Jack Griffes - Cleanliness Testing to ISO 16232 and OEM Specifications_EngineExpo 25 Oct 2016

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Cleanliness Testing to ISO 16232 and OEM Specifications

Lessons from the Cleanliness Testing Laboratory

by

Jack Griffes

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So why bother with cleanliness testing?

Doesn’t it take time and add cost? Doesn’t it have potential to delay shipment?

Doesn’t a failed cleanliness test cause:

Product on hold Rewash potentialRetest after rewash

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So why bother with cleanliness testing?

Doesn’t it take time and add cost? YESDoesn’t it have potential to delay shipment? YES

Doesn’t failed cleanliness test cause:

Product on hold YESRewash potential YESRetest after rewash YES

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So why bother with cleanliness testing?

Reducing early warranty failure costs

Increasing reliability

Increasing longevity

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So why bother with cleanliness testing?

Reducing early warranty failure costsBenefits both Manufacturers & Consumers

Increasing reliability Benefits both Manufacturers & Consumers

Increasing longevityBenefits both Manufacturers & Consumers

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So what is cleanliness testing?

Extracting 90+% of residual contamination from part and transferring it to a filter patch/membrane for further analysis.

Further analysis could be:Gravimetric (mass of contamination)Maximum Particle Size (length or multi-axis)Particle Count / Particle DistributionParticle Identification

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Gravimetric Testing Contamination is extracted from part

– Pressure Rinse– Agitation– Ultrasonic– Functional Test Bed

Extraction fluid is vacuum filtered through a pre-weighed filter patch/membrane with specified micron rating.

Membrane is dried and weighed. Net weight = overall contaminant on part.

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Maximum Particle Size Generally in addition to Gravimetric Limit Typically X-axis (longest axis) only

– Less common multi-axis limits (X & Y, or X & Y & Z)– Can be “any particle” or a specific type like “Metallic”– Should be directly related to a known failure mode

• Margins of Safety (Limits set lower than what can cause failure) or Limits extended to particle types not able to cause a failure can exponentially increase cost of meeting the Limit

Often measured in microns

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Pop QuizHow big is a micron?

A. 1 millionth of a meterB. 1 thousandth of a millimeterC. Smaller than the diameter of a grain of sand?D. 0.000039 of an inchE. All of the above

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Perspective on Particle Size

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Particle Counting Filter patch from Gravimetric testing is

sandwiched between glass slides. Automated Optical Microscope (AOM) takes

hundreds of photos of filtered area Visual analysis is used to count & size particles

inside entire filtered area Particles can be sorted based on optical

properties – Ex. Metallic based on luster & intensity

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Particle Counting Strengths:

– Measures all particles on patch– Categorizes particles within size ranges.– Allows photos of particles to be included in report along

with x & y-axis measurements Weakness:

– Equipment expensive – Technician training is vital– Time consuming

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So what is ISO 16232 all about?• Spells out principles of cleanliness testing• Spells out 90+% extraction efficiency• Spells out blank value under 10% of limits• Spells out principles for 4 methods of extraction

• Pressure Rinse• Ultrasonic• Agitation• Functional Test Bed

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So what is ISO 16232 all about?• Spells out principles of Particle Counting• Presents a uniform cleanliness code for

particle count limits and reporting• Examples:

• CCC = A(B15/C14/D13/E12/F11/G10/H8/I4/K0)• CCC = V(B15/C14/D13/E12/F11/G10/H8/I4/K0)• CCC = N(E1500/F250/G130/H64/I16/K1)

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Understanding ISO 16232 code• CCC = Component Cleanliness Code• A = Standard Area = 1,000cm^2• V = Standard Volume = 100cm^3• N = Numbers of particles per component

• Examples:• CCC = A(B15/C14/D13/E12/F11/G10/H8/I4/K0)• CCC = V(B15/C14/D13/E12/F11/G10/H8/I4/K0)• CCC = N(E1500/F250/G130/H64/I16/K1)

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ISO 16232 code for A or V reporting• B = 5µm ≤ x < 15µm • C = 15µm ≤ x < 25µm • D = 25µm ≤ x < 50µm • E = 50µm ≤ x < 100µm• F = 100µm ≤ x < 150µm• G = 150µm ≤ x < 200µm• H = 200µm ≤ x < 400µm• I = 400µm ≤ x < 600µm• J = 600µm ≤ x < 1,000µm• K = 1,000µm ≤ x

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ISO 16232 code for N reporting• N = Numbers of particles per component

• Contamination Level Code is NOT used• Actual numbers of particles are listed after size

class Letter• Example:

• CCC = N(E1500/F250/G130/H64/I16/K1)

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Crown Cleanliness Testing Laboratory2070 Brooklyn Rd; Jackson, MI 49203 USA (517) 905-5328 or 5304 or 5329

Benefits of using a 3rd party Lab• Capital equipment cost borne by Lab• Skilled Lab Technicians hired by Lab• Calibrations, record keeping, etc.

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Crown Cleanliness Testing Laboratory Capabilities

Class 100,000 Clean Room Extraction Area

Gravimetric Testing per ISO 16232 & VDA 19 plus many OEM standards

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Crown Cleanliness Testing Laboratory Capabilities

Two systems with fully ISO 16232 compliant

calibration factors

We test to ISO 16232, VDA 19And many OEM specifications

Particle Counting & Sizing

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Crown Cleanliness Testing Laboratory Capabilities

Liquid Particle Count Testing – is done according to ISO 16232 or other similar

standards using Automated Optical Microscope (AOM) systems

– rather than count the particles suspended in the liquid the particles are counted on a filter membrane which allows multi-dimensional measurements and photos of the largest particles

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Crown Cleanliness Testing Laboratory2070 Brooklyn Rd; Jackson, MI 49203 USA

Jack Griffes (517) 905-5328 jgriffes@crownindservices.com

Allen Zubke (517) 905-5304 azubke@crownindservices.com