Our cleaning philosophy for: optimum and reproducible cleaning results!
Basic principle n°1: First remove oil and grease
There are 3 main reasons why the removal of the oil and grease film from the casting must be given top priority:
- It is easier to wash off the boring and cutting emulsion as long as the casting is still wet than to do that when the water portion has already evaporated.
- Optimum bath maintenance is especially laborious when there is oil or grease present. Simply removing demulsifying oils is by no means sufficient. That is why it is indispensable to use micro-/ultrafiltration or coalescence separation for the removal of oil emulsions.
- It might happen that extremely small metal shavings which cling to the casting due to the adhesive forces of the oil cannot be completely removed by the subsequent mechanical cleaning.
Basic principle n°2: Bath maintenance
As far as possible, subsequent castings must be treated under the same conditions as the casting treated first.
To achieve this, it is necessary to immediately remove the dirt carried into the bath so that the chemical function of the cleaning agent can be kept constant all the time during the process.
Basic principle n°3: Matching of cooling lubricant, chemical cleaning agent and oil separation
Both cooling lubricant and degreasing agent are highly complex chemical compositions.
This is why the individual elements to be used must be very carefully matched.
Additionally, an adjusted and optimized oil separation technology can reduce the consumption of tensides considerably.
Basic principle n°4: Avoiding carryover of dirt
Leaving the cleaning bath, the castings must be spray-washed with freshly-cleaned cleaning agent or water and, if necessary, be blown off.
Basic principle n°5: Choosing the most efficient process for the removal of tenacious particles and metal chips
In the case of castings with complex inner geometries, conventional methods are not able to bring the energy level needed for the mechanical cleaning process into the casting. To solve this problem, the CERABITE® shock wave process efficiently combines two physical effects arising during the generation of underwater capacitor discharge.
- The shock wave which is created from the injection of the discharge channel (plasma channel) into the water spreads with high frequency of approx. 85 kHz and high pressure level reaching sound velocity. Due to the different impedances between water and metal the shock wave is reflected at the inner walls of the casting and thus reaches every area of the cavities. In this process, impurities are broken up and loosened.
- The high temperature of the plasma channel creates a steam bubble which accelerates the surrounding water to a velocity of several hundred meters per second. This leads to extremely strong water flows flushing through the casting.