Ultrasonic cleaners have mature applications in industrial fields such as automotive manufacturing, aerospace, electronic semiconductors, optical precision manufacturing, medical devices, etc., thanks to their micro cleaning ability caused by cavitation effect. The following are specific and practical application cases, covering process schemes, implementation effects, and key parameters, which are convenient for direct reference.
1、 Automotive parts manufacturing: Multi slot automated cleaning, compatible with batch production lines
Automotive components (engine cylinder heads, transmission gears, pistons, fuel injectors, etc.) often contain stubborn pollutants such as cutting oil, metal shavings, and grinding paste, which directly affect assembly accuracy and lifespan.
Typical case: A German automotive parts supplier uses a five slot ultrasonic cleaning system to treat engine cylinder heads, achieving full process automation of "heavy oil cleaning → precision rinsing → spraying → rust prevention → drying".
Core parameters: First tank with 40kHz alkaline cleaning agent (60 ℃, 8 minutes), second tank with 68kHz deionized water rinsing (45 ℃, 5 minutes), robot automatic loading and unloading, production capacity of 120 pieces/hour.
Cleaning effect: The residual oil content has decreased from ≥ 15g/m ² to ≤ 0.5g/m ², the number of metal particles has decreased from ≥ 50 particles/cm ² to ≤ 5 particles/cm ², and the cleanliness has reached Class 2 of VDA19 standard.
Another case: A gearbox manufacturer used a 28kHz/40kHz dual frequency multi slot system to clean gears, and the pass rate increased from 92% to 99.7%, reducing cleaning costs by 65% and achieving mass production of 400 pieces per hour.
Core value: Replace traditional manual or spray cleaning, solve the cleaning dead corners of complex cavity walls, threaded holes, and blind holes, and provide stable surface quality for subsequent assembly and coating.
2、 Aerospace precision manufacturing: non-destructive deep cleaning, improving component fatigue life
Titanium alloy/high-temperature alloy components such as aircraft engine blades, turbine discs, and hydraulic valve bodies require high cleanliness. Residual oil stains and heat-treated oxide layers can seriously affect coating adhesion and fatigue life.
Typical case: A certain aircraft engine manufacturer cleans turbine blades using a multi frequency ultrasonic system (28kHz+40kHz) combined with high-temperature alkaline cleaning solution and circulating filtration to achieve deep degreasing and oxide layer removal.
Key effect: After cleaning, the surface roughness decreased from Ra0.8 μ m to Ra0.2 μ m, the coating adhesion increased by 3 times, the blade fatigue life increased by 40%, and the risk of high-altitude failure caused by small pollutants was avoided.
Hydraulic valve body case: A certain aerospace enterprise cleaned the servo valve core (with precision up to micrometer level), using 68kHz high-frequency ultrasound combined with deionized water to remove residual cutting fluid and metal chips, ensuring smooth movement of the valve core, and reducing the finished product leakage rate from 0.3% to 0.01%.
Core value: Achieve micro cleaning of complex structures without damaging the substrate, ensuring high reliability and long lifespan of aviation components.
3、 Electronic and semiconductor manufacturing: high-frequency non-destructive cleaning, compatible with advanced processes
Semiconductor wafers, PCB boards, SMT steel mesh, lead frames, etc. need to be cleaned of micron sized particles, flux, ion pollutants, and must not damage sensitive circuits or photoresist.
Wafer cleaning case: A 7nm process wafer factory replaced some RCA cleaning steps with high-frequency (130kHz) ultrasonic cleaning to perform "non-destructive cleaning" on the surface particles of the wafer after photolithography.
Effect comparison: Traditional RCA cleaning has a residual particle count of 32/cm ², while ultrasonic cleaning reduces it to 0.8/cm ² without damaging the photoresist, resulting in a 5% -8% increase in yield.
Case study of PCB and SMT steel mesh: A certain electronics factory cleaned SMT steel mesh (mesh diameter 50-150 μ m) using 40kHz ultrasound combined with neutral cleaning agent to remove solder paste blockage and flux residue, avoiding printing short circuits.
Implementation points: Adopt high-frequency low-power mode to prevent deformation of the steel mesh. After cleaning, the reuse frequency of the steel mesh increases from 50 times to 120 times, and the downtime of the production line is reduced by 70%.
Core value: Adapt to advanced chip processes and high-density packaging requirements of electronic devices, control micro interface cleanliness, and improve product reliability and yield.
4、 Optics and optoelectronic manufacturing: scratch free cleaning, ensuring transparency and imaging quality
Optical lenses, lenses, filters, LCD display glass, etc. need to be cleaned of polishing powder, fingerprints, grease, etc., and surface scratches are strictly prohibited. Traditional wiping can easily cause damage.
Typical case: A certain optical lens factory uses a 40kHz+80kHz dual frequency ultrasonic cleaning system to process DSLR camera lenses. The process is "pre washing (removing polishing wax) → main washing (degreasing) → rinsing (deionized water) → drying".
Key parameters: Low power (≤ 50W/L), temperature controlled below 40 ℃ to avoid damage to the lens coating.
Implementation effect: The single shift cleaning volume has increased from 500 pieces manually to 2000 pieces, reducing labor costs by 60%. The lens transmittance has increased from 92% to 99.5%, and the scratch free rate has reached 100%.
LCD glass case: A panel factory cleaned the glass substrate with 100kHz ultrasound before coating to remove surface organic pollutants and micro particles, ensuring coating uniformity. The defect rate of the finished product decreased from 1.2% to 0.15%.
Core value: Replace contact cleaning, achieve non-destructive and highly consistent cleaning of optical surfaces, and ensure optical performance and imaging quality.