Ultrasonic Cleaning

© 2001 Linda Alexander

Per client specification and as originally published by:
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Ultrasonic cleaning uses sound waves and vibrations to clean. Various industries use ultrasonic cleaning, such as automotive rebuilders, golf club users, jewelers, machining, the medical and metals industries. It cleans contaminants such as bacteria, compounds, dust, dirt, fingerprints, grease and mold, oils, sludge and wax.

Ultrasonic cleaning works by converting electricity into high frequency sound waves (humans can't hear these) and alternating between high and low pressure within a cleansing bath. The low pressure causes bubbles to form, called "cavitation."

The bubbles implode under the high pressure, releasing an enormous amount of energy, which cleans the dirt. Because the bubbles work in all directions, ultrasonic cleaning works even on surfaces with many recesses, crevices, and holes. Almost all areas of industrial cleaning use some form of ultrasonic cleaning.

It is very effective for cleaning hard surfaces like metals, glass and ceramics, but not as effective at cleaning soft materials. The cleaning process can be used with aqueous, semi-aqueous, and solvent-based systems. Numerous solvents are used, such as fluorocarbons, acids, alcohols, or ether.

When using ultrasonics, you must comply with regulations by such organizations as OSHA, the EPA and the FCC, as well as other federal, state, and local requirements. You must also control interference with computers. Radio frequency (RF) filters will control some interference.

Types of Contaminants Cleaned and Energy Used

The more stubborn the contaminant, or the more complex the part configuration, the more likely ultrasonic cleaning will work. Buffing compounds and baked-on carbon, for example, are good candidates for ultrasonics. There are other factors that contribute to the cleaning process, such as type of soil, temperature, cycle time, volume of the part, etc.

Thermal energy, chemical energy, and mechanical energy are the types of energy that may be used in the cleaning process. Ultrasonics is one type of mechanical energy and is not the only factor in successful cleaning. Other forms of mechanical energy that can be used in cleaning are immersion, spray, agitation, and rotation of the part.

Before finding the right cleaning process for your application, you must consider using a combination of these energies and finding the right balance. It can be difficult. The relationship of the chemistry, the temperature of the bath, and the degree of mechanical motion that the parts can withstand are factors to consider when choosing the right cleaning process for you.

Cleaning Agents

Most cleaning agents used in ultrasonic cleaners are environmentally safe, non-toxic, biodegradable, and concentrated. They enhance cleaning performance, conditioning the water to maximize cavitational energy in the cleaner. Some are mildly alkaline, ideal for cleaning soft metals, electronic equipment, and painted surfaces.

For blind cleaners, there is a blind cleaning powder available specifically for blind cleaning equipment. It can also clean other surfaces, such as PVC, glass, metal, and painted surfaces. There are specific agents made for injection mold cleaners, too. There are also agents designed to clean the ink off of print rollers.

Another popular application of ultrasonic cleaning is fire restoration. Certain cleaning agents will help clean smoke and fire residue and carbons from various surfaces. The same agent can be used on porcelain, glass, plastic and metal. With so many uses, it's a wonder more people don't know about ultrasonic cleaning!

While some cleaning agents should not be used with aluminum, others are designed specifically for metals. They will remove rust and oxides from damaged metal parts, and tarnish and heat scale from iron, steel, aluminum, brass, copper, plastic and painted surfaces. If odor is a problem, ultrasonic agents can also be found that will deodorize parts.

Mold Cleaning Methods

Mold cleaning methods are necessary in many households, as mold, mildew, fungi and bacteria are the leading biological pollutants found in people's homes. Areas with high humidity, such as bathrooms, kitchens, or basements, are especially susceptible to mold.

There are several mold cleaning methods available. First, do not give the mold a chance to grow. Before it is able to weaken or rot the material, brush off any surface growth to prevent mildew spores from spreading in the house. Wash mildew-stained articles right away with detergent and water, then dry in the sun. Bleach will also remove it, if it is safe to use bleach on that fabric.

Other mold cleaning methods include chlorine bleach solutions, lemon juice, and sun bleaching. For cleaning bathrooms, walls, and basements, use a solution of one cup of chlorine bleach per gallon of water. Scrub off with a sponge or brush. On clothing, you can launder your clothes, then lay them in the sun to bleach.

Of course, the best mold cleaning methods are the ones you don't need. So if you can prevent mold from forming in the first place, do so. Use a dehumidifier in your bathroom or basement. Turn up the heat to dry the air if necessary. Wipe shower doors and tiles down after your showers. Prevent mold from forming, and you won't have to clean it.

Water Treatment

Water treatment plants could someday purify water with ultrasonic technology instead of harsh chemicals. The technology is still early in its development. But ceramic membrane filters might be used in place of chemicals, as it has been done in research studies recently.

Water treatment done this way might minimize the cost, increase safety, and help the problem of disposing the treatment chemicals. Membrane filters are networks of tiny channels separated by thin ceramic membranes, similar to honeycombs. When water flows through the channels, the membranes catch contaminants such as clay, iron oxide, bacteria, and viruses. However, over time the membranes become clogged and must be cleaned.

If using ultrasound for water treatment, plants wouldn't have to remove filters to clean them. The contaminants would be flushed away with a separate exhaust flow. If the ultrasound is allowed to run continuously, the filters might never get clogged in the first place.

More testing will help scientists figure out how ultrasound wears on different types of filters. They will also learn what frequencies work on different pollutants in the water. In time, ultrasonics may be the most popular, greenest form of treating water.

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