Slide 1: Quaker Houghton Technical Training: Metalworking Cleaners
Quaker Houghton Technical Training Metalworking Cleaners
Slide 2: Agenda
Agenda 1. Introduction – The Basics 2. Cleaner Processes 3. Product Line 4. Troubleshooting 5. Resources 6. Questions CONFIDENTIAL, DO NOT DISTRIBUTE 2
Slide 3: The Basics
The Basics CONFIDENTIAL, DO NOT DISTRIBUTE 3 ©2019 Quaker Houghton. All Rights Reserved
Slide 4: The Basics – What do cleaners do?
The Basics – What do cleaners do? The cleaning task involves: • The removal of a soil from the surface of the material • More specifically, removing previous metal working fluids (dirt, fines, etc.) from processed parts • At the end of the cleaning process, the material is left unchanged/undamaged T
Slide 5: The Basics – Function/Purpose
The Basics – Function/Purpose Cleaning – Washing • Chips removal (Chips, fines, graphite…) • Soils removal (Grease, Drawing oil, Cutting neat oil, soluble oil, Quenching oil…) Rinsing (optional) • Minimize the amount of chemicals on the metal surface • Avoid the formation of residues during drying P
Slide 6: The Basics - Function/Use
The Basics - Function/Use • Used in aqueous solutions Drying • Typical dilution Cleaning Rinsing (3%) (0,5%) • Wash 1% - 20% • Rinse 0.5% - 1% • Application applications • Spray (medium and high spray) • Ultrasound • Immersion • Hand washing CONFIDENTIAL, DO NOT DISTRIBUTE QUAKER CHEMICAL - Confiden
Slide 7: The Basics - Function/Trends
The Basics - Function/Trends Washing temperature • Lower washing temperatures close to room temperature (30-35°C) • Provides energy savings Cosmetic appearance • Lowering part’s cleanliness thresholds. Parts must be clean with no visible residue Anti-corrosion protection • Avoids the use of oily rus
Slide 8: The Basics – Types of Metals
The Basics – Types of Metals Steel • Can be processed in a high pH range • Needs rust protection Aluminum • pH needs to be low or inhibited • Prone to oxide formation Yellow metals • Sensitive to amines CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 9: The Basics – Types of Soils
The Basics – Types of Soils • Coolants • Hydraulic Oils • Way Lubricants • Quench Oils • Cutting Oils • Drawing, Stamping, and Forming Compounds • Rust Preventives CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 10: The Basics - Water Based Soils
The Basics - Water Based Soils Cutting fluids/coolants are the most common type of water-based soil which include: • Assembly • Storage • Inspection • Coolant Change/Secondary Operation CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 11: The Basics - General Composition
The Basics - General Composition • Water • Alkalinity • Corrosion Inhibitors • Chelating/Sequestering Agents • Surfactants/Wetting Agents • Additives CONFIDENTIAL, DO NOT DISTRIBUTE 11 ©2019 Quaker Houghton. All Rights Reserved
Slide 12: The Basics- Alkalinity
The Basics- Alkalinity • Caustic: Allows heavy duty cleaning for difficult soils such as stearates, greases, varnishes, etc. • Carbonate: Provides alkalinity for cleaning. • Amines: Most frequent source of alkalinity. Typically, a blend of amines to allow for pH, alkalinity reserve, and special prop
Slide 13: The Basics - Corrosion Inhibitors
The Basics - Corrosion Inhibitors Ferrous • Carboxylate salts • Sodium Nitrite • Phosphate esters • Borate salts Yellow Metals • Benzotriazole/ Tolyltriazole Aluminum • Phosphate esters • Silicates CONFIDENTIAL, DO NOT DISTRIBUTE 13 ©2019 Quaker Houghton. All Rights Reserved
Slide 14: The Basics - Chelating/Sequestering Agents
The Basics - Chelating/Sequestering Agents Ethylenediamine tetra-acetic acid (EDTA) • Most effective for hard water stability • Downsides are corrosion • Waste treatment issues Citric acid • Light chelate for iron • Limited performance for hardness Polyacrylic acid • Good option for hardness control
Slide 15: The Basics - Additives
The Basics - Additives Biocides • Rarely used Defoamers • Modified polysiloxanes CONFIDENTIAL, DO NOT DISTRIBUTE 15 ©2019 Quaker Houghton. All Rights Reserved
Slide 16: Process and Equipment
Process and Equipment CONFIDENTIAL, DO NOT DISTRIBUTE 16 ©2019 Quaker Houghton. All Rights Reserved
Slide 17: Cleaner Process - Equipment
Cleaner Process - Equipment Different applications require different chemistries CONFIDENTIAL, DO NOT DISTRIBUTE 17
Slide 18: Cleaner Process - Washer Types
Cleaner Process - Washer Types Spray Immersion/Ultrasonics Maintenance/ • Most common • Less common Floor Cleaning • Higher throughput • Good cleaning for difficult • Floor Scrubber geometry • Longer sump life • Builds up soils • Many configurations • Slower process • Minimal emulsification • Good e
Slide 19: Cleaner Process - Spray Cabinet Washer
Cleaner Process - Spray Cabinet Washer • Parts loaded on conveyor lines and are carried through the washer • Large footprint • Continuous cleaning • Separated stages • Wash, rinse and RP stage CONFIDENTIAL, DO NOT DISTRIBUTE 19 ©2019 Quaker Houghton. All Rights Reserved
Slide 20: Cleaner Process - Clamshell Washer
Cleaner Process - Clamshell Washer • Top loading washer • Batch cleaning • Trays or baskets CONFIDENTIAL, DO NOT DISTRIBUTE 20 ©2019 Quaker Houghton. All Rights Reserved
Slide 21: Cleaner Process - Drum Washer
Cleaner Process - Drum Washer • Internal spiral unit to turn parts as they move through the washer • Good for small flat parts that may stick together • Size and weight limitations • Ruggedly constructed for optimal durability • Latest in spray system and dry off technology • Consistent high quality
Slide 22: Cleaner Process – Soak/Immersion
Cleaner Process – Soak/Immersion Advantages • Foaming • Can be Multi-metal • Good detergency • Good for difficult part geometry Disadvantages • High soil loading • Shorter system life • Needs adequate agitation • Possible foam issues CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 23: Cleaner Process – Spray vs Soak
Cleaner Process – Spray vs Soak Spray • Advantages • Disadvantages • Low foaming • Requires good impingement • Rust protection • Needs proper orientation • Oil rejection • Rinse/RP/Drying? • Longer sump life • Better filtration • Advantages • Disadvantages Soak • Foaming • High soil loading • Good d
Slide 24: Cleaner Process – Floor and Maintenance
Cleaner Process – Floor and Maintenance Properties • High detergency • General purpose maintenance cleaning • Moderate to high foam • Good solvency for cutting grease Uses • Floor scrubbers • Manual bucket cleaning • General maintenance cleaning CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 25: Cleaner Process - Drying
Cleaner Process - Drying Vacuum Dryer • Moisture can be evaporated in complex shaped places such as deep holes and tap holes. • Blow air supply is not required, to save energy. Automotive parts, electronic parts CONFIDENTIAL, DO NOT DISTRIBUTE QUAKER CHEMICAL - Confidential
Slide 26: Cleaner Process – Other Equipment
Cleaner Process – Other Equipment Disc skimmer Paper filtration Coalescence oil remover Dosatron or Dosmatic pump Belt skimmer CONFIDENTIAL, DO NOT DISTRIBUTE QUAKER CHEMICAL - Confidential
Slide 27: MW Cleaner Product Line
MW Cleaner Product Line CONFIDENTIAL, DO NOT DISTRIBUTE 27 ©2019 Quaker Houghton. All Rights Reserved
Slide 28: MW Product Line
Cleaners – MW Product Line Spray washer cleaners • Major sales group • Largest range Immersion cleaners • Minor sales group • Limited selection Floor/Maintenance cleaners • Support sales group • Minimal upkeep CONFIDENTIAL, DO NOT DISTRIBUTE 28
Slide 29: Good Spray / Immersion
Cleaners – Good Spray / Immersion • Low temperature • Non-nitrited spray cleaner • Non-chelating • Good for moderately hard water • Provides short term RP CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 30: Better Spray / Vibratory / Immersion
Cleaners – Better Spray / Vibratory / Immersion • Ultrasonic cleaning • Ford approval • Multi-metal CONFIDENTIAL, DO NOT DISTRIBUTE 30 ©2019 Quaker Houghton. All Rights Reserved
Slide 31: Better Spray / Deburr
Cleaners – Better Spray / Deburr • Dual-Purpose Cleaner with RP • Low foaming CONFIDENTIAL, DO NOT DISTRIBUTE 31 ©2019 Quaker Houghton. All Rights Reserved
Slide 32: Better Spray Cleaner
Cleaners – Better Spray Cleaner • Biostable • Oil splitting CONFIDENTIAL, DO NOT DISTRIBUTE 32 ©2019 Quaker Houghton. All Rights Reserved
Slide 33: Better Spray
Cleaners – Better Spray • Phosphate free • Biostable • High pressure spray • All metal CONFIDENTIAL, DO NOT DISTRIBUTE 33 ©2019 Quaker Houghton. All Rights Reserved
Slide 34: Better Spray
Cleaners – Better Spray • Nitrite free • Low residue CONFIDENTIAL, DO NOT DISTRIBUTE 34 ©2019 Quaker Houghton. All Rights Reserved
Slide 35: Better Spray
Cleaners – Better Spray • Good on all metals • Oil rejecting • In process RP CONFIDENTIAL, DO NOT DISTRIBUTE 35 ©2019 Quaker Houghton. All Rights Reserved
Slide 36: Best Spray
Cleaners – Best Spray • Biostable • Alkaline liquid spray cleaner • OEM Approvals CONFIDENTIAL, DO NOT DISTRIBUTE 36 ©2019 Quaker Houghton. All Rights Reserved
Slide 37: Best Spray Heat Treat
Cleaners – Best Spray Heat Treat • MEA and Nitrite free • Low residue • In process RP CONFIDENTIAL, DO NOT DISTRIBUTE 37 ©2019 Quaker Houghton. All Rights Reserved
Slide 38: Best Spray / Vacuum
Cleaners – Best Spray / Vacuum • Low foam • Rapid drying • Low residue • Thin film RP • QH EXOMAX P 6411 is the boron-free version CONFIDENTIAL, DO NOT DISTRIBUTE 38 ©2019 Quaker Houghton. All Rights Reserved
Slide 39: Best Spray / Vibratory
Cleaners – Best Spray / Vibratory • Low foam • Biostable spray cleaner CONFIDENTIAL, DO NOT DISTRIBUTE 39 ©2019 Quaker Houghton. All Rights Reserved
Slide 40: Maintenance Cleaners
Cleaners – Maintenance Cleaners • Central System cleaner • General sump cleaner CONFIDENTIAL, DO NOT DISTRIBUTE 40 ©2019 Quaker Houghton. All Rights Reserved
Slide 41: Maintenance Cleaners
Cleaners – Maintenance Cleaners • Machine tool and system cleaner • Can be added directly to coolant before dump CONFIDENTIAL, DO NOT DISTRIBUTE 41 ©2019 Quaker Houghton. All Rights Reserved
Slide 42: Floor Cleaners
Cleaners – Floor Cleaners • Non-hazardous • pH neutral • Low-cost maintenance cleaner • Compatible with Epoxy CONFIDENTIAL, DO NOT DISTRIBUTE 42 ©2019 Quaker Houghton. All Rights Reserved
Slide 43: Floor Cleaners
Cleaners – Floor Cleaners • Machine tool and system cleaner • Can be added directly to coolant before dump CONFIDENTIAL, DO NOT DISTRIBUTE 43 ©2019 Quaker Houghton. All Rights Reserved
Slide 44: Solvent Cleaner
Cleaners – Solvent Cleaner • Slower drying petroleum solvent for oily and greasy soils • Solvent cleaner • 100°C flash CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 45: CONFIDENTIAL, DO NOT DISTRIBUTE
CONFIDENTIAL, DO NOT DISTRIBUTE 45 ©2019 Quaker Houghton. All Rights Reserved
Slide 46: Troubleshooting
Troubleshooting CONFIDENTIAL, DO NOT DISTRIBUTE 46 ©2019 Quaker Houghton. All Rights Reserved
Slide 47: Troubleshooting
Cleaners - Troubleshooting What to look for • Physical appearance – reasonably clean looking bath • pH – loss of pH can mean biological issues or poor cleaning • Concentration control – by titration, not refractometer • Biological issues • Soil load – as soil increases cleaning decreases • Elements
Slide 48: Typical Problems
Cleaners – Typical Problems • Inadequate Cleaning • Corrosion & Staining • Biostability • Filtration • Foam • Residue • Control CONFIDENTIAL, DO NOT DISTRIBUTE 48 ©2019 Quaker Houghton. All Rights Reserved
Slide 49: Inadequate Cleaning
Cleaners – Inadequate Cleaning • Check Cleaner integrity • Check for process changes • Temperature • Time • Concentration • Check operation of washer • Clogged nozzles • Oil Skimmer not working • Check previous processes for change • New soils in process or changed CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 50: Corrosion and Staining
Cleaners - Corrosion and Staining • Steel • Rusting • Low pH, concentration, high bios, high hardness, high chlorides • Aluminum • Staining • Can be caused by alkalinity • Can be caused by hard water source and evaporation make-up • Alloy incompatibility • Mixed metals in contact CONFIDENTIAL, DO NO
Slide 51: Corrosion
Cleaners - Corrosion Causes: • Infection by Acid generating bacteria • Check infection carry-over from coolant from previous operation • Insufficient degree of protection from Degreaser • Concentration of product too low • Severe storage/atmospheric conditions • High chloride level in water supply •
Slide 52: Staining
Cleaners - Staining Causes: • Zinc and aluminium are attacked by alkalis and some amines • Copper is attacked by amines to form blue complexes Solutions: • Select product designed for these materials • Check compatibility in lab before making recommendation • Use amine-free or inhibited amine-contai
Slide 53: Biostability Issues
Cleaners – Biostability Issues Causes: • Concentration is low • pH is low • Previous soil contamination • Build-up in lines and overhead areas Solutions: • Biostable cleaners • Complete system cleanouts may be necessary from time to time • Keep tramp oil concentration as low as possible • Biocides (
Slide 54: Filtration
Cleaners – Filtration Increased Soil Load • Causes decreased free alkalinity to achieve cleaning • Dirty cleaner can redeposit soil on the part • Can result in excessive foaming in spray applications Use filtration and splitting additives to increase sump life • Polypropylene filters strip defoamers
Slide 55: Foam Issues
Cleaners – Foam Issues Causes: • Contamination from previous process fluid • Pumps drawing air • Poor air release from high turnover/low air release time • Low water hardness • Soap formation during cleaning • High foam Degreasers in Spray Washing Machines. • Incorrect operating temperature • Too Hi
Slide 56: Residues
Cleaners – Residues • Gaging or inspection • High Concentration • RP application • Subsequent processes • Soil build up • Water quality • Hard water soaps • Water Residue CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 57: Residues (White)
Cleaner – Residues (White) Causes: • Residues left after drying of inorganic-based Degreaser which has not been rinsed • Hard water salts from water • Concentration too high • Contamination of rinse fluid • Flash drying of parts Solutions: • Rinse with softened/deionised water +corrosion inhibitor •
Slide 58: Control
Cleaners - Control pH Control • Corrosion control • The higher the alkalinity, the fewer problems with steel corrosion • Biological control • Bacteria and fungus grow faster below pH of 9.0 • Excessive pH can lead to excess soap formation, excess foam, dermatitis Concentration Control • Refractomete
Slide 59: Monitor
Cleaners – Monitor Daily • pH • Concentration Weekly • Concentration • Tramp oil • Biological counts • Possibly metals analysis CONFIDENTIAL, DO NOT DISTRIBUTE 59
Slide 60: Lab Capabilities
Lab Capabilities CONFIDENTIAL, DO NOT DISTRIBUTE 60 ©2019 Quaker Houghton. All Rights Reserved
Slide 61: Lab Capabilities
Cleaners – Lab Capabilities • Spray Washers • Non-Condensing Humidity • Salt Spray • Foam • CICT • Tramp Oil • Bio CONFIDENTIAL, DO NOT DISTRIBUTE 61
Slide 62: Lab Capabilities Spray Washer
Lab Capabilities Spray Washer Large spray cabinets for panel and part processing CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 63: Lab Capabilities – Non Condensing Humidity
Lab Capabilities – Non Condensing Humidity Non-condensing humidity cabinet CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 64: Lab Capabilities – Salt Spray Cabinet
Lab Capabilities – Salt Spray Cabinet Salt spray cabinet CONFIDENTIAL, DO NOT DISTRIBUTE
Slide 65: Lab Capabilities – Blender Foam Test
Lab Capabilities – Blender Foam Test Blender Foam Test CONFIDENTIAL, DO NOT DISTRIBUTE 65 ©2019 Quaker Houghton. All Rights Reserved
Slide 66: Lab Capabilities – Cast Iron Chip Test
Lab Capabilities – Cast Iron Chip Test • Saturate cast iron chips • Rate results 0-4 heavy or light CONFIDENTIAL, DO NOT DISTRIBUTE 66 ©2019 Quaker Houghton. All Rights Reserved
Slide 67: Lab Capabilities – Oil Rejection
Lab Capabilities – Oil Rejection CONFIDENTIAL, DO NOT DISTRIBUTE 67 ©2019 Quaker Houghton. All Rights Reserved
Slide 68: Lab Capabilities – Bio Testing
Lab Capabilities – Bio Testing Bacteria and Fungi CONFIDENTIAL, DO NOT DISTRIBUTE QUAKER CHEMICAL - Confidential
Slide 69: Cleaner Questions
Cleaner Questions • Washer type? • Process cleanliness requirements and specifications? • Operating temperature, time and pressure? • Number of stages in cleaning process (rinse, drier)? • Presence of oil skimmer, filtration facilities? • Inter-stage corrosion protection requirements? • Life-time of
Slide 70: Questions?
Questions? CONFIDENTIAL, DO NOT DISTRIBUTE 70 ©2019 Quaker Houghton. All Rights Reserved
Slide 71: Thank You!
Thank You! CONFIDENTIAL, DO NOT DISTRIBUTE 71 ©2019 Quaker Houghton. All Rights Reserved