PARTS WASHER
with details on FPI liquid penetrant test equipment.
Industrial parts washers can be effectively used to save labor and time cleaning parts. Cleaning systems can also save money by providing clean and dry parts to the next process, eliminating component rejects and quality issues.
Parts washers can be broken into three categories:
- Aqueous parts washer
- Solvent parts washers
- Metal Finishing and NDT such as FPI and Passivation
There are dozens of parts washing technologies and cleaning systems suppliers. This overview will hopefully show some possible industrial wash equipment that might suit your requirements. Often parts testing is required to determine the optimal cleaning system, the proper cleaning solutions, and to fine tune any rinse or drying cycles required.
Cellular Parts Washers
New England Sales offers a broad range of cellular parts washers ideal for cleaning parts on an as produced continuous flow basis. These cellular parts washers range from simple manual sink style industrial washers, to top loading spray wash stations, to dunk style cleaning tanks which agitate and turbulate the bath, often called immersion washers. For site with limited cleaning fluid disposal, we can provide closed loop fluid recycle systems to eliminate waste and fluid discharge to drain.
We offer the following cellular washers:
Kleentec- recirculating sink style Kleentec parts washers - available aqueous and non-aqueous solvent style fluids.
Ramco- single station immersion parts washers, and multi-station agitating, turbulating washers. Parts dryers can be stand alone or integral to the system for dry corrosion free parts at the end of the cleaning cycle.
JRI Industries- top loading single station spray washers, multi-station rotating table spray washers, and inline tunnel style spray washer systems.
Almco Innovance – Spray cabinet washers and Inline belt conveyer wash systems
Proceco – large part aqueous washers, automated cleaning systems, hydro-deburring, and metal finishing systems
Vapor Degreasing
New England Sales and Durr Ecoclean offer an environmentally friendly closed loop cleaning and degreasing system. This uses a cleaning oil an alternative to existing vapor degreasing solvents which are ozone depleting and can have serious health and environmental effects. The Durr Ecoclean systems uses a common safe commodity hydrocarbon called isoparafin, which is very effective at cleaning parts which are soiled with oil, chips, dirt, and debris. The Durr vacuum technology and closed loop design allows the isoparafin to clean effectively and perform like classic chlorinated solvents such as Tri and Perc.
The Durr system recovers the cleaning fluid on board by distillation for reuse and to eliminate waste. There are no air permits or other discharges to deal with using the Durr Vapor Degreasing System. Since the isoparafin is a simple hydrocarbon like the oil it cleans from the parts, any oil removal from the system is disposed of as common waste oil. There are no regulated disposal issues, no cradle to grave liability associated with isopar. Unlike other solvents used in vapor degreasing, there is no acidification of the isoparafin so you don’t have to continually change the fluid inventory.
The Durr system first injection floods the parts, can rotate and oscillate to agitate if required, has optional ultrasonics cleaning if needed, and then vapor degreases the parts. The final step is to completely dry the parts under vacuum – providing a very clean and bone dry part at the end of the cleaning cycle.
Spray Washers
New England Sales, Inc. offers spray washers of all type, sizes and configurations from the simplest cellular single station machine to the largest high capacity production washing system. We distribute products for:
JRI Industries specializing in pre-engineered standard Top Loading and Front Loading single station and multi-station Spray Cabinets and cellular belt washers
Almco Kleentec specializing in custom designed Front Loading Spray Wash Cabinets. Rotary Drum Washers, Continuous Belt Washers and U-Bend Belt Washers. Almco
Kleentec washers can be configured for wash only or wash, rinse and dry.
Proceco – large part aqueous washers, automated cleaning systems, hydro-deburring, and metal finishing systems
Belt Washers
New England Sales, Inc. offers belt washers of all sizes and configurations from the simplest cellular single station mini belt to the largest high capacity continuous production belt washing system. We distribute products for:
Almco Kleentec specializing in custom designed Continuous Belt Washers and U-Bend Belt Washers. Almco Kleentec washers can be configured for wash only or wash, rinse and dry.
JRI Industries specializing in pre-engineered standard cellular belt washers.
Proceco – large part precision aqueous washers, automated belt and tunnel spray wash cleaning systems, and material transport systems to automate load and unload of difficult to maneuver components
Immersion parts washers
Agitated parts washers are an effective parts cleaning technology used for Aqueous Based Parts Washing Systems.
RAMCO manufactures single station and multi-station modular parts washing systems to meet a wide variety of industrial needs. Systems can be custom designed using pre-engineering standard products. RAMCO immersion parts washers feature: agitation, turbulation, solution spray and ultrasonics to handle even the most difficult cleaning requirements. RAMCO’s system design is ideal for other chemical processes including Passivation, Chromating, Alodine, and Fluorescent Penetrant (FPI). Manual, semi-automated and fully automated systems are offered.
Proceco – large part aqueous washers, automated cleaning systems, hydro-deburring, and metal finishing systems
Parts wash rinse dry system
Ramco’s multi-station parts washing systems can be configured to meet any parts cleaning requirement. The system can be configured to include one or more wash stations, one or more rinse stations including cascade rinsing and Ramco’s unique recirculating Blow Off Dryer.
Ramco’s multi-station systems can be offered in a semi-automated configuration where each station is automated but the work transfer is manual or in a fully automated configuration where work is placed ion the load conveyor and automatically proceed through the system
Almco Innovance – Continous inline belt conveyer wash/rinse/dry systems
Proceco – large part aqueous washers, automated cleaning systems, hydro-deburring, and metal finishing systems
FPI - Liquid Penetrant Test Systems
It is becoming more common to automate FPI systems to eliminate labor, reduce operator error, provide precision cleaning and application of penetrant and developer to the parts, and to provide repeatable and documented NDT results. Some typical systems we provide include:
Ultrasonic heated immersion wash
Immersion rinse
Dryer
Cool down
Penetrant immersion with dwell (water or oil based)
Spray rinse to remove penetrant
(for oil based penetrant, emulsifier rinse is used and optional second immersion rinse)
Dryer
Application of dry developer
Parts are then inspected in a black light read booth
Pre Cleaning Methods
The success of the FPI liquid penetrant test depends on proper processing during each step. Pre cleaning of the parts is the first step in a successful FPI test. Parts must be clean and dry prior to applying any penetrant. Pre cleaning is done to assure the penetrant has complete access into any discontinuities without being affected by soils and contaminants on a dirty part. If cleaning, the first step, is not done properly, all the following processes including penetrant and developer will be ineffective.
Examples of soils are:
--dirt
--rust and corrosion
--scale
--lubricants and cutting oils
--water
--paint and coatings
--chemical residues
--dry penetrant
Typical pre wash steps:
Ultrasonic cleaning - Ultrasonic parts washing uses high-frequency vibrations. Parts are immersed in a cleaning solution bath that is subject to high frequency vibrations from a generator. This cleaning station typically will be an immersion style, with agitation and turbulation of the cleaning bath for effective parts cleaning.
Rinse – agitated immersion tanks thoroughly and properly rinse the parts to remove any excess cleaning solution
Dry – parts are completely dried
Cool down station – parts are cooled for proper temperature prior to penetrant application
Penetrant Application Methods
There are various methods for applying penetrant. The method chosen for penetrant depends on the size of the parts, and specifications for FPI on the particular part. The different methods of applying penetrants are:
--dipping or immersion
--brushing
--spraying
--electrostatic
Immersion of parts is very effective and controlled, but must be followed by adequate drain or dwell time. This method is suitable for small to large parts, the only limitation is the size of the tank required and we offer tanks that can handle any part which would be run thru FPI. Multiple small parts are handled in wire baskets designed properly for the components. The process is to dip parts for the proper time to ensure that all the surfaces to be inspected are wetted, and thenfollowed by removal from the tank (either dwell in tank vapor space or in a dwell station) for draining for the remainder of the dwell time. This dwell in the tank top reduces waste and carryover by allowing much of the excess penetrant to drain back into the dip tank.
Spraying can cover large areas
Spray systems include spray guns and aerosol application. Spray application are often used in automated penetrant lines. Aerosol spray cans are useful for small scale testing and spot checks.
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Penetrant Removal
Excess surface penetrant must be totally removed so it does not interfere with interpretation of indications. Methods of removal are:
--Water washing.
--Penetrant emulsification followed by water rinse.
--solvent removable.
This is a critical step in FPI penetrant testing as insufficient removal can result in false indications and/or masking of flaws/indications because of excessive background dyes. For excessive removal you can dilute penetrant within the flaws and reduce sensitivity. For fluorescent dyes, removal can be checked out under black light.
Water washable penetrants
Water based penetrants are formulated with emulsifiers in the penetrant itself. When mixed with water, the penetrant will disperse readily. The excess penetrant can be readily removed by immersion in an agitated water tank like the Ramco immersion system. The process is critical, and time/pressure in spraying and immersion is required to ensure adequate surface washing, and to avoid over-washing.
Water spray rinse
There are two types of emulsifiers that can be applied after the penetrant dwell. These emulsifiers operate in different ways and have different processing methods.
Lipophilic
Lipophilic means oil loving and describes the emulsifier’s affinity for oil-based penetrants, into which it readily diffuses and dissolves. Parts are immersed in emulsifier, or wetted by flowing, then allowed to drain.
Hydrophilic
Hydrophilic emulsifiers are water-based surfactants that act like cleaning detergents. With proper parts agitations, the cleaning action removes the film of penetrant. Emulsifiers are pre mixed in water before use for proper concentrations. If applied by immersion, it is recommended to assist with some means of proper agitation.
Dry powder developer
Parts must be completely dry before the developer step, the agitated Ramco parts dryer works very well for PFI parts drying. Dry developer is usually composed of extremely fine particles and can be applied by dusting the parts. We often utilize a sealed “developer dusting” chamber which test parts are placed and the powder is applied by a storm like fan action. In some designs, we filter the air in the storm application chamber to remove airborne particles. Some systems call for single use developer.
The powder gives an extremely thin, almost invisible coating that clings to the exposed penetrant surface at discontinuity areas. This provides the capillary paths for the penetrant to bleed out. There are a few different dry developer application methods which can be supplied.
Inspection for Indications
For inspection to be effective, it is necessary to have proper lighting conditions.
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Interpretation of Indications
Indications are classified as relevant, non-relevant, and false. The benefit of semi and automated FPI systems are eliminating operator error, and providing a precise and documented, repeatable process. False indications are often caused by poor technique. With a repeatable process and less errors system payback time is often very fast.
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Post-cleaning
Post FPI cleaning is typical to Remove Residues of Liquid Penetrant Media
Post cleaning is required if penetrant residues and developer powder interfere with downstream subsequent processing. Post cleaning is easiest when done quickly after the test, as the developer becomes harder to remove as allowed to dry. Methods of removal are chosen to suit the type of penetrant and developer that were used. For water based penetrants the water rinse or agitated immersion wash method is best. Oil based penetrants respond best to emulsifiers and solvent cleaning. Baked on developer can be removed by pre-soaking, then using a spray detergent wash, or immersion and agitation type cleaning.
Test records and reporting
FPI procedures should be documented and tested components should be marked to indicate conformance to acceptance specifications
FPI SYSTEM by Ramco
Ramco and New England Sales have become a leading supplier of precision FPI (fluorescent penetrant inspection) equipment for the aircraft and aerospace industry including precision bearings and aerospace components. FPI equipment is also standard for medical components, medical implantables, and surgical instruments. Ramco has taken NDT (non destructive testing) and FPI to a new level of precision accuracy with our semi automated and completely automated FPI equipment and systems.
In addition to the FPI process it self, Ramco can also provide the pre wash equipment , or pre-inspection preparation steps which typically include an ultrasonic wash, immersion rinse, parts dry and cool, and any etching if required. Post FPI cleaning steps can also be provided as part of the package. Ramco systems are applicable for Oleophilic oil based FPI and Water Washable dye penetrant specifications. Ramco can provide immersion style penetrant application or spray style penetrant application as well as precision rinsing by controlling the time, temperature and pressure to properly rinse without over-rinsing penetrant. Ramco FPI systems are easily configured for the latest specifications for “single use penetrant” and “single use developer” requirements.
New England Sales can help specify a system to automate each step to eliminate the variability of manual operations. The Ramco fully automated system performs all the functions of semi-automated systems plus automatic transfer of the work from the load station through to the Read Booth. We have extensive details on FPI systems – call us and we can provide any technical details you need and equipment pricing upon request.
Passivation System by Ramco
Metal Surface Finishing
Ramco and New England Sales offer agitating parts washing technology which is easily adaptable to many chemical surface finishing processes including Passivation, Alodine, Chromate, Acid Etching and others. Ramco offers both semi automated and fully automated Passivation Systems including Nitric Acid Passivation and citric Acid Passivation equipment.
Ramco’s semi-automated systems take the guess work out of process compliance by automating each step of the process. The agitation and turbulation parts immersion technique can accelerate the Passivation process for either Nitric or Citric Acid applications. The fully automated systems will take work placed on a load conveyor though the entire passivation equipment line with no operator labor or attention.
Ramco Citric Acid based Passivation systems can be provided with Ultrasonics to further accelerate the process when required. These Passivation and Surface Finishing Systems are reliable, repeatable, environmentally sound and certifiable to meet the robust and demanding requirements of the medial industry, aircraft and aerospace , and general heavy duty and precision metalworking and manufacturing.
Metal Surface Treatment, FPI System, and Metal Finishing by Proceco
Proceco and New England Sales offers metal surface treatment systems including iron, zinc, manganese, phosphate conversion coatings, acid pickling, and rust and corrosion protection.
--phosphate lines
--Inline immersion rust and corrosion protection, RP application
--Anodizing
--Decontamination
--Deoxidizing
--Desmutting
--Etching
--FPI and LPI, Fluorescent penetrant inspection systems
--Passivation – nitric and citric acid passivation lines
--Phosphating
--Pickling
--Rust-inhibiting
--Hydro Deburring
--High speed CNC hydro-deburring systems
For more information on any part washer or metal finishing systems, please contact us at sales@newenglandsalesinc.com or call us at 781-826-8855.
NEW ENGLAND SALES – servicing the northeast including CT, MA, RI, ME, VT, NH, and NY
PARTS WASHER AND INDUSTRIAL PARTS CLEANING SYSTEMS
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