Dr. Darren Williams

PF: Why have you devoted much of your academic career to cleaning research?

DW: I’m driven to use my skills to serve others, make a difference and be a valuable contributor. During a solvent substitution project for the Department of Energy in 1998, I realized that very few academic researchers were focused on cleaning research. I found my niche. My Cleaning Research Group is improving the safety, effectiveness and environmental impact of cleaning processes. This is my way to make a difference serving others because every product ever made has to be cleaned.

PF: Do you foresee a large change in cleaning requirements in the U.S. similar to what VDA-19 did to Europe?

DW: The Lautenberg Chemical Safety Act amended the Toxic Substances Control Act and this will impact all companies that use n-propyl bromide, trichloroethylene, n-methyl pyrrolidone, methylene chloride and many other popular and effective cleaning solvents. Find out more at epa.gov/chemicals-under-tsca. As for European standards, they almost always impact U.S. suppliers. Many attendees of the Product Quality Cleaning Workshop were interested in VDA-19 and ISO 16232 requirements for particle contamination.

PF: What’s the best piece of advice you were given?

DW: There are three: My father said “the measured task gets done” and this has been both the secret to my success and an explanation of my failures. Proverbs 15:22 says, “Without counsel, plans fail; but with many advisers they succeed.” Ask questions, form teams and don’t try to do everything on your own. And James 1:19 says, “Be quick to listen, slow to speak and slow to become angry.” Listening, engaging in thoughtful dialog, and living a life of patience and grace will serve everyone in your sphere of influence.

PF: What was your first job and what did you learn from it?

DW: I was a clerk at Oshman’s Sporting Goods. My boss taught me to string tennis rackets. I had a marketable skill from that moment on. Even after I left Oshman’s, he would call me to come string rackets. I learned that when you have a skill that’s in demand, the work finds you.

PF: If you had $100,000 to give to a charity, which one would it be?

DW: I would support Camp Lone Star in La Grange, Texas, because of the positive character developed in my children by this church camp.

PF: What was your first car and what is your dream car?

DW: My first car was a 1973 Oldsmobile Cutlass and my dream car is a 2020 Laramie Edition Dodge Ram pickup truck with “all the fixins.”

PF: What leadership traits have helped you along the way?

DW: “Overcoming the fear of the unknown” has been a key leadership trait. We naturally fear new locations, new bosses and new methods, procedures and processes. We can be paralyzed by uncertainty. But standing still is not an option. Get the bicycle moving and then you can steer it.

PF: What did you want to be when you grew up?

DW: I wanted to be something exciting like a fireman or an astronaut. Becoming a physical chemist who teaches precision cleaning techniques for liquid oxygen systems for the space program has met my goal.

PF: Night owl or early bird?

DW: Night owl.

PF: Favorite place you’ve ever lived?

DW: My hometown of Fort Worth, Texas.

PF: What organization or company, aside from your own, do you most admire?

DW: I am impressed with SpaceX as they have made seemingly impossible advancements in space vehicles.

PF: If you could trade jobs with anyone for a day, who would it be?

DW: I’d want to have the largest possible impact, so I’d choose the YouTuber PewDiePie. With his 102 million subscribers, I would have fun and would have a large platform for my thoughts and perspectives.

PF: Where would we find you on a typical Saturday?

DW: Flying remote control planes with my son, fishing with my daughter or running errands with my wife; all very enjoyable activities for me.

PF: Best way to keep competitive edge?

DW: In my business, you need to have lots of students on your team who are reading publications, trying new things in the lab and writing up their results.

PF: Personal heroes?

DW: My current heroes are the few academic professors who, at great personal cost, are taking a stand for free speech and constitutional values on today’s crazy college campuses.

PF: What’s your secret talent that no one knows about?

DW: I am a decent marksman.

PF: How do you motivate people?

DW: I tap into their intrinsic motivation to achieve, to earn and to learn new things.

PF: How do you motivate yourself?

DW: I align my to-do list with my priorities of service, discovery and impact.

PF: Three greatest passions?

DW: Love for Christ, love for family, and love for my neighbors.

PF: If you could pick up a new skill in an instant what would it be?

DW: Fluency in Spanish, Greek and Hebrew.

PF: Most unique office décor?

DW: Small gifts that my international students have given me from Sri Lanka, India, China, Egypt, Germany, Italy, Brazil, Hungary and South Africa.

PF: Best business decision?

DW: Leaving my first academic job to take a job in industry. Seeing how chemistry is applied “in the real world” transformed by life.

PF: Worst business decision?

DW: Writing grant proposals or taking contracts just to get the money is a bad idea. If you take money for work you are not fully equipped to do, you will actually lose money when you account for the time needed to climb the steep learning curve. This may be necessary at the beginning so you can learn new skills, but it can be disastrous.

PF: Biggest management myth?

DW: “You have to bust heads to get people to work.” Not true. Find a person’s intrinsic motivators, find their hook and get them to grow into the job you have for them. If they refuse to advance, don’t be afraid to let them go.

PF: Do you collect anything?

DW: Koozies. They are functional, they remind me of good times, they don’t take up any space and they don’t break.

PF: What advice would you give to yourself 10 years ago?

DW: Buy 100 bitcoin for $32,000 in 2009 and sell in 2017 for $1.97 million. Gold would have merely doubled in that time.

PF: Word that best describes you?

DW: Intentional

Blackstone-NEY Ultrasonics Torrent M Series

Blackstone-NEY Ultrasonics (Jamestown, N.Y.) introduces the Torrent M Series automated ultrasonic aqueous cleaning systems designed for high precision medical and pharmaceutical cleaning applications. The Torrent is a single chamber, front-loading rotary basket style machine that features 640 watts of Blackstone-NEY single or multi-frequency ultrasonics for vacuum and non-vacuum immersion wash or rinse, basket rotation with user-selected speed, direction and short cyclic modes, compressed air blowoff, spray rinsing and hot air dry or vacuum dry with hot air assist.

The Torrent M Series machines are self-contained, skid-mounted machines designed for both single pass or multiple pass chemistries utilizing onboard reservoirs while reducing water consumption through a broad range of user-defined machine operation parameters.

The Torrent M is an in-process or final clean ultrasonic cleaning system that is stated to meet FDA 21 CFR Part 11 audit trail regulations and GAMP 5 recommendations while simplifying machine IQ and OQ validation in the most demanding Medical and Pharmaceutical applications.

Cleaning Technologies Group |www.ctgclean.com

Blackstone-NEY Ultrasonics (Jamestown, N.Y.), a Cleaning Technologies Group company, has introduced the new Agi-Sonic AS-6000 ultrasonic parts cleaning systems. The Agi-Sonic system platform has had a long and successful history in heavy duty cleaning applications. The combination of ultrasonics and part agitation has been demonstrated to provide the best results in challenging applications such as engine and transmission remanufacturing and Aerospace MRO for the removal of corrosion and carbonaceous soils.

In parallel, the systems are employed in day-to-day manufacturing applications such as component degreasing, swarf removal and passivation in nearly every industry.

In recent years, the company says customers have asked for a larger version of the Agi-sonic with higher payload and larger working envelopes. With payload capacity up to 500 lbs and tank volumes of up to 675gallons, the AS-6000 answers the call. These larger systems have already been deployed in new applications such a mold cleaning and degreasing of exhaust systems for heavy duty trucks.

In addition to part agitation and best-in-class ultrasonic performance, the systems also include particle filtration, sparging, and oil skimming as standard features to further enhance cleaning performance and maximize the useful life of the cleaning chemistry.   The system HMI allows recipe setting to control cycle time and temperature, ultrasonic power and pump recirculation cycles.  The auto-fill functionality guarantees adequate liquid level for proper oil separation and filtration function and the lift-out platform returns the parts basket to the operator level at the completion of the cycle.  

The Agi-sonic units can be linked together with standard roller platforms and optional dryers to create semi-automated cleaning lines to reduce the need for operator support. Fully automated hoist and control systems are also offered for customers requiring a complete system solution.

Cleaning Technologies Group | ctgclean.com

Hubbard-Hall (Waterbury, Conn.) is now a North American distributor for critical cleaning products from Alconox Inc. (White Plains, N.Y.). Under the partnership, Hubbard-Hall will provide Alconox cleaners to industrial manufacturers with strict, residue-free cleaning requirements.

Alconox’s product line includes residue-free products, NSF White Book-listed and USDA-compliant cleaners that break down proteins, and cleaners that remove organic, oily films and contaminants to ease equipment maintenance. This reduces the potential for contamination and residue, a reduction essential for manufacturers of medical devices, electronics, cosmetic packaging and other critical cleaning applications.

“This partnership gives industrial manufacturers more access to products designed for critical, residue-free cleaning,” notes Mike Valenti, director of Cleaning Technologies for Hubbard-Hall. “Together with the extensive cleaner line Hubbard-Hall already provides — and backed by over 170 years of cleaning experience — manufacturers get a one-stop shop for all of their cleaning needs.”

“We are proud and excited to have Hubbard-Hall as an official distributor of our critical cleaning detergents,” says Michael Moussourakis, senior director of Strategic Affairs for Alconox Inc. “Both companies have been family owned for generations, and both share common, traditional approaches to serving the needs of our customers. Hubbard-Hall’s experience in aerospace, precision manufacturing and related industries facilitates Alconox Inc.’s goal of further extending our critical cleaning detergents to these vital sectors.”

Alconox’s cleaners are available for spray, soak, ultrasonic and manual washing operations. The company markets its product line under the Citranox, Luminox, Liquinox, Detonox, Tergazyme, Alcojet and Solujet brand names, among others.

Fuchs

Precision cleaning expert John Fuchs passed away on Monday, January 25. Fuchs was associated with Blackstone NEY Ultrasonics for 52 years in many different roles and is well known in the industry as the creator of the Cleaning Technologies technical blog covering many subjects on precision cleaning.

Fuchs was a recognized figure in the field of precision cleaning, specializing in ultrasonics and cleaning processes. He authored numerous articles on ultrasonics and presented major papers to such groups as The Society of Manufacturing Engineers, Precision Cleaning Conferences, NEPCON, NASA, Naval Weapons Center in China Lake, the American Electroplaters and Surface Finishers Society, the Society of Vacuum Coaters, the Ultrasonic Industry Association and the Porcelain Enamel Institute. 

In recent years, Fuchs was heavily involved in the development of advanced aqueous cleaning techniques and processes to meet new cleaning challenges.  Fuchs was a popular and lively speaker who used a variety of analogies and simple demonstrations to bring otherwise complex concepts down to earth. His passion for teaching and sharing industry knowledge will truly be missed.

SanRex’s DCAuto HKD-G Series comes in a variety of options, including 10A to 100A with 1ph 100V/200V input voltage; 100A to 300A with 3ph 200V/400V input voltage; up to 30A with natural cooling; 50A to 300A for forced air cooling, but inside is duct structure, so electric components are protected from environment. The series also has a selectable output waveform mode (DC, single-phase full-wave, customized waveform); an open field network as an available option; and weight is 15 lbs. (as much as 30A) to 53 lbs. (300A).

SanRex | 516-625-1313 | www.sanrex.com

UCM AG plans to discuss the latest trends and challenges in precision and ultrafine cleaning during its first virutal customer day. It also plans to showcase its upcoming UCMsmartline cleaner. Photo Credit: UCM AG

World premiere of the highly-adaptable, modular UCMSmartLine

UCM AG will debut its UCMsmartline during the virtual customer day. The company is particularly proud of the UCMsmartline’s standardized modules for both process steps and transport. It claims users can use these modules to configure customized systems for pre-cleaning, intermediate and final cleaning, and can reconfigure these systems at any time in response to changing requirements and market conditions.

Recognizing trends and providing optimal solutions

The virtual customer day will host several presentations with Q&A addressing different growing demands around various industries. UCM AG will hold these presentation in both German and English with a time delay. Topics include:

• Customized solutions for precision cleaning
• UCMsmartline – modular solutions for ultrafine cleaning
• Solvent-based processes for ultrafine cleaning
• Innovative processes for highest cleanliness requirements

Participants can also visit the virtual exhibition booth after the online event. Access to the customer day and exhibition booth is available to participants via https://ucm-ag.com/virtual-customer-day/.

Machined parts that have been soiled with cutting fluids, grease, metal shavings and other debris also require regular cleanups. And while this, too, can be accomplished by hand, the results are often the same as cleaning clothes with a wash board—only adequate. The fact is, grime and dirt must be thoroughly removed from all surfaces, threads and blind holes. Otherwise, plating, anodizing and coatings of all types simply will not adhere. Ultrasonic cleaners are for machined parts what washing machines are for cleaning clothes—a transformative solution that not only gets the job done faster and easier—but also more thoroughly.

The Technology Bubble

Ultrasonic cleaning uses ultrasonic waves, or sound that is far higher than the human ear can detect. Sound is created by waves, or vibrations in the air created by vibrating an object, which then causes the molecules surrounding it to vibrate. Our ears pick up these vibrations, translating them into sounds. The faster the vibrations, the higher the pitch of sound we hear. Ultrasound is created by waves, which resonate at higher than the upper human detection limit of 20 kHz (20,000 cycles or vibrations every second).

 

Ultrasonic cleaning machines use special transducers that are mounted to a diaphragm and then to the cleaning tank of a unit and immersed in water. The transducer vibrates rapidly, creating ultrasonic waves. This produces tiny “cavitation bubbles” clean parts well.

 

Ultrasonic cleaning machines use special transducers that are mounted to a diaphragm and then to the cleaning tank of a unit and immersed in water. The transducer vibrates rapidly, creating ultrasonic waves, usually between 20-kHz and 40-kHz, but sometimes as high as 1 MHz (known as megasonic technology). This produces tiny “cavitation bubbles,” bubbles that are so small that it would take 1,250 of them to measure a single centimeter. Each second, millions of these cavitation bubbles are generated. And, because they are so miniscule and gentle, they eliminate contaminants, such as dust, dirt, rust, oil, grease, soot, mold, carbon deposits, polishing compounds, wax, pigments, lime scale,

Small bubbles in an ultrasonic tank eliminate contaminants on a variety of parts and even debris embedded in tiny cracks and cervices.

bacteria, algae, fungus, fingerprints and biological soil. This process effectively cleans a variety of parts and equipment made from metals, plastics, glass, rubber and ceramics. It even removes debris embedded in tiny cracks and crevices.

First, users need to choose which ultrasonic machine design is best for their applications. The tabletop cleaner can be placed on a countertop or table and is designed for occasional and low-volume cleaning loads. For larger parts and loads, benchtop cleaners are the answer, as they are larger and generally stronger than tabletop cleaners. Floor models are intended for industrial cleaning, as are multi-stage systems, which use a wash tank, rinse area and drying chamber.

 

Finding the right ultrasonic machine design is critical to getting the best results. This floor model is intended for industrial cleaning and only washes parts.

 

When it comes to cost considerations, the individual, single-batch floor models are more costly than benchtop units. The price of floor models and multi-stage cleaning systems are fairly similar, however floor models only wash, whereby multi-stage cleaning systems integrate washing, rinsing and drying into a single system. Multi-stage systems are used when higher precision rinsing and drying are required

 

The multi-stage ultrasonic cleaning system integrates washing, rinsing and drying in a single system. These systems are used when higher precision ringing and drying are required and perform most effectively in the least amount of time.

 

 

and perform most effectively in the least amount of time—and the time saved directly translates to money saved.

Now that the machine design is chosen, other questions need to be asked prior to making a final decision about the machine purchase.

• What types of contaminants need to be removed—oils, light dirt, heavy dirt or dark dirt? If oils are being removed, a filtration system that skims from the top is needed. Heavier, excessive dirt that creates sludge at the bottom of the tank lends itself to bolt-on transducers so that the sludge doesn’t interfere with the ultrasonic performance. If you are removing dirt that suspends, you want the main bath to be filtered.
• What are the ultrasonic power requirements? Selecting enough power to clean within the time frames required is important. For most applications, 25-50 watts per gallon are sufficient.
• What frequency is needed? 40 kH is the most common. This frequency creates a mid-range bubble that is small enough to penetrate most blind holes, yet strong enough to clean any application.
• What is the required process? This is key to having a positive outcome. Knowing the right chemistry, the right amount of cleaning time and the proper temperature is critical for success. Using the proper software is also critical for success.

Solving the Solution Dilemma

Ultrasonic cleaning solutions contain specially designed ingredients that increase the effectiveness of the process. However, one single detergent cannot remove every kind of contaminant. The type of part being cleaned also needs to be taken into consideration when selecting a solution because while removing the contaminant is necessary, the part must also be protected.

• General-Use Soap Solutions: With a high alkaline content, these solutions remove oil, grease and carbon deposits from metals and composites.
• Descalers: These acidic detergents remove corrosion, rust, hard mineral deposits and heat scale from metals and help restore parts that operate in hard water or high-humidity environments.
• Enzyme Detergents: Enzymes remove oil from stainless steel, aluminum, brass and titanium parts. They also remove biological contaminants from medical and dental tools.
• Low pH Cleaners: These citrical acid solutions clean and shine metals, but they can sometimes damage aluminum, copper and brass items.
• Specialty Detergents: Specialty solutions are designed to clean specific contaminants such as ink, resins or epoxies.

When choosing a solution for your ultrasonic cleaning application, one should consider the lifespan of the solution as well as how to dispose of it. Though ultrasonic cleaning baths are generally environmentally friendly and water-based, depending on the contaminants removed and solution used, various methods of waste disposal may be required.

Why Choose Ultrasonic Cleaning?

There are three main benefits manufacturers derive from using ultrasonic cleaning technology.

1. Financial savings: Because these systems can clean more items in less time versus cleaning them manually, labor costs are reduced. Also, your investment in ultrasonic cleaning will pay off in the long run. According to the U.S. Environmental Protection Agency, the “payback period” generally ranges anywhere from as short as three months to less than five years.
2. Health and welfare benefits for your employees: Manual cleaning can expose workers to harsh solvents, highly caustic chlorinated and fluoridated agents and hydrocarbons, which can pose health risks to those performing the cleaning. However, with ultrasonic cleaning systems, these non-toxic, aqueous-based detergents are completely safe for users.
3. Environmentally friendly: This technology reduces the amount of hazardous waste put into the atmosphere because ultrasonic cleaning occurs in a contained tank environment. Plus, other forms of immersion cleaning use considerably more energy than ultrasonic cleaning, and less energy use means less pollution. Also, most ultrasonic cleaning detergents are approved by the EPA.

For machining manufacturers, ultrasonic cleaning units are an equivalent “game changer” in terms of the time, quality control and money saving benefits they offer. Cleaning things by hand, whether they are shirts or manufacturing components, has proven to be inefficient and ineffective thanks to the continual strides made in technology over the last several decades. It’s time to embrace a more precise, less time-consuming and more cost-effective way to clean parts by incorporating ultrasonic cleaning into all cleaning operations.

Omegasonics |  800-669-8227 |omegasonics.com

Blackstone-NEY Ultrasonics’ Agi-Sonic AS-6000 ultrasonic parts cleaning systems platform is known for heavy duty cleaning applications. With payload capacity up to 500 lbs and tank volumes of up to 675 gallons, the latest Agi-Sonic AS-6000 model is a larger system than its past offerings. This model has already been deployed in applications such as mold cleaning and degreasing of exhaust systems for heavy duty trucks.

The combination of ultrasonics and part agitation has been demonstrated to provide the best results in challenging applications such as engine and transmission remanufacturing and aerospace MRO for the removal of corrosion and carbonaceous soils. The systems are employed in day-to-day manufacturing applications such as component degreasing, swarf removal and passivation.

In addition to part agitation and ultrasonics, the systems also include particle filtration, sparging and oil skimming as standard features. The system HMI enables recipe setting to control cycle time and temperature, ultrasonic power and pump recirculation cycles. The auto-fill functionality guarantees adequate liquid level for proper oil separation and filtration function and the lift-out platform returns the parts basket to the operator level at the completion of the cycle. 

The Agi-sonic units can be linked together with standard roller platforms and optional dryers to create semi-automated cleaning lines to reduce the need for operator support. Fully automated hoist and control systems are also offered for customers requiring a complete system solution.

Dr. Darren Williams and Lori Beckman

Dr. Williams, a professor at Sam Houston State University, has been involved with the Parts Cleaning Conference for many years, and is a long-standing member of the cleaning industry. Beckman is parts cleaning editor of Production Machining and Products Finishing brands, and will help provide attendees a quality program with a top-notch speaker lineup.

Dr. Williams teaches Physical Chemistry I and II, General Chemistry I and II, and graduate courses in spectroscopy and thermodynamics at Sam Houston State. He has authored over two dozen research articles and a book chapter on parts cleaning.

A recent grant from the Strategic Environmental Research and Development Program — a joint program of the Environmental Protection Agency and the Department of Defense — helped Dr. Williams to identify, create and test azeotropic blends for the replacement of trichloroethylene and n- propylbromide solvents in military vapor degreasing operations.

Beckman has been reporting, writing and editing content in Production Machining since 2003. She attends IMTS and PMTS regularly, and visits machine shops and OEMs to find the most valuable content for readers. She is also the parts cleaning editor for Production Machining and Products Finishing magazines, covering the manufacturing parts cleaning segment of the industry. She has attended the parts2clean trade show in Germany and aids in organizing the Parts Cleaning Conference.

The Parts Cleaning Conference gives attendees updated information on the latest cleaning technologies. As environmental limitations become stricter and manufacturers demand high quality clean parts, this conference will detail how to make it all happen, while staying within compliance and on budget. Visit partscleaningevent.com