Category Archives: Cleaning Applications
Water break testing. Dyne pens. Goniometer. No method at all.
The search for a reliable, repeatable, objective method (i.e. not based on opinion) for measuring surface readiness in manufacturing was a search all too common among our current customers, and these methods are the most commonly tried and (formerly) used among them.
Achieving great adhesion in manufacturing comes down to surface preparation (we call it “Clean to a Number”) and optimal surface prep is the difference between an average product…and an industry-leading one.
But getting there means having an objectively quantified understanding of the top 3 molecular layers of your material surface.
Did we just say “top 3 molecular layers?”
On May 21-24, BTG Labs heads back to Long Beach, CA but this time for the SAMPE 2018 Conference & Exhibition.
Recently in Long Beach for AeroDef, one of the aerospace and defense industries’ most widely recognized conferences, BTG Labs now contributes to this tradeshow that features “the latest technologies and research advancements in the industry.” Maybe you’ve heard of a little instrument called The Surface Analyst?
New industry buzzword?
Or a new generation of process and quality control?
Parts washers play an integral role in manufacturing, especially on machined parts and bonding surfaces. Prior to coating, sealing, painting, and welding, parts washers help remove contaminants generated from fabrication to facilitate stronger bonds.
But, for a reliable bond to form, the surface must not only be free of particles, it must also be chemically clean. Thus, quantifying and analyzing parts washer effectiveness in removing chemicals is the key to ensuring the desired surface is achieved.
The importance of monitoring cleaning processes in preparation for bonding is becoming increasingly necessary as sealing processes are rapidly replacing traditional mechanical fasteners and gaskets.
However, when sealing, the surface must be clean and clear of contaminants to guarantee the bond. The Surface Analyst monitors and optimizes washer systems to ensure the part comes out chemically clean and ready to hold a reliable bond. …Read More
BTG Lab’s recently held another successful webinar. Hosted by Products Finishing and presented by Dr. Giles Dillingham, the webinar emphasized the importance of monitoring cleaning processes and explored different ways to measure surface cleanliness.
In the webinar, Dr. Dillingham discusses measuring surface cleanliness as a way to quantify cleaning processes. By measuring the success of cleaning processes, manufacturers can determine the ideal solution for their application.
Precisely evaluating cleaning processes with water contact angle is a fast, easy, accurate, quantitative to way to gain ensure consistency and precision on the factory floor.
Challenges often arise when verifying critical surface processes on the factory floor when measuring hard to reach areas and varying angles. The Surface Analyst conquers those challenges with the unique ability to measure on vertical surfaces, which include assembled parts and hard to reach spots. This allows for easier surface analysis on the factory floor.
A few examples of the Surface Analyst’s ability to measure on vertical surfaces on the factory floor:
- Airplane wings prior to bonding, painting, and repair
- Canopy of jet fighters after cleaning
- Wind turbine blades prior to bonded repair
- Silkscreen bottles post flame treatment
- Ship hulls prior to painting and bonding
- Interior of automobile headlights prior to application of anti-fog coating
- Windshield bond lines prior to sealing
- Class A paint surface for decals applications and reapplications
- Measuring appliances after metal cleaning and prior to power coating
Thanks to advancements in powertrain manufacturing, sealing processes have improved assembly efficiency. Formed-in-place gaskets (FIPG) are replacing traditional mechanical fasteners as they are more cost effective, stronger, and easier to apply. However, adhesive bonding rather than mechanically fastening presents different challenges and requires new protocols.
Lead Sales Engineer Lucas Dillingham has presented “Defining Cleanliness in Powertrain Manufacturing for FIPG Applications,” at several events and automotive factories. BTG Labs works with numerous automotive manufacturers on surface chemical cleanliness and what it means for assembly.
Traditional millipore tests reveal particulate contamination, but on a sealing surface, one must detect chemical contamination. To adhere successfully, surface cleanliness on a chemical level is vital.
A byproduct of automotive manufacturing processes is contaminants that are detrimental to adhesion. Processes entailing unwanted contaminants include:
Every year for Memorial Day weekend, my family would pack up the station wagon and head to the lake. The weekend would be filled with red, white and blue, firing grills, festive picnic tables, and bathing suits. My mother would chide me to apply sunscreen before doing anything. And time after time, I would jump in the pool first. The sun screen could wait. I had been pining all winter for the water and some smelly, greasy paste wasn’t going to stop me.
And then I would fry.
I’ve since learned to appreciate the importance of sunscreen, but perhaps that is because it is much better than when I was younger. It’s less greasy and smelly, can withstand sweat and water, and better absorbs into the skin—thankfully preventing that touristy semblance.
Skin care manufacturers work constantly to improve their brand. With a product that works so intimately with the human body and at times for important applications such as UV protection, failures are not acceptable. Yet, developing skin care products comes with challenges. Testing on artificial skin falls short of the real thing as skin types vary greatly. However, in-vivo testing is nearly impossible. …Read More
Manufacturers are all too familiar with the challenges of getting a bond to stick and hold. The success of a bond relies on the surface created prior to that bond, so, monitoring and measuring surface processes is the only way to know that the surface is ready to bond reliably.
BTG Labs’ President Tom McLean and Sales Engineer Lucas Dillingham presented during Plasmatreat’s Open House on the 4 Surface Fundamentals for Successful Bonding in Manufacturing. They presented to industry leaders who can easily relate to bonding and cleaning issues. The presentation was such a success that BTG Labs decided to turn it into a webinar.
Challenges with establishing a strong, reliable bond, when painting, coating, sealing, or printing are tied into the surface preparation process and the ability to monitor that process. This presentation focuses on the bond surface and what it takes to bond properly to that surface. There is also a comparison of various cleaning methods using contact angles taken with the Surface Analyst.
While other monitoring processes such as dyne and water break fail to provide quantitative insight, monitoring cleaning processes with the precise and quantitative Surface Analyst tells the user, objectively, whether the surface is properly prepared to hold a reliable bond. …Read More
Manufacturers working with metal are all too familiar with the obstacles that come along with coating, painting, bonding, printing, or sealing it. While the uses of metal in manufacturing are countless and exist in numerous industries, the common denominator is ensuring the appropriate surface cleanliness prior to surface critical processes to guarantee successful adhesion. Common surface cleanliness gauges—dyne inks and water break—are subjective and do not offer quantitative results. Water break can be messy and time consuming and dyne is destructive to the part and dangerous to the user. While these methods can offer some insight into surface cleanliness, they are less than ideal.
BTG Labs Surface Analyst is a fast, easy, accurate, and non-destructive surface cleanliness gauge that tells the user right on the manufacturing floor how prepared the surface is to bond. This hand-held instrument improves surface processes and guarantees a bond will stick. Numerous manufacturers in industries such as consumer goods, automotive, and aerospace, have implemented the Surface Analyst in their specifications to improve their critical metal surface processes. …Read More