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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 parameters. 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 condition 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 approximately 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-

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c. L * '. ed. Automatic water level controls should be included with t h e tank to maintain

the solution levels during and between operations.

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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 ultrafiltration 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.

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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


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


, Warm Water ' Rinse 90-14OoF _I

Pilot Line Process Flow (Cont'd)

Yes ,


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Water Break- Dry or Continue Free Surface Wet Processing

Condition 2 (Skip Alkaline Cleaning) *

GS91-0715-020

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Alk" BAC 5749

EMULSION CLEANING

Warm Water Water Break- Free Surfaces hinse 90-l4O0F

4


, VaDor Dearease Yes AC 5408

Pilot Line Process Flow (Cont'd)

Alkaline Clean Warm Water BAC 5749 Rinse 90=14O0F


Condition 3 (Salvage Production Parts) Goal

Water Break Surfaces

I

Water Break- I Free Surfaces


pH Versus Daraclean 282 Concentration -


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

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5

3 0 2 4

Number of mls 6

GS810715.08

. -


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


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

. -


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 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%


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 "


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


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 "

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65.5OC (1 56")


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)


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



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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65m5OC 6585OC (150°F) I (150°F)

3% Contaminant

65.5OC (150°F)

Daraclean Conc. No8 mls


Alka Ratio Emuls, Oil



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

1817 81 OYO I*

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)


(140°F) 2 " 2 " 2 "

86.7240


(140") 2 " 2 " 2 "

86.9%

Daraclean Conc. No. mls


Alka Ratio Emuls. Oil



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

3OYoI 11%

1.18 I 1.21

6OoC I 60°C

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Emulsion Cleaning Effectivity Matrix

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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


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


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




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




GS9i-0715-013



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



GS91-0715-014

EMULSION CLEANING

Conc.


5% 8% 9% 10%


38OC 49OC

2 Min / IOOOF Cleaning Ability 2 Min / 120°F Cleaning Ability


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




GS91-0715-015

EMULSION CLEANING

Conc.


I 5% 8% 9% I OYO


38°C 49°C

2 Min / IOOOF Cleaning Ability 2 Min / 120°F Cleaning Ability

Boeing Commercial Aiplanes, Wichita Division


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




GS91-0715-016

EMULSION CLEANING

~~ -~

2 2 2 2 2 2 2


2 2 1 2 1 1 2 1 1 2 1 1 2 2 1 2 1 1 2 21 1



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



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


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



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




GS91-0715-020

EMULSION CLEANING

~

5% 2 2 2 2 2 I 2 2 2


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


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


GS91-0715-019

EMULSION CLEANING

1987 1988 1989


. .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


.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


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


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


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 \


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


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


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


Summary Boeing Commercial Airplanes, Wichita Division

. Evaluated emulsion cleaner manufacturing performance

Developed solution control parameters

Developed cleaner regeneration technology

Investigated process waste disposal

05910715.02

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