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instance, the first process of sand casting could have the casting sand with a certain shape and size (probably spherical and 5-20 microns in size), molten aluminum (probably spherical and ~20-100 microns) and dross (irregularly shaped and 50-150 microns). These sizes are only a suggestion, and you would need a measuring microscope to better define the size and shape of your particulate. From there you could move onto the machining process, which is likely producing the springlike particle 10-15-mm long. Each of the incoming components should be examined in a similar way. What is the material and processing of each component added to this gearbox? Then what are the size, shape and compositions of the particles from each of these parts? While this may seem time-consuming, it will enable you to focus your time on the correct process steps that are contributing to the residue. For instance, if the spring particles are coming from your machining operation, instead of immediately trying to come up with a better cleaning process, you may first want to see what you can do upstream to minimize particulate even entering the part. Are all machining cells vertical end mills? Can parts be oriented in a way so particulate cannot fall into them? Is particulate filtration of the machining fluid as effective as it can be to minimize re-deposition? Try it once, Y ou'll use it forever! Once you are satisfied that you have examined and improved upstream processing as much as possible, you will need to examine the effect on the final process. If parts are still not getting clean enough, you should look at the current cleaning process for optimization (alternate cleaners, filtration, time and temperatures). Hopefully, when that is complete you will be in compliance with your cleaning requirements. If not, you will need to investigate alternate processes. Some possibilities would be an immersion process such as ultrasonics to insure you are wetting and getting good impact onto all surfaces equally (blind holes as well as outer surfaces). An alkaline etch may also be effective to completely dissolve all the aluminum particulate, although this will also dissolve the base metal of the aluminum casting. If you have enough tolerance in the part, this may be effective, but it would require immersion of the part, something you are currently not doing. n LearnMORE Dig Deeper Searching for in-depth analysis of a cleaning or pretreatment process? Look no further than PF's Research and White Paper Zone, an entire section of our site dedicated to free papers and presentations from leading researchers in the finishing industry. Visit pfonline.com/zones/technology. Supplying Quality Finishing Systems for 30 Years FINISHING SYSTEMS: SIMICHROME is the world's outstanding industrial-grade metal polish. Designed to polish –– without scratching –– any metal, any precision metal product, any die mold. Words can't do SIMICHROME justice, so we want you to try it–– FREE! Just call 641648-5121 and re q u e s t y o u r sample and complete information on our products. removes heat-caused discoloration from chrome, stainless steel, and other metals. Have you heard about BlueAway? Our newest product, BlueAway is the fantastic cleaner that Competition Chemicals, Inc. Dept. 722, Box 820 Iowa Falls, IA 50126 • PORCELAIN ENAMEL • POWDER COAT • E-COAT • WET SPRAY SERVICES: • SYSTEM AUDITS • SYSTEM UPGRADES • SPARE PARTS The KMI mission is to engineer, design and build paint and porcelain enamel fnishing systems at a reasonable cost and within the project schedule. These systems must be reliable, environmentally friendly, require low operating cost and produce high quality fnishes. We achieve customer satisfaction so consistently that our customers insist on becoming repeat customers! With decades of experience, KMI has the knowledge and expertise to meet your needs. KMI, we are in your home. Why not include us in your business? Phone: 815-459-5255 Fax: 815-459-6051 sales@kmisystemsinc.com www.kmisystemsinc.com www.competitionchemicals.com pfonline.com 39