Clean aluminium sustainably and efficiently
MACHINING & MACHINERY CLEANING WITH PURPOSE
KLUTHE
Clean aluminium sustainably and efficiently
Innovation combined with sustainability forms the foundation for long-term viability in the metalworking industry. A US plant belonging to a leading german automotive supplier, which manufactures high-quality transmissions for both e-mobility and combustion engines, is demonstrating this through the optimisation of its aqueous alkaline cleaning process.
The challenge was to consistently achieve the required cleanliness standards for the aluminium die-cast housing after ultrasonic immersion cleaning. In addition, the service life of the cleaning baths needed to be significantly extended, from one week to up to three weeks, while maintaining a constant throughput of parts. This was an ambitious objective that required a comprehensive analysis of the existing processes, including upstream machining operations.
The company identified the solution by switching to HAKUFLUID ® 185, a mineral oil-free, water-soluble coolant and HAKUPUR 439-1, an efficient parts cleaner designed for sensitive aluminium alloys. Both products from Chemische Werke Kluthe promised reduced environmental impact without compromising performance.
Consistent achievement of cleanliness standards
Following successful trials conducted in collaboration with the chemical manufacturer’ s applications engineering department, it became clear that the cleanliness requirements were consistently met thanks to the coordinated combination of oil-free coolant and a pH-neutral parts cleaner.
Taking a holistic view of the entire process chain was the key to success.
The reason was that the previously used oily coolant no longer floated on the surface of the cleaning bath and therefore no longer re-contaminated the gearbox housing when it was removed from the ultrasonic immersion bath.
On this basis, all seven cleaning systems were converted to the new neutral cleaner. The cleaning process consists of ultrasonic immersion cleaning combined with a spray process.
Extended service life through oilfree coolant
At the same time, the upstream machining operations were also converted to the oil-free coolant; Initially the aluminium production lines and, three months later, the steel lines as well. These adjustments resulted in a cleaning bath that remained foam-free and clear even after several weeks of use, a condition that had previously been impossible due to increasing levels of tramp oil from the coolant. Previously, this had led to additional work, nonconforming parts and shorter bath service life.
Even after three weeks under full load, the workpieces continued to meet the requirements of the 100 % cleanliness test.
Energy savings through lower cleaning temperatures
Another decisive step was reducing the bath temperature from 60 ° C to 40 ° C, contributing to considerable energy savings whilst maintaining high cleaning performance. The temperature was reduced gradually in steps of 5 ° C to ensure process reliability. The long-term biostability of the cleaner proved convincing. User acceptance was high, and the resulting energy savings represent a clear step towards cost reduction and resource conservation.
This practical example from the US manufacturer demonstrates how existing processes can be reevaluated and improved to reduce environmental impact while simultaneously minimising production costs.
Taking a holistic view of the entire process chain was the key to success. It shows that investing in sustainable technologies not only benefits the environment but also enhances efficiency and product quality.
For further information, please visit www. kluthe. com
106 PECM Issue 79