation conditions
Determined the effect on subsequent processes
Identified equipment requirements GS9107lS.04
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Pilot Line Evaluation Matrix Boeing Commercial Aitplanes, Wichita Division
Table VIII (Cont'd)
Test Parameter Requirement
Emulsion rinse - Total solids 350 PPm
- Rinse flow Solids control I00 ppm s max
- Temperature 90 - 140OF (32°C = 60°C)
- Part agitation Moderate - Immersion time - Part cleanliness Visually clean
5 min. minimum
Test Freauencv
Weekly Weekly Each rack Each rack
Each rack Each rack Each rack
GS91-0715-022
0 S v) 0 c S
I
z 3 3 5. (D
J 0 U 0
v) (D
G3
m 9) 0 =r 9) 0 X
T
I 4 (D
m (D
S
3
3 3 rc
a N 0
ot 0
I d
+I
m 9) 0 ==r 9) 0 X
m
T 9) 0 h
W 0
r -8
S CD m e nj r
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Pilot Line Evaluation Matrix Boeing Commercial Airplanes, Wichita Division
Table Vlll (Cont'd) Test
Test Parameter Reauirement Freauencv
BAC 5749 Alkaline Clean and rinse - Continued wet Water break-free Each rack - processing surfaces
Corrosion resistance - 336 hour salt spray BAC 5019 or Three test
BAC 5632 - 168 hour salt spray BAC 5719 Panels each
GS9 1-071 5-023
EMULSION CLEANING \
MANUFACTURING RESEARCH AND DEVELOPMENT
Cost Study Boeing Commercial Airplanes, Wichita Division
0
0
0
e
e
0
Identify material initial cost
Establish material make-up cost
Determine equipment cost
Identify labor cost
Determine waste treatment cost 1y
Calculate energy cost
GS910715.05
EMULSION CLEANING MANUFACTURING RESEARCH
AND DEVELOPMENT
Evaluation Results Boeing Commercial Airplanes, Wichita Division
Emulsion cleaning process exhibit:
Effective cleanness (water break free,
Corrosion resistance Acceptable tank life Adaptability to manufacturing facilities Minimal hazardous waste Manufacturing personnel acceptance Cost effectiveness
UV light)
GS910715.06
EMULSION CLEANING MANUFACTURING RESEARCH AND DEVELOPMENT
Metal Bond Test Results Boeing Commercial Airplanes, Wichita Division
BMS 5-101
Metal-to-Metal Peel
VaDor Deurease
74 psi = 0851 MPa 74 psi = 0851 MPa 74 psi = 0851 MPa
TABLE 1X
Emulsion Clean
74 psi = 0851 MPa 74 psi = 0851 MPa 74 psi = 0851 MPa
GS91-0715-025
MANUFACTURING RESEARCH AND DEVELOPMENT
EMULSION CLEANING
Metal Bond Test Results Boeing Commercial Airplanes, Wichita Division
Vapor Degrease
4524 psi = 31.9 MPa 4486 psi = 30.9 MPa 4338 psi = 29.9 MPa 4400 psi = 30.3 MPa 4504 psi = 31.1 MPa
BMS 5-101 Lap Shears
Emulsion Clean
4476 psi = 30.9 MPa 4492 psi = 31.0 MPa 4432 psi = 30.6 MPa 4600 psi = 31.7 MPa 4566 psi = 31.5 MPa
14450 psi = 30.7 MPa I Average I4513 psi = 31 .I MPa 1
TABLE 1X GS91-0715.024