-rc c

AQUEOUS ALTERNATIVES TO VAPOR DEGREASING

NASA REPLACEMENT TECHNOLOGY TEAM (FIT2)

VAPOR DEGREASING AND HAND WIPE SOLVENT ALTERNATIVES

SEMINAR / WORKSHOP

THURSDAY. NOVEMBER 5, 1992

Rockwell International ROChldyn. Dlrldon

Ron Sodemeijer. Manager Hazardas Materials Elimination Team MateMLP Engineering & Technology

VAPOR DEGREASE 1,1,1 - tric. ,

I r 1

! 100,080 CLASS CLEANROOM

I EMULSION i VISUALLY 1 DEGREASE . ; CLEAN \

I TERNATE

I 1 CLEAN

1 r t NVR < 1mg/ft2

NO PARTICLES >4OOp

I i I

VAPOR CFC 113 DEGREASE OR FLUSH,

VERIFY 1,1,1 - tric., VERIFY

PACKAGE

A0128.1

I 4

w CD 0

ROCKETDYNE ALL AQUEOUS CLEANING PROGRAM

0 CONVERSION TO ALL AQUEOUS CLEANING

0 PHASE I - I . D . AQUEOUS FINE CLEAN PROCESS

0 PHASE I1 - I.D. AQUEOUS ROUGH & PRECLEAN PROCESSES

o PHASE I11 - I.D. & CONTROL POTENTIAL CONTAMINANTS

PHASE IV - 1.D. EFFECTIVE VERIFICATION SOLVENT & TECHNIQUE

.

.

-.

* n

1

PHASE I - AQUEOUS FINE CLEAN TEST PROGRAM

S K D P L I E D SHOP LUBRICANT & METALLIC FINES TO TEST HARDWARE

e PRECLEANED TO WATER BREAK FREE CONDITION

0 VAPOR DEGREASED, ELMULSION CLEAN, ALKALINE CLEAN

0 ADDED ULTRASONIC CLEAN IN ALKALINE CLEANER I

c e FINE CLEANED 0:

ULTRABONIC CLEAN WIT11 0 . 0 4 % SURFACTANT

0 IMMERSION & SPRAY RINSE WITH D.I. WATER

e VACUUM DRY (3 150°F, 4 0 mm Hg

E) VERIFIED CLEANLINESS

0 FLUSHED WITH 500-ml ALIQUOT TCA h COLLECTED

o FILTERED TCk FOR PARTICLE COUNT, EVAPORATED FILTRATE FOR W R

t .’

d t . +.

AQUEOUS FINE CLEANING TESTS

HARDWARE FOR EACH TEST SEQUENCE WAS PROCESSED BY THE SAME PROCEDURE

. MUST EMPHASIZE THAT TCA WAS USED AS PART OF PRECLEANING PROCESS

0. THREE SURFACTANTS WERE TESTED ct + TEN TEST SEQUENCES CONDUCTED FOR EACH SURFACTANT

. SURFACTANT H - 20% SUCCESS IN MEETING > tmg/ft NVR REQUIREMENT

SURFACTANT X - 609L SUCCESS IN MEETING > lmg/ft2 NVR REQUIREMENT

AVERAGE NVR RESULTS WERE 5.5m&

0 AVERAGE NVR RESULTS WERE 1.4my'ff

TURCO 4215 ADDITIVE - 80% SUCCESS IN MEETING >Img/ft2 NVR

AVERAGE NVR RESULTS WERE 0.5mg/ft2

A0147.3

AQUEOUS FINE

0 INITIAL AQUEOUS FINE CLEAN PROGRAM HAS BEEN COMPLETED

RESULTS INDICATE SURFACTANT CURRENTLY USED IS MOST EFFECTIVE

TURCO 4215 ADDITIVE > SURFACTANT X > SURFACTANT H

PARTICULATES WERE SEPARATED INTO TWO GROUPS - PARTICLES & FIBERS PARTICLES WERE EASY TO REMOVE

FIBERS CONTINUE TO BE A PROBLEM

0 DATA WILL CONTINUE TO BE COLLECTED TO ESTABLISH CONFIDENCE

a DATA FOR RESULTS ARE BEING PRESENTED AT ASTM SYMPOSIUM

ALTERNATIVES TO CFC FLUIDS IN THE CLEANING OF 0 2

& AEROSPACE SYSTEMS & COMPONENTS

, A0147 1

I

PIIASE I11 - I . D . h CONTROL POTENTIAL CONTAMINANT6

0 SHOP SOILS

0 CUTTING FLUIDS 0 FORMING LUBE6

0 MACHINING WAXES 0 GREASES

0 ADBESIVE TAPE RESIDUES MASKANTS

0 USED LABORATORY TESTS TO EVALUATE REMOVABILITY

0 TESTED WITH CURRENT IN-HOUSE CLEANERS

tn 03 W Z W > 0 W U LL W

(9 z Z

W -I 0

Q 0 U

v)

0 I- W z I- v) W k-

0

i=

- a

n r

LL

0 0 01

0

2 i r 7

0 W Y a m od -1 W z Q

0 I- n W i a a a v,

5 v)

a 0 I cn -I Q

a

J

0 2 e

z 0 i=

0 tn a W z a !Y

3

0 Z

c E

- .- 0 v U 0

2 8 a Q

LL

W cn U W 2 2 v,

a a

0

n

-

-1 W Z

0

400

e

a

“Cleaiiliiiess 1l;uikiiig Nuiiiber (Boeing Cui p ” t l i o i i ) I = I ~ C S I , Wuier Break Free Surfiiace 2 = Cleati, But Not Waier Break 1 % ~ 3 = Good. Most Soil Removed 4 = Worse, L i l k Soil Ilernovcd 5 = Worst, No Soil Ilctiiovcd

Rockwell Internetlonal Rochddyzm Dlrlslon

/ I

tb 0 N

"Cleiiiiliiiess Ranking Nuiiikr (Ilocing Gqxmtinn) I = IJcst, Water Ureiik Free Surfisc 2 = Clcen. llut Not Water Ilreiik Free 3 = Gtiixl, Most Soil Itenioved 1 = Worse, Ilttle Soil Ileniovetl 5 = Woi-SI, No Soil Ilcmovctl

Rockweil Interrletlonal ROcheldrn. Olrlilon .

TABLE 5. ROCKETDYNE LUBRICANTS AND DYES LISTED IN ORDER OF MOST DIFFICULT TO REMOVE FIRST.

PRODUCTION SUPPORT MATERIAL

...................................... I.

HOUGHTON DRAW OIL 3105 HYDRAULIC OIL MIL-H-5606 MICROFINISH CENTERPOINT LUBE DYKEM BLUE LIQUID

(Similar rating for the 3 other Dykem Dyes)

MOLLY DEE RUST FOIL L-492 DTE 26 OIL . ......................................

AVERAGE REMOVAL RATING (a)

4.5 3.8 3.3 3.0 2.8

2.5 2.3 2.0

ROUGH CLEAN PROCESS WITH 400 p s i SPRAY

0 PROCESS WAS PERFORMED USING A HAND-HELD SPRAYER I N A GLOVE BOX

0 SPRAY WAS DIRECTED AT HARDWARE BY OPERATOR

0 PROCESS WAS LABOR I N T E N S I V E & OPERATOR DEPENDENT

o 2 CLEANING CYCLES WERE USED

EMULSION DEGREASE SPRAY FOLLOWED BY D . I . H z O IMMERSION R I N S E

0 A L K A L I N E CLEANER SPRAY FOLLOWED BY D . I . H r O IMMERSION R I N S E

PRECLEAN PROCESS WITH 30 kHZ ULTRASONICS

9 PROCESS WAS PERFORMED I N A 3-ga l . ULTRASONIC TANK

0 ULTRASONIC FREQUENCY WAS 30 kHZ, POWER WAS 3.4 watts/sq.in.

0 2 CLEANING CYCLES WERE PERFORMED

0 EMULSION DEGREASER FOLLOWED BY FLUSHING WITH D . I . H2O

0 A L K A L I N E CLEANER FOLLOWED BY FLUSHINQ WITH D . I . HzO ,

F I N E CLEAN PROCESS WITH 30 k H z ULTRTASONICS

0 SAME EQUIPMENT AS FOR PRECLEAN

0 0 . 0 4 % TURCO 4215 A D D I T I V E FOLLOWED BY FLUSHING WITH D . I . H t O

0 V4CUUM DRY

406

\ \

\

!

m I -

I

T-

I

I+ 0 Q:

MF DTE 26 CPL CT HYD. OIL A0128.4 *

0 . . . . . * '

. . , -_ ,. . . . . PROPOSED ALL-AQUE \.,

!

i VISUALLY ! CLEAN

PROCESS CLEAN

WATER BREAK FREE

I PRECLEAN

VERIFY 1. A01282

Q c

STATUS OF FACILITY DESIGN FOR A OUS FINE LEANING

THE 50% DESIGN REVIEW HAS BEEN COMPLETED

EXCEPT FOR SELECTION OF THE ULTRASONIC FREQUENCY(1ES)

NASA-KSC STUDY HAS IMPACTED ORIGINAL SELECTION cp P w

ROCKETDYNE STUDY IS BEING CONDUCTED

WILL TEST 25, 30, 40 & 47kHz ULTRASONIC CLEANERS

TRANSDUCER TYPE SELECTION BIASED BY PAST EXPERIENCE

. MAGNETOSTRICTIVE MORE RELIABLE

A0147.2

GROUNC L E E 1

6 /

# I #

LID I

HIGH LIOUID BASKET+\ , )) 1 1

I

LOW LIOUID

PUSH AIR

SPACE ALLOWED FOR TRANSDUCERS

I ROOM ALLOWED FOR STEAM HEATING C O I L S ( T Y P I

ELEVATION DRAW1 NG

.

AQUEOUS FINE CLEAN TANKS

0

I

0

STATUS OF ALL-AQUEOUS CLEANING PROGRAM

I.D. MORE AGGRESSIVE AQUEOUS ROUGH CLEAN TECHNIQUES

EVALUATE EFFECTIVENESS OF ULTRASONICB AS PRECLEAN TECHNIQUE

VERIFY CENTRIFUGATION AS MEANS TO CLEAN CLEANING SOLUTION

RESOLVE SPECIFIC CLEANING PROBLEMS

0 SSME INJECTOR O ANODIZED HARDWARE RIGIMESH FILTER 0 BOFT GOODS

0 CLEANING PRIOR TO PLATING 0 44QC BEARINGS

I.D. SHOP SOILS NOT REMOVALBE BY CURRENT AQUEOUB CLEANERS

0 I.D. ALTERNATES FOR THOSE MATERIALS

0 I.D. ALTERNATE CLEANERS THAT WILL REMOVE THOSE SOILS OR

I.D. ALTERNATE NVR VERIFICATION SOLVENT & TECHNIQUE

0 FOR LARGE COMPLEX HARDWARE

REEVALUATE THE REQUIREMENTS OF <i mg/ft2 m for o2 SYTEMS

AVD ADVANCED VAPOR DEGREASING

"ADVANCED VAPOR DEGREASING" PROCESS DEVELOPED BY PETROFERM PARTNERSHIP AMONG: PETROFERM (SOLVATING AGENT)

3M (RINSING AGENT) DETREX (EQUIPMENT)

PROCESS UTILIZES VAPOR DEGREASER

TWO CHAMBERS - BOILING CHAMBER AND RINSE CHAMBER

RECIRCULATING PUMPS AND SPRAY NOZZLES FOR EACH CHAMBER

- 150% FREEBOARD I@ F 3 STEP CLEANING PROCESS

INITIAL CLEANING BY IMMERSION IN BOIL CHAMBER CONTAINING PHYSICAL MIXTURE OF SOLVATING AGENT (ALIPHATIC ESTER) AND RINSING AGENT (PERFLUOROCARBON, C6 Fi4)

RINSING BY IMMERSION IN CHAMBER CONTAINING PERFLUOROCARBON

FINAL RINSE/DRY IN PERFLUOROCARBON VAPOR ABOVE RINSE CHAMBER

Rockwell 1n:ernational Rockeldyne Division MLFl1-1-92.01

4 .

AVD PROCESSING EQUIPMENT

I

Heating Elements

CONVENTIONAL VAPOR DEGREASING EQUIPMENT

Rockwell International ?!A!! Rocketdyne Dwston

(Not tokale)

~ Extended Chiller 0 Freeboard Coils 0

0 0

Recirculating Heating Recirculating Pump and Elements Pump and

Spray Nozzles Spray Nozzles AVD PROCESS EQUIPMENT

MLF11-1-92.02

AVD ROCKETDYNE EVALUATION PROGRAM

PROCESS TO BE EVALUATED FOR APPLICATIONS WHERE AQUEOUS CLEANING INEFFECTIVE OR DETRIMENTAL TO HARDWARE

POTENTIAL HARDWARE CLEANING APPLICATIONS

440C BEARINGS ANODIZED ALUMINUM RlGlMESH DRY FILM LUBRICATED PARTS LOW ALLOY STEELS, INCOLOY 903 PARTS

FEASIBILITY STUDY INCLUDES PRELIMINARY MATERIAL COMPATIBILITY AND CLEANING EFFECTIVENESS bal

CI Q: MATERIALS SOILS

440C INCOLOY 903 MACHINING OILS 2024 ALUMINUM COPPER CUTTING FLUIDS 4130 STEEL 321 STAINLESS STEEL HYDRAULIC OIL INCONEL 71 8 DRY FILM LUBRICANT PARAFFIN WAX NICKEL PLATE SOLDERING FLUX

Rockwell international Rocketdyne Division MLFll-1-92.03

t-

5 L

AVD CONCERNS

HIGH FREEBOARD REQUIREMENTS

POTENTIAL AIR POLLUTION ISSUES - SOLVATING AGENT IS VOC

COULD BE A PROBLEM IN AREAS SUCH AS SOUTHERN CALIFORNIA

GLOBAL WARMING POTENTIAL OF RINSING AGENT

COULD BE AN ISSUE IN SEVERAL YEARS

CLEANING CAPABILITY

FLASHPOINT OF SOLVATING AGENT, 218 "F

Rockwell International Rocketdyne Division MLFl1-1-92.04

H AN DW IPE SOLVENTS

H REGULATIONS IMPACTING THE USE OF SOLVENTS FOR HANDWIPE APPLICATIONS

CONFLICTING REQUIREMENTS FOR OZONE DEPLETION, SMOG REDUCTION,TOXICITY, ETC.

COMPLEXITY AND INCONSISTENCY OF REGULATIONS

I SOME EXEMPT FLIGHT HARDWARE, SPECIALTY USES

ELIMINATION OF ALL "PRACTICAL" SOLVENTS

.

D I r

WHAT ARE THE TYPICAL APPLICATIONS FOR HAND WIPING ?

ACETONE

CLEANING OFF TAPE RESIDUE

CLEANING FOR WELDING

REMOVING MARKING INKS

REMOVING LOC-TITE

ALCOHOL(IPA)

CIRCUIT BOARDS, ELECTRONICS

REPLACING FREON(N0N OXID)

REPLACING TCA(N0N OXID)

FREON ALL OXID SURFACE CLEANING

SEALING SURFACES

WHERE CLEANER RESIDUE MAY INTERFERE

DRY FILM LUBE

SOFT GOODS

MAINTENANCE OF CLEANLINESS

TCA POSSIBLE REPLACEMENT FOR FREON (NEED HOODS)

WHAT IS GOING OUT AND WHEN ?

I AT CANOGA: I FREON IN OCT, 1993

TCA IN OCT, 1995

LEAVING ONLY: . - - - - - - - - - - - - .

AQUEOUS SOLT'S

IPA

ACETONE

I AT SANTA SUSANA: I FREON IN OCT, 1993 TCA IN OCT, 1995 IPA ON JAN 1,1993 ACETONE NOW

LEAVING ONLY: .------------. AQUEOUS SOLT'S

NOTE 1.

NOTE 2.

NOTES 1. IPA (90% + 10% WATER) HAS VAPOR PRESSURE <25 TORR AND THEREFORE COULD

RE SURSTITUTED FOR IPA IN MANY APPLICATIONS.

2. NEW PRODUCTS OUT ON MARKET SUCH AS "CITRA-SAFE" WHICH HAVE A LOW

VAPOR PRESSURE AND COULD BE USED AS A SUBSTITUTE FOR ACETONE IN SOME CASES.

I CONSIDERATIONS IN SELECTING A HANDWIPE SOLUTION

IS IT ?

AN OZONE DEPLETER: ~

e.g, FREON, TCA, CTET

(ALL SUBSTANCES WITH MORE THAN 200 G/L OF VOC'S AND/OR A VAPOR PRESSURE >25 TORR)

b b f3 CANCER CAUSING: P

AQMDS RULE 1401

HEALTH EFFECTS:

ASSY BILL AB 2588 (LIST OF SUBSTANCES REQUIRING WARNINGS)

(REQUIRES PUBLIC NOTIFICATION AFTER USE OF TOXIC SUBSTANCE)

PROP 65 (LIST OF SUBSTANCES REQUIRING WARNINGS)

(REQUIRES PUBLIC NOTIFICATION BEFORE USE OF TOXIC SUBSTANCE)

HAZARDOUS: e.g, FLAMMABLE

OTHER CONSIDERATIONS 1

EACH COUNTY HAS DIFFERENT RULES

WILL THE SYSTEM BE ENCLOSED ?

WILL THERE BE HOODS ?

IS IT A CURED SUBSTANCE BEING CLEANED ?

WILL THERE BE ENTRAPMENT ?

IS THE SUBSTANCE LOX COMPATIBLE ?

IS THERE POTENTIAL CORROSION ?

IS THERE AN UNACCEPTABLE ODOR ?

DOES IT MEET CUSTOMER REQUIREMENTS ?

HANDWIPE CLEANING OF ROCKET ENGINE COMPONENTS

WHAT ARE SOME TYPICAL SOLVENTS CONSIDERED ? (CONSIDERING LAWS, PERMITS. AND PRACTICABILiTY)

- -- - FLIGHT OTHER

EXPOSURE 0 LIMIT

ACETONE 750 PPM OK NO NO OK VOWFLAMMABLE

IPA (PURE) 400 PPM OK NO YES (UNTIL 1/93) OK VOWFLAMMABLE

TCA 350 PPM OK OK OK OK OZONE DEPLETER

FREON 1000 PPM .OK OK OK OK OZONE DEPLETER

AQUEOUS SOL'TS VARIAELE OK OK OK OK MAY BE TOXICNOC

\

.~

.. ~_. - - -__-- -__-- -___-_-- - -_- -_- - - -__-- - - - - - - -_- - -__-- - - - - -_-_-- - -_- -_- - - - bb PJ G .1111-1111111.1-111.11.1-111..

ETHYL 1000 PPM NO NO NO NO VOCFLAMMABLE

METHYL ' 2OOPPM VOWFLAMMABLE

CARBON TETRA CHLORIDE 5PPM TOXIC/OZONE DEPLETER

METHYL ETHYL KETONE 200 PPM voc METHYL ISOBUTYL KETONE 50PPM

TCE 50 PPM

PERC 50 PPM

vociloxIc

voc~oxlc NO TOXICNOC

voc NO NO VOCFLAMMABLE

OK VOCffLAMMABLE

TOXIC

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ TOLUENE 100 PPM OK

BUTYL ALCOHOL 50 PPM OK' ________.__________________________

- - - - - - - - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ NAPTHA VARIABLE OK OK(S0ME)

METHYLENE CHLORIDE 50 PPM NO NO NO NO . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES 1. VENTURA COUNTY HAS A PROPOSAL THAT IS BEING READIED FOR PASSAGE THAT WOULD BAN ALL SOLVENTS ON MAINTENANCUGSE USE.

HANDWIPE APPLICATION ALTERNATIVES

ELIMINATE EXCESSIVE USE

H IMPROVE PACKAGING AND MAINTENANCE OF CLEANLINESS

EMPLOY PERFLUORINATED COMPOUNDS

H POOR SOLVENCY

EXPENSIVE

H MAY BE COMPATIBLE WITH OXIDIZERS

EMPLOY 90% IPA, DI WATER WHERE POSSIBLE

MAY REQUIRE INCREASED DRYING

EMPLOY AQUEOUS CLEANERS WHERE POSSIBLE

MAY REQUIRE RINSING AND DRYING

SUMMARY OF BASIC PROBLEMS IN HANDWIPING APPLICATIONS

NO SUBSTITUTE FOR FREON HAS BEEN IDENTIFIED FOR OXIDIZER SYSTEMS OTHER

THAN TCA AND TCA MAY REQUIRE HOODS. ALSO, TCA WILL BE GONE IN 3 YRS.

= AQUEOUS SOLUTIONS FOR HANDWIPING HAVE POTENTIAL CORROSION PROBLEMS

AND ALSO TEND TO LEAVE RESIDUES. _.

= THE 90% IPA SOLUTION IS AN ALTERNATIVE BUT LIQUID ENTRAPMENT

IN AN OXIDIZER SYSTEM COULD BE HAZARDOUS. THE RESIDUE FROM

EVAPORATED IPA IS NOT AN OXIDIZER HAZARD.

I PROBLEM AREAS:

LIQUID ENTRAPMENT IN OXIDIZER SYSTEM

= RELATIVELY POOR CLEANING EFFECTIVENESS = = INCREASED POTENTIAL FOR CORROSION

ADDITIONAL DRYING MAY BE REQUIRED

ELIMINATE THE USE OF PERCHLOROETHYLENE AIRTOXIC CARCINOGEN REGULATED BY.AB2588 AND PROPOSITION 65

ALTERNATE PROCESS IDENTIFIED fs Q.

USES HIGH TEMP OIL TO MELT AND DISSOLVE WAX USES AQUEOUS CLEANING TO REMOVE OIL SUBSTITUTES 1 , I ,I TRICHLOROETHANE FOR VERIFICATION

NO001 1 OF 4

HOT OIL TURCO 6802 230 t 20" F 2 HOURS MIN.

ACETIC ACID FLUSH AMBIENT TEMP 2 HOURS MIN

r

INTERMEDIATE DUPONT

1 8 5 t 15" F AXAREL 56 18&5" F . D.I. WATER FLUSH - - 2 HOURS MIN 5 - 10 MINS

INTERMEDIATE D.I. WATER FLUS 185 t 15 "F 5-10 MiNS

4 I

I INTERMEDIATE TURCO D.I. WATER FLUSH VITROKLENE 1 8 5 t 15°F 5-10 MlNS

HOT D.I. WATER OVEN DRY WITH

250t 20°F 2 HOURS MIN 2 HOURS MIN I

c, HYDROCARBON

INTERMEDIATE D.I. WATER FLUSH 1 8 5 t 15" F 5-10 MlNS

112 HOUR SOAK

NO001 2 0 F 4 NOTE: ONLY ONE TANK IS UTILIZED FOR THE INTERMEDIATE . FLUSHES SHOWN - - - - . .

TEST #

HYDRO- 11 HR 1 SOAK TEST RESULT 1/2 HR MG/200ML SOAK

DEWAX METHOD

A B C D

HOT OIL HOT OIL PERCH HOTOIL GN2 (BENCH AQUEOUS PURGE PURGE

AXAREL M R E L A UEOUS AQUEOUS %- CLEAN

MARK) CLEAN

CL AN

GN2

NOTE: 0.50 MG WAW200ML IS ALLOWABLE NOOOl3OF4