When purchasing an ultrasonic cleaner, the first step is to understand the types of items that will be cleaned. The second is to determine the desired cleaning effect. The third is to assess the company’s growth potential and reliability. Next, consider the maximum capacity of the machine. Then, research the cleaning process used by others in the industry or whether the manufacturer has updated their methods. It's also important to compare several professional manufacturers based on their cleaning processes, pricing, and after-sales support. When signing a contract, ensure that key details such as the brand and model of components, consumable costs, and maintenance terms are clearly stated to prevent fraud by unscrupulous companies. Afterward, arrange for on-site inspection if the equipment is large-scale, bringing your parts to the manufacturer for evaluation. Finally, ensure that your employees receive proper training from the installer, not just a confirmation that it was done.
Power selection is crucial in ultrasonic cleaning. Using low power may result in long cleaning times without effective dirt removal. However, when the power reaches an optimal level, dirt is removed more efficiently. Too much power can cause excessive cavitation, which might damage delicate parts or cause corrosion on the tank’s bottom. While using organic solvents like trichloroethylene is generally safe, water or water-based solutions are more prone to pitting corrosion. If the vibrating plate is scratched, high power can worsen cavitation effects. Therefore, selecting the right power level depends on the specific application and materials being cleaned.
Frequency plays a significant role in the cleaning process. Ultrasonic frequencies range from 28 kHz to 120 kHz. Low frequencies (28–40 kHz) are ideal for general cleaning, especially with water or aqueous solutions, as they produce stronger cavitation forces. For small gaps, narrow slots, or deep holes, higher frequencies (40 kHz or above) are more effective, sometimes even reaching hundreds of kHz. For delicate items like watch parts, 100 kHz is often used. Broadband frequency modulation can further enhance cleaning results.
Using a cleaning basket is common when handling small parts. However, the mesh size can affect ultrasonic performance. At 28 kHz, a mesh size of 10 mm or larger is recommended to minimize signal loss.
The temperature of the cleaning fluid also impacts effectiveness. Water-based solutions work best between 40–60°C. In colder conditions, lower temperatures reduce cavitation efficiency. Some machines include heating elements to maintain optimal temperatures. However, once the temperature rises too high, gas pressure increases, reducing cavitation intensity and cleaning efficiency. Organic solvents, on the other hand, are typically used near their boiling point.
The amount of cleaning fluid and the placement of parts within the tank are equally important. The liquid level should be at least 100 mm above the vibrating surface. Single-frequency systems may create standing waves, leading to uneven cleaning. To maximize effectiveness, place parts within the 3–18 cm range, where ultrasonic energy is most concentrated.
Before purchasing a system, analyze the materials, structure, and dirt on the parts to be cleaned. This helps determine the best cleaning method and solution. Aqueous solutions are widely used due to their cost-effectiveness and ease of use, but certain materials or contaminants may require solvents. Testing different solutions through experiments ensures the best results. The physical properties of the cleaning fluid—such as vapor pressure, surface tension, viscosity, and density—also influence cavitation efficiency. Temperature affects these properties, so it must be carefully controlled.
When choosing a cleaning solution, consider three main factors: efficiency, safety, and cost. The solvent should be effective, non-toxic, and easy to handle. While the cheapest option may seem attractive, it’s essential to evaluate its efficiency, safety, and overall value. The solution must also be compatible with the material being cleaned. Water is commonly used, but for specific cases, solvents offer better results. Cleaning systems vary depending on the type of solution used, from simple open tanks to complex multi-tank setups with filtration, rinsing, and drying stages.
Solvent-based systems often include vapor phase degreasing, where hot solvent vapors combine with ultrasonic agitation to remove oils, grease, and wax. These systems usually have waste recovery devices for efficiency and environmental compliance.
Finally, the design of the tooling or baskets used to hold parts during cleaning is critical. Parts should not touch the tank’s bottom, and the total area of the items should not exceed 70% of the tank’s cross-section. Materials like rubber or soft plastics can absorb ultrasonic energy, so care must be taken in their selection. Insulating parts and improper tooling design can significantly reduce cleaning efficiency. Proper support structures like hooks, shelves, or beakers help maintain optimal performance.
Cleaning time typically ranges from 3 to 10 minutes, and it’s best to use a timer for consistency.
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