Ultrasonic cleaning is perhaps the single most effective cleaning method for metal parts, and cannot be compared to other part cleaning technologies, such as spray washers or oscillation parts washers which are not equipped with ultrasonic components.  Although the largest benefit is the level of cleanliness which can be achieved, other benefits include significantly reduced maintenance and operating costs.

Spray washing systems are "line of sight" cleaners.  The only part areas which are effectively cleaned are those which are directly attacked by the spray action, although lighter contaminants may be flushed away in the absence of direct spraying action.  Since many parts include bends, blind holes, and detail which is difficult or  impossible to reach effectively with spray action, these part designs will not be effectively cleaned in a spray washing system, even those equipped with turntables or moving spray heads.

Spray washing systems also require significantly more maintenance, and cost more to operate due to the evaporation of water which is common to these systems.  Cleaning fluid temperatures are also typically higher in these systems, and heat is very expensive to generate electrically.  Spray nozzles must also be periodically removed and cleaned to ensure the best possible cleaning results.

Another common parts washing method, an Oscillation Parts Washer, involves the oscillation of a parts load within a heated cleaning fluid, and, in some cases, the addition of Spray Under Submersion or turbulence produced by high pressure pumps.  Although these cleaning methods can be effective at removing light oils, shop contaminants, and coolants, they are not effective at removing bonded contaminants, or contaminants which are thicker and more difficult to remove.  Oscillation washers are also marginally effective when cleaning parts with internal detail which blocks the cleaning fluid from circulating.  Some parts washer manufacturers lacking experience with ultrasonic cleaning systems include roller conveyors to support parts in the cleaning tank.  These rollers, mounted between the ultrasonic emitters (commonly known as transducers) and the parts being cleaned, absorb much of the ultrasonic activity produced.  This process, known as Ultrasonic Shadowing, virtually eliminates the effectiveness of the ultrasonic system, especially when combined with fluid turbulence and/or oscillation devices.

Since both spray washing and oscillation parts washers cannot produce very aggressive cleaning action, they are also more dependent upon the effectiveness of the cleaning fluids in use.  In many cases, these systems require the use of cleaning fluids which are significantly more aggressive than those used in an ultrasonic cleaner for the same application.  As such, disposal of cleaning agents may also be more costly and difficult.

Ultrasonic cleaning systems have the capability to clean inside of holes the size of a human hair and smaller, an accomplishment which simply cannot be duplicated with other parts cleaning methods.  The cleaning action produced is microscopic in size, and has the ability to clean detail which is typically missed by alternative technologies.  In fact, the ultrasonic action produced cleans the microscopic "hills and valleys" on the surface of the parts to a microscopic scale.

Ultrasonic cleaners also have the ability to clean the INSIDE of objects which can not be cleaned using spray or oscillation methods, such as the inside of tubing, injection mold gas cavities and channels, carburetors, complex solenoid valves, and other similar part designs, since the ultrasonic energy has the ability to pass through the walls of the material to cavitate liquids which are contained within the parts.  Although some energy loss is encountered when the ultrasonic energy passes through a wall of material, this can be overcome by using proper ultrasonic operational frequencies, effective cleaning fluids, and the proper amount of ultrasonic power.

Maintaining an ultrasonic cleaning system is simplicity itself.  Ultrasonic cleaners require no specific maintenance whatsoever, other than keeping the tank as clean as possible, and preventing the buildup of contaminants on the tank bottom which may interfere with the ultrasonic transducers.  If the cleaning application in question includes a significant amount of contaminant, transducers can be mounted to the side of the tank rather than the bottom to prevent these contaminants from interfering with the ultrasonic cleaning action produced.

When to Use an Ultrasonic Cleaner over a Spray or Oscillation Washer:

• When the Ultimate in Part Cleanliness is Required Throughout the Part.
• When Attempting to Obtain Zero Residue Cleaning Results.
• If Cleaning Parts prior to Any Coating Operation.
• When Parts Include Internal Detail which Requires Cleaning
• When Cleaning Thicker Contaminant Layers.

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Zenith Mfg. & Chemical Corp.
85 Oak St.
Norwood, NJ  07648-0412
800-432-SONIC (7664)
201-768-6999
sales@zenith-ultrasonics.com