Introduction to VDA-19.1 and ISO-16232

1 Introduction to and ISO-16232 . Cleanliness control Particular contamination Dr. Sebastian Wex Contaminants on Surface Particulate and Filmic Contamination Go Together Particulate contamination Filmic contamination Filmic contamination provides adhesion for particles [ ]. Particulate contamination : Solid granular particles und fibers Filmic contamination : Thin layer of oily, waxy or greasy compounds 76689 Karlsdorf-Neuthard Germany 2. Contamination Categories Typical Contaminants Found on Component Surface Particulate Contamination Filmic Minerals Metals Salts Organic Oil/ Grease hard soft 76689 Karlsdorf-Neuthard Germany 3. Standardized Cleanliness Testing ISO-16232 and are the Most Common Directives World-Wide What is regulated in the norms? Selection of methods approved for testing How to apply and validate the test methods What is not regulated?

2 Which test method is suitable for a specific part Which cleanliness level to apply for a specific part See customer requirement 76689 Karlsdorf-Neuthard Germany 4. Cleanliness Testing Overview Three-Step Approach Standardized in and ISO-16232 . 1 Extraction of particles from component surface Filtration of contaminant particles on a membrane 2. 3 Analysis of contaminant particles (mass, size, numbers and type). 76689 Karlsdorf-Neuthard Germany 5. Cleanliness Testing Overview Three-Step Approach Standardized in and ISO-16232 . Liquid extraction Air extraction 1 Pressure-rinsing Internal rinsing Air jet extraction Ultrasound Agitation Air throughflow extraction 2 Analysis filtration Light optical from 50 m Light optical from 5 m SEM-EDX. Gravimetric Raman spectroscopy IR spectroscopy 3 Micro-CT LIBS. Standard analysis Extended analysis 76689 Karlsdorf-Neuthard Germany 6.

3 Particle Extraction Rinsing with Pressurised Liquid Jet Starting Parameters ( ISO-16232 ). Application Volume flow: l/min Fluid volume: 5 ml/cm2. Distance: max. 15 cm Single components Large surfaces Nozzle shape, diameter: round, mm Use cabinet or laboratory equipment Small parts Interior surfaces [ ] [ ]. [Hydac]. 76689 Karlsdorf-Neuthard Germany 7. Particle Extraction Rinsing with Pressurised Liquid Jet 76689 Karlsdorf-Neuthard Germany 8. Particle Extraction Ultrasonic Vibration Application Starting Parameters ( ISO-16232 ). Frequency 35-40 kHz Power density 10 Watts/liter Duration 30-60 sec Small parts in beaker Use cabinet or laboratory equipment Small parts in basket Single components [ ] [Sonorex]. [Hydac]. 76689 Karlsdorf-Neuthard Germany 9. Particle Extraction Ultrasonic Vibration 76689 Karlsdorf-Neuthard Germany 10.

4 Particle Extraction Internal Rinsing by Liquid Flow Application Starting Parameters ( ISO-16232 ). Volume flow 1-20 l/min (turbulent). Duration 15-60 sec Pulsation, reversal of direction Bores, feedthroughs Pipes, tubes Use cabinet or laboratory equipment Coolers, housings [ ] [Sartorius]. [Hydac]. 76689 Karlsdorf-Neuthard Germany 11. Particle Extraction Agitation by Shaking Application Starting Parameters ( ISO-16232 ). Volume filling 40-50%. Amplitude 30 cm, Frequency 1 Hz Time 15-60 sec Containers Pressure tanks Use cabinet or laboratory equipment Do not! Large tubes Small components [ ]. 76689 Karlsdorf-Neuthard Germany 12. Cleanliness Testing Overview Three-Step Approach Standardized in and ISO-16232 . Liquid extraction Air extraction 1 Pressure-rinsing Internal rinsing Air jet extraction Ultrasound Agitation Air throughflow extraction 2 Analysis filtration Light optical from 50 m Light optical from 5 m SEM-EDX.

5 Gravimetric Raman spectroscopy IR spectroscopy 3 Micro-CT LIBS. Standard analysis Extended analysis 76689 Karlsdorf-Neuthard Germany 13. Analysis filtration Direct-Filtration filtration funnel analysis filter Filter holder [Hydac]. Vacuum source [VDA-19]. Cleaning cabinet 76689 Karlsdorf-Neuthard Germany 14. Analysis Filtration Deposition of Contaminants on a Membrane by Vacuum Filtration Filtration funnel Analysis filter Filter holder Vacuum source Vacuum flask Laboratory equipment for vacuum filtration 76689 Karlsdorf-Neuthard Germany 15. Analysis Filtration Vacuum Filtration Unit 76689 Karlsdorf-Neuthard Germany 16. Drying of Membrane Preparation for filter analysis 76689 Karlsdorf-Neuthard Germany 17. Analysis filtration Well-prepared membrane 76689 Karlsdorf-Neuthard Germany 18. Cleanliness Testing Overview Three-Step Approach Standardized in and ISO-16232 .

6 Liquid extraction Air extraction 1 Pressure-rinsing Internal rinsing Air jet extraction Ultrasound Agitation Air throughflow extraction 2 Analysis filtration Light optical from 50 m Light optical from 5 m SEM-EDX. Gravimetric Raman spectroscopy IR spectroscopy 3 Micro-CT LIBS. Standard analysis Extended analysis 76689 Karlsdorf-Neuthard Germany 19. Cleanliness Specifications Typical Requirements from the Customer Particle mass Particle size Particle material Example: Example: Example: Total particle mass less No particles larger than No abrasive particles of than 5 mg per 1000 cm . 400 microns allowed, soft quartz, corundum, silicon fibers are tolerated. carbide allowed larger than 100 m. test complexity equipment cost 76689 Karlsdorf-Neuthard Germany 20. Gravimetry Determination of Particle weight 76689 Karlsdorf-Neuthard Germany 21.

7 Standard Analysis Determination of Particle Size and Number By Microscope or Scanner Standard Analysis > 50 m [Leica]. [Zeiss]. [RJL]. Particle size 76689 Karlsdorf-Neuthard Germany 22. Standard Analysis Typical Cleanliness Report on Three Pages 76689 Karlsdorf-Neuthard Germany 23. Comparison to Light Microscopy Light-optical analysis using a light microscope or scanner particle scanner light microscope Particles > 25 m Particles > 5 m (model dependant). fast (2 minutes + reporting) widely used standard low investment, maintenance free high image quality, variable magnification Imaging of entire membrane sequential analysis of fields, stitching 76689 Karlsdorf-Neuthard Germany 24. Comparison to Light Microscopy Excellent Correlation of MicroQuick and Five Light Microscopes (6/2014). MicroQuick (green bar).

8 Others: Leica, Zeiss, Jomesa 76689 Karlsdorf-Neuthard Germany 25. Identification of Metallic Particles Determination of Particle Material by SEM-EDX. Electron Microscopy (SEM) with X-Ray Spectroscopy (EDX). automated measuring of particle size, number and material smallest particles from m Determination of origin of particles gez hlte R ntgenquanten Peak-Height =. Weight proportion [FEI]. X-ray energy (keV). 76689 Karlsdorf-Neuthard Germany 26. Automatische Partikelanalyse Aspex Automated Feature Analysis (AFA) im Video Steels Coatings Non-ferrous metals Abrasive Minerals Cleaner 76689 Karlsdorf-Neuthard Germany 27. RJL Micro & Analytic GmbH. Analysis Services & Instruments | From One Source Product Lines Particle Scanner (MicroQuick). Compact SEM-EDX (Coxem). X-Ray Micro & Nano-CT (Bruker). Digital 2D X-Ray Imaging (Kubtec).

9 Contract Analyses Cleanliness Testing Determination of Foreign Particles With Accreditation DIN EN ISO/IEC 17025. Karlsruhe 76689 Karlsdorf-Neuthard Germany 28.