Are You Playing the Clean Manufacturing Game?
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Wasting Away Your Manufacturing Profits – Part 1 of 10
Manufacturing waste is generally thought of as any resource used in a production process that does not go out as part of the product and costs money to get rid of it. However, manufacturing waste also exists in many other forms, for example excessive factory space utilization for equipment (production and waste treatment equipment), inefficient material and process flows, inefficient use of facility labor and lost productivity of both labor and equipment. These types of wastes significantly impact a company’s bottom line too, but are often obscured in overhead accounts or generally overlooked in the manufacturing operation.
In an era of complex business challenges; intense global competitiveness, increasing environmental regulation and energy supply/cost issues, managers must have both lean and green (clean) manufacturing skills necessary to identify and eliminate multifaceted manufacturing wastes in their operations that stealthily steal away business profits. Numerous educational resources are available to manufacturers that teach methods for the identification of and financial accounting of both lean and green wastes. An integrated waste minimization program is being developed by Cleanlogix for use in its CleanTech marketing and sales programs. The new Cleanlogix program is called Cleanopoly™, Clean Manufacturing Strategy Game, and will provide a useful method for determining manufacturing wastes and implementing CleanTech solutions.
Manufacturers of advanced products need state-of-the-art clean manufacturing technology (CleanTech) and CleanTech implementation strategies for successful design and execution of manufacturing waste reduction programs. Manufacturing waste reduction programs may include one or a combination of the following technology components:
• Integrated CleanTech to eliminate or reduce all forms of manufacturing waste: time, labor, space, transport, defect, inventory, processing, equipment, raw materials, air pollution, water pollution, wastewater, solid wastes, and energy wastes.
• Advanced CleanTech for improved quality and reliability imposed by advanced materials, manufacturing methods and processes, and applications.
• Flexible automation, modular and clustered assembly operations (cells) to reduce operational waste.
• More adaptable and flexible production tools and methodologies to improve efficiency and productivity in low volume-high mix-high value production operations.
This series of blog articles provides manufacturing managers with an introduction to clean manufacturing and carbon dioxide (CO2) CleanTech for improving production cleaning, assembly processes and machining operations while eliminating operational and resource waste. CO2 CleanTech prevents or eliminates waste at the source by modifying cleaning, assembly, and machining processes using clean and green chemistry, and unique tool and process implementations. CO2 CleanTech increases both productivity and profitability.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 2 of this series introduces clean manufacturing technology.
Wednesday, June 16, 2010
The Clean Manufacturing Game Part 2 of 10
Are You Playing the Clean Manufacturing Game?
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Clean Manufacturing Technology (CleanTech) – Part 2 of 10
Clean manufacturing technology (CleanTech) includes equipment, processes, policies, practices and continuous improvement measures that concentrate on optimizing manufacturing resources to minimize or eliminate wastes of various forms. CleanTech helps companies achieve maximum productivity and profitability with minimal waste. CleanTech is a hybrid manufacturing strategy involving Lean Manufacturing techniques; a waste reduction focus that emphasizes manufacturing actions and operations to maximize efficiency, and Green Manufacturing techniques; a waste reduction focus that emphasizes manufacturing actions and operations to minimize environmental waste. Its principal benefit to companies is that CleanTech reduces operating cost in the form of time, transport, chemical management, material consumption, waste treatment, and end-of-pipe pollution control. CleanTech provides opportunities to reduce regulatory obligations, risks, and associated costs, and increases manufacturing process efficiency and productivity.
Thus CleanTech incorporates both Lean and Green elements as an integrated operational strategy to reduce or eliminate both operational and resource wastes as they relate to manufacturing and assembly processes, and is uniquely enabled with advanced CO2 CleanTech.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 3 of this series introduces CO2 CleanTech.
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Clean Manufacturing Technology (CleanTech) – Part 2 of 10
Clean manufacturing technology (CleanTech) includes equipment, processes, policies, practices and continuous improvement measures that concentrate on optimizing manufacturing resources to minimize or eliminate wastes of various forms. CleanTech helps companies achieve maximum productivity and profitability with minimal waste. CleanTech is a hybrid manufacturing strategy involving Lean Manufacturing techniques; a waste reduction focus that emphasizes manufacturing actions and operations to maximize efficiency, and Green Manufacturing techniques; a waste reduction focus that emphasizes manufacturing actions and operations to minimize environmental waste. Its principal benefit to companies is that CleanTech reduces operating cost in the form of time, transport, chemical management, material consumption, waste treatment, and end-of-pipe pollution control. CleanTech provides opportunities to reduce regulatory obligations, risks, and associated costs, and increases manufacturing process efficiency and productivity.
Thus CleanTech incorporates both Lean and Green elements as an integrated operational strategy to reduce or eliminate both operational and resource wastes as they relate to manufacturing and assembly processes, and is uniquely enabled with advanced CO2 CleanTech.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 3 of this series introduces CO2 CleanTech.
The Clean Manufacturing Game Part 3 of 10
Are You Playing the Clean Manufacturing Game?
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
CO2 CleanTech – Part 3 of 10
CO2 clean manufacturing technology (CO2 CleanTech) eliminates or significantly reduces waste generation at the production operation level (i.e., at the source) by modifying manufacturing processes, for example cleaning, assembly processes requiring cleaning, machining operations and thermal spray coating. CO2 CleanTech is uniquely capable of modifying a manufacturing process in numerous ways, as follows:
1. Physically; shape, size, space, application and configuration; and
2. Chemically; solvency, toxicity, wetness, and chemical process.
Owing to CO2’s inherent dry and compatible chemistry, the technology may be implemented directly into a variety of production equipment and process configurations to meet the needs of lean production schemes and product flow constraints, including both existing (aftermarket) and new production implementations.
As an example, replacing conventional surface cleaning agents with CO2’s green chemistry eliminates process inputs such as liquid cleaning solvents, aqueous clean agents, detergents, deionized rinse water, and heated air dryers, among other waste-producing inputs. In another example, CO2-based advanced minimum quantity cooling lubrication (CO2 Machining) replaces flooded cutting fluids and associated waste-producing operations such as fluids management, waste hauling and air pollution control.
Substantial environmental benefits are derived by using CO2 CleanTech. The U.S. Environmental Protection Agency (USEPA) has determined that CO2 is an environmentally benign alternative chemistry for the manufacturing industry because there is no net increase in global warming gases or environmental damage as a result of using CO2. Removing or minimizing the usage of organic compounds such petroleum-derived cutting and cleaning fluids in manufacturing processes and in particular not having to produce as much of these compounds and replacing them with CO2 will lower energy usage, lower emissions of global warming gases, improve water and air quality and natural resource conservation. CO2 is a cost- and performance-effective replacement in a variety of cleaning and machining applications.
Machining and cleaning are two common manufacturing processes, which are typically performed sequentially in a production cycle. Many types of manufacturing wastes are generated in these processes in the form of solvents, water, wastewater, sludge, filters, treatment chemicals, metalworking fluids, air emissions, spills and leaks, damaged equipment, rework or scrap parts, machinery maintenance, cleaner maintenance, boilers, cooling towers, environmental management operations, productivity and energy. Specific examples of precision cleaning and machining activities that produce a waste include:
• Moving products off-line or out of cells to clean them and then returning them back to the line or cell
• Filtering and treating spent alkaline cleaning chemistries
• Monitoring cleaning and machining fluid chemistries
• Rinsing parts
• Drying parts
• Treatment and disposal of spent cleaning and machining agents
• Completing waste hauling manifests
• Environmental reports
• Deionized water treatment
• Rinse water treatment and disposal
Given this, following considers how CO2–enabled machining and cleaning operations can eliminate many of these waste elements:
• Materials selection and productivity: Recycled CO2 itself does not generate waste, does not require environmental management, and eliminates equipment cleaning and maintenance.
• Energy conservation: Using recycled CO2 eliminates the need for additional energy to heat cleaning baths, dry parts, or evaporate and concentrate wastes.
• Waste reduction and elimination: CO2 does not itself become a waste by-product. CO2 eliminates the wasteful consumption, treatment and disposal of water, wastewater and associated solid wastes.
• Air pollution reduction: Recycled CO2 is not considered an air pollutant, is non-toxic and is odorless within the factory atmosphere.
• Space and process step reduction: CO2-enabled cleaning processes can reduce multiple processing steps to a single step and perform in less space, sometimes no extra space is needed if the CO2 process is integrated directly with an existing manufacturing tool such as a bonder, dispenser, or machining tool.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 4 of this series gives some examples of how CO2 cleaning technology cleans up the factory.
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
CO2 CleanTech – Part 3 of 10
CO2 clean manufacturing technology (CO2 CleanTech) eliminates or significantly reduces waste generation at the production operation level (i.e., at the source) by modifying manufacturing processes, for example cleaning, assembly processes requiring cleaning, machining operations and thermal spray coating. CO2 CleanTech is uniquely capable of modifying a manufacturing process in numerous ways, as follows:
1. Physically; shape, size, space, application and configuration; and
2. Chemically; solvency, toxicity, wetness, and chemical process.
Owing to CO2’s inherent dry and compatible chemistry, the technology may be implemented directly into a variety of production equipment and process configurations to meet the needs of lean production schemes and product flow constraints, including both existing (aftermarket) and new production implementations.
As an example, replacing conventional surface cleaning agents with CO2’s green chemistry eliminates process inputs such as liquid cleaning solvents, aqueous clean agents, detergents, deionized rinse water, and heated air dryers, among other waste-producing inputs. In another example, CO2-based advanced minimum quantity cooling lubrication (CO2 Machining) replaces flooded cutting fluids and associated waste-producing operations such as fluids management, waste hauling and air pollution control.
Substantial environmental benefits are derived by using CO2 CleanTech. The U.S. Environmental Protection Agency (USEPA) has determined that CO2 is an environmentally benign alternative chemistry for the manufacturing industry because there is no net increase in global warming gases or environmental damage as a result of using CO2. Removing or minimizing the usage of organic compounds such petroleum-derived cutting and cleaning fluids in manufacturing processes and in particular not having to produce as much of these compounds and replacing them with CO2 will lower energy usage, lower emissions of global warming gases, improve water and air quality and natural resource conservation. CO2 is a cost- and performance-effective replacement in a variety of cleaning and machining applications.
Machining and cleaning are two common manufacturing processes, which are typically performed sequentially in a production cycle. Many types of manufacturing wastes are generated in these processes in the form of solvents, water, wastewater, sludge, filters, treatment chemicals, metalworking fluids, air emissions, spills and leaks, damaged equipment, rework or scrap parts, machinery maintenance, cleaner maintenance, boilers, cooling towers, environmental management operations, productivity and energy. Specific examples of precision cleaning and machining activities that produce a waste include:
• Moving products off-line or out of cells to clean them and then returning them back to the line or cell
• Filtering and treating spent alkaline cleaning chemistries
• Monitoring cleaning and machining fluid chemistries
• Rinsing parts
• Drying parts
• Treatment and disposal of spent cleaning and machining agents
• Completing waste hauling manifests
• Environmental reports
• Deionized water treatment
• Rinse water treatment and disposal
Given this, following considers how CO2–enabled machining and cleaning operations can eliminate many of these waste elements:
• Materials selection and productivity: Recycled CO2 itself does not generate waste, does not require environmental management, and eliminates equipment cleaning and maintenance.
• Energy conservation: Using recycled CO2 eliminates the need for additional energy to heat cleaning baths, dry parts, or evaporate and concentrate wastes.
• Waste reduction and elimination: CO2 does not itself become a waste by-product. CO2 eliminates the wasteful consumption, treatment and disposal of water, wastewater and associated solid wastes.
• Air pollution reduction: Recycled CO2 is not considered an air pollutant, is non-toxic and is odorless within the factory atmosphere.
• Space and process step reduction: CO2-enabled cleaning processes can reduce multiple processing steps to a single step and perform in less space, sometimes no extra space is needed if the CO2 process is integrated directly with an existing manufacturing tool such as a bonder, dispenser, or machining tool.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 4 of this series gives some examples of how CO2 cleaning technology cleans up the factory.
The Clean Manufacturing Game Part 4 of 10
Are You Playing the Clean Manufacturing Game?
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Cleaning up the Factory – Part 4 of 10
Advanced CO2 cleaning technology includes CO2 composite sprays (NOT Snow Guns or Sprays!), plasmas, hybrid sprays, centrifugal liquid carbon dioxide immersion systems, supercritical fluid extraction systems, and fluids purification and management systems. This technology is available in stand-alone, mobile, bench-top, robotic, cleanroom, and production equipment integration modules (i.e., CPUs). CO2 cleaning and surface treatment applications are diverse and include precision degreasing, departiculation, outgassing, drying, disinfection and surface modification and functionalization.
CO2 CleanTech delivers both lean and green waste reduction benefits to manufacturers including the elimination of toxics, reduction of cleaning steps, lower energy costs and improved cleaning quality and consistency, among many other benefits. For example, a major ball point pen manufacturer installed a CO2 centrifugal degreasing system to replace an ultrasonic PERC solvent cleaning system. The new CO2 cleaning system cleaned faster, better and allowed lubricating oils to be recycled back into the machining process. Annual operating costs decreased by more than $130,000 per year during the first year of service and resulted in more than a $1,500,000 in operating cost reductions over a 10 year installation period. In another example, a major hard disk drive manufacturer reduced cost-per-clean by over 70% by eliminating the manufacturing wastes associated with parts disassembly, aqueous cleaning and deionized water rinsing, and drying operations. In another example, a major printer manufacturer eliminated multiple cleaning steps with a single-step CO2 composite spray (solid-plasma) cleaning process, which increased product yield while eliminating a number of manufacturing wastes.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 5 of this series introduces clean machining technology.
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Cleaning up the Factory – Part 4 of 10
Advanced CO2 cleaning technology includes CO2 composite sprays (NOT Snow Guns or Sprays!), plasmas, hybrid sprays, centrifugal liquid carbon dioxide immersion systems, supercritical fluid extraction systems, and fluids purification and management systems. This technology is available in stand-alone, mobile, bench-top, robotic, cleanroom, and production equipment integration modules (i.e., CPUs). CO2 cleaning and surface treatment applications are diverse and include precision degreasing, departiculation, outgassing, drying, disinfection and surface modification and functionalization.
CO2 CleanTech delivers both lean and green waste reduction benefits to manufacturers including the elimination of toxics, reduction of cleaning steps, lower energy costs and improved cleaning quality and consistency, among many other benefits. For example, a major ball point pen manufacturer installed a CO2 centrifugal degreasing system to replace an ultrasonic PERC solvent cleaning system. The new CO2 cleaning system cleaned faster, better and allowed lubricating oils to be recycled back into the machining process. Annual operating costs decreased by more than $130,000 per year during the first year of service and resulted in more than a $1,500,000 in operating cost reductions over a 10 year installation period. In another example, a major hard disk drive manufacturer reduced cost-per-clean by over 70% by eliminating the manufacturing wastes associated with parts disassembly, aqueous cleaning and deionized water rinsing, and drying operations. In another example, a major printer manufacturer eliminated multiple cleaning steps with a single-step CO2 composite spray (solid-plasma) cleaning process, which increased product yield while eliminating a number of manufacturing wastes.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 5 of this series introduces clean machining technology.
The Clean Manufacturing Game Part 5 of 10
Are You Playing the Clean Manufacturing Game?
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Clean Machining – Part 5 of 10
The literature suggests that operational costs related to the use of flooded cooling lubricants can range between 7% and 17% of the total costs of the manufactured workpiece. Intangible costs to a business must also be considered. For example, cutting fluids, especially those containing petroleum oils, have become a huge liability. No matter how safe and environmentally friendly a cutting fluid may be, governmental regulations demand special handling the moment it is poured into a sump.
A new cooling-lubrication technology called CO2 machining has been recently introduced. CO2 machining provides superior penetration, cooling, cleaning and lubricating capability for very demanding machining applications. CO2 machining resolves many of the waste characteristics of conventional machining fluid processes and can be implemented along side many older and newer metalworking machinery, tools and fluids for cleaner and leaner machining operations.
The CO2 machining system combines a source of propellant gas (i.e., compressed air), minute amounts of bio-based lubricants (i.e., soybean oil), and CO2 in various concentrations to form an infinitely adjustable cooling lubricant spray. CO2 machining systems employs a novel Coanda-coaxial injector and spray applicator and controls machining heat by using both a physical and chemical effect. Frictional heat generated at the cutting edge is eliminated through the delivery of reactive lubricants (chemical effect), including carbon dioxide (CO2) gas, which produce beneficial tribochemical reactions. The majority of the machining heat produced by the deformation of the material itself is removed using adjustable spray compositions containing microscopic particles of solid carbon dioxide, which impact hot surfaces at high velocity and remove heat through a phase change (physical effect) phenomenon.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 6 of this series discusses bio-based lubricant technology.
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Clean Machining – Part 5 of 10
The literature suggests that operational costs related to the use of flooded cooling lubricants can range between 7% and 17% of the total costs of the manufactured workpiece. Intangible costs to a business must also be considered. For example, cutting fluids, especially those containing petroleum oils, have become a huge liability. No matter how safe and environmentally friendly a cutting fluid may be, governmental regulations demand special handling the moment it is poured into a sump.
A new cooling-lubrication technology called CO2 machining has been recently introduced. CO2 machining provides superior penetration, cooling, cleaning and lubricating capability for very demanding machining applications. CO2 machining resolves many of the waste characteristics of conventional machining fluid processes and can be implemented along side many older and newer metalworking machinery, tools and fluids for cleaner and leaner machining operations.
The CO2 machining system combines a source of propellant gas (i.e., compressed air), minute amounts of bio-based lubricants (i.e., soybean oil), and CO2 in various concentrations to form an infinitely adjustable cooling lubricant spray. CO2 machining systems employs a novel Coanda-coaxial injector and spray applicator and controls machining heat by using both a physical and chemical effect. Frictional heat generated at the cutting edge is eliminated through the delivery of reactive lubricants (chemical effect), including carbon dioxide (CO2) gas, which produce beneficial tribochemical reactions. The majority of the machining heat produced by the deformation of the material itself is removed using adjustable spray compositions containing microscopic particles of solid carbon dioxide, which impact hot surfaces at high velocity and remove heat through a phase change (physical effect) phenomenon.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 6 of this series discusses bio-based lubricant technology.
The Clean Manufacturing Game Part 6 of 10
Are You Playing the Clean Manufacturing Game?
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Bio-based Lubricant CleanTech – Part 6 of 10
Renewable bio-based lubricants provides an environmentally sound and worker friendly alternative to petroleum-based cooling lubricants. Vegetable-based lubricants offer significant advantages such as superior tool lubricity, better surface finish, higher feed rates and a safer chemistry. Using a bio-based lubricant in minimum quantity application eliminates the costs associated with treatment, environmental compliance, and disposal, among other operational cost factors. Moreover, vegetable oils such as soybean oil exhibit natural rust inhibition on metal surfaces, a very important characteristic for ferrous machining applications.
Compared to petroleum-based fluids, bio-based lubricating fluids perform as well as or better when machining steel and aluminum, cooling and lubricating the cutting surface as it removes small metal chips and allowing faster, more accurate machining to be done. Bio-based lubricating fluids are biodegradable, non-toxic, have low volatile organic compounds (VOCs) emissions, a high flash point and no offensive odor.
The initial purchase of a cutting fluid is merely the beginning of a much more expensive endeavor. According to a TechSolve, Inc., a non-profit testing laboratory based in Cincinnati, Ohio, for every $1 of coolant purchased, operational costs associated with using, maintaining and disposing of it can be more than $10. The real costs associated with cutting fluid purchases include the labor involved in mixing and transporting the fluids as well as machine draining and cleaning. In addition, deionized water make-up and coolant concentrate replenishment costs with coolant maintenance and disposal costs all contribute to a very high coolant life-cycle cost.
CO2 machining with bio-based lubricant additives eliminates the high cost of machining coolants and provides the opportunity to increase machining productivity in the form of longer tool life, increased speeds and depths of cut, and increased machine utilization, all of which can substantially improve the profitability of a machining operation.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 7 of this series discusses CO2 CleanTech for thermal spray coating operations.
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Bio-based Lubricant CleanTech – Part 6 of 10
Renewable bio-based lubricants provides an environmentally sound and worker friendly alternative to petroleum-based cooling lubricants. Vegetable-based lubricants offer significant advantages such as superior tool lubricity, better surface finish, higher feed rates and a safer chemistry. Using a bio-based lubricant in minimum quantity application eliminates the costs associated with treatment, environmental compliance, and disposal, among other operational cost factors. Moreover, vegetable oils such as soybean oil exhibit natural rust inhibition on metal surfaces, a very important characteristic for ferrous machining applications.
Compared to petroleum-based fluids, bio-based lubricating fluids perform as well as or better when machining steel and aluminum, cooling and lubricating the cutting surface as it removes small metal chips and allowing faster, more accurate machining to be done. Bio-based lubricating fluids are biodegradable, non-toxic, have low volatile organic compounds (VOCs) emissions, a high flash point and no offensive odor.
The initial purchase of a cutting fluid is merely the beginning of a much more expensive endeavor. According to a TechSolve, Inc., a non-profit testing laboratory based in Cincinnati, Ohio, for every $1 of coolant purchased, operational costs associated with using, maintaining and disposing of it can be more than $10. The real costs associated with cutting fluid purchases include the labor involved in mixing and transporting the fluids as well as machine draining and cleaning. In addition, deionized water make-up and coolant concentrate replenishment costs with coolant maintenance and disposal costs all contribute to a very high coolant life-cycle cost.
CO2 machining with bio-based lubricant additives eliminates the high cost of machining coolants and provides the opportunity to increase machining productivity in the form of longer tool life, increased speeds and depths of cut, and increased machine utilization, all of which can substantially improve the profitability of a machining operation.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 7 of this series discusses CO2 CleanTech for thermal spray coating operations.
The Clean Manufacturing Game Part 7 of 10
Are You Playing the Clean Manufacturing Game?
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Cool and Clean Under Fire – Part 7 of 10
Thermal spray coating uses a spray gun of one form or another to deposit finely divided and molten materials onto a substrate. Various materials, including metals and alloys, carbides, polymers, lubricants, ceramics, cermets and composites, can be thermally sprayed onto a substrate to protect critical components, rebuild worn surfaces and to reduce friction. For example, sprayed coatings are widely used to rebuild worn machine parts or to re-manufacture used equipment.
Precision surface preparation is a critical step prior to most thermal coating applications. The majority of coating failures occur at the coating-substrate interface. The reason for this is the discontinuity in the materials system (i.e., mismatched cohesion energies) and/or an improperly prepared bonding surface (i.e., cleanliness and surface area). Proper surface preparation insures that the adhesion between the first splat layer and substrate is strong. Oxides, microscopic particles and hydrocarbon films on bonding surfaces will reduce or prevent local bonding. Surface roughening with microabrasive grit blasting, for example using aluminum oxide particles, removes surface oxides while increasing the bonding surface area for the purpose of providing mechanical keying or anchoring of the first layer of solidified coating. A follow-on precision cleaning operation is used to remove ablated surface and microabrasive particles which typically populate newly formed surface topography.
Besides microscopic particles, oxides and hydrocarbons, another thermal coating process contamination is heat. During thermal spray coating processes such as flame spray, electric-arc (wire-arc) spray, plasma spray and detonation gun spray, substrates are subjected to very high and localized spray temperatures. Under continuous treatment, the temperature of a substrate will increase as the molten coating contacts and heats the surface. It is believed by experts in the field of thermal coating that if thermal migration and build-up is not managed, coating adhesion is greatly affected by the mismatch in thermal expansion or temperatures between a coating and substrate surface. For example, related to adhesion is splat formation during the application of a thermal sprayed coating.
Finally, following thermal coating of precision components, machining of coated surfaces to dimension the coating may be performed. As discussed above, machining heat must be managed properly to increase tool life, improve surface finish and increase the productivity of the machining operation.
A CO2 composite spray uniquely manages the variety of contamination present in a thermal spray coating operation, eliminating the need for separate cleaning fluids, cooling agents and machining agents.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 8 of this series discusses a new surface inspection CleanTech called Optically Stimulated Electron Emission (OSEE).
A 10 part blog series discussing important aspects of clean manufacturing technology and implementation strategy.
Cool and Clean Under Fire – Part 7 of 10
Thermal spray coating uses a spray gun of one form or another to deposit finely divided and molten materials onto a substrate. Various materials, including metals and alloys, carbides, polymers, lubricants, ceramics, cermets and composites, can be thermally sprayed onto a substrate to protect critical components, rebuild worn surfaces and to reduce friction. For example, sprayed coatings are widely used to rebuild worn machine parts or to re-manufacture used equipment.
Precision surface preparation is a critical step prior to most thermal coating applications. The majority of coating failures occur at the coating-substrate interface. The reason for this is the discontinuity in the materials system (i.e., mismatched cohesion energies) and/or an improperly prepared bonding surface (i.e., cleanliness and surface area). Proper surface preparation insures that the adhesion between the first splat layer and substrate is strong. Oxides, microscopic particles and hydrocarbon films on bonding surfaces will reduce or prevent local bonding. Surface roughening with microabrasive grit blasting, for example using aluminum oxide particles, removes surface oxides while increasing the bonding surface area for the purpose of providing mechanical keying or anchoring of the first layer of solidified coating. A follow-on precision cleaning operation is used to remove ablated surface and microabrasive particles which typically populate newly formed surface topography.
Besides microscopic particles, oxides and hydrocarbons, another thermal coating process contamination is heat. During thermal spray coating processes such as flame spray, electric-arc (wire-arc) spray, plasma spray and detonation gun spray, substrates are subjected to very high and localized spray temperatures. Under continuous treatment, the temperature of a substrate will increase as the molten coating contacts and heats the surface. It is believed by experts in the field of thermal coating that if thermal migration and build-up is not managed, coating adhesion is greatly affected by the mismatch in thermal expansion or temperatures between a coating and substrate surface. For example, related to adhesion is splat formation during the application of a thermal sprayed coating.
Finally, following thermal coating of precision components, machining of coated surfaces to dimension the coating may be performed. As discussed above, machining heat must be managed properly to increase tool life, improve surface finish and increase the productivity of the machining operation.
A CO2 composite spray uniquely manages the variety of contamination present in a thermal spray coating operation, eliminating the need for separate cleaning fluids, cooling agents and machining agents.
David Jackson is President/CEO of Cleanlogix LLC and serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Part 8 of this series discusses a new surface inspection CleanTech called Optically Stimulated Electron Emission (OSEE).
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