Ultrasonic Cleaners
Ultrasonic cleaners are advanced cleaning machines used in a variety of industries. Sectors that utilize ultrasonic cleaners for effective cleaning include healthcare (such as general practice, surgery, optometry, and podiatry), laboratories (for sonochemistry, cleaning scientific and research instruments, cell disruption, and mixing applications), manufacturing, jewelry, aerospace, automotive, defense, filtration, molding and fabrication, pharmacy, as well as equipment reconditioning and maintenance.
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The History of Ultrasonic Cleaners
The technology behind ultrasonic cleaners originates from ultrasound, which was discovered by chance in the 1930s in a laboratory. Employees at the Radio Corporation of America (RCA) were using freon to cool radio components and observed ultrasonic wave activity around a crystal running at 300 kHz. Although this discovery was initially set aside, ultrasonic technology was not put to practical use until about 1949. By 1952, ultrasonic cleaners were used in production facilities, and by the 1970s, this cleaning technology became popular for affordable home use.
Since the 1990s, ultrasonic cleaning technology has advanced significantly, with higher frequencies and new cleaning processes developed. These improvements include power spraying, rinsing, precision flushing, and parts drying. Today’s systems can perform these actions quickly, and when paired with deionized water, ultrasonic cleaners can leave parts completely residue-free.
Advantages of Ultrasonic Cleaning
Ultrasonic cleaners offer a deep clean that traditional parts cleaning methods cannot match. They also provide many other benefits: they are environmentally friendly, cost-effective, time-saving, versatile, gentle on delicate items, energy efficient, highly reliable, and excellent for cleaning small or intricate components.
- Environmental Friendliness
- Ultrasonic cleaning reduces waste, minimizes emissions, and provides a safer workplace environment.
- Cost Effectiveness
- Ultrasonic cleaning uses soap-based solutions and sonic energy, resulting in low operating costs. Costs may vary depending on the cleaning agent and parts, but they are generally much lower than other cleaning methods.
- Time Efficiency
- Ultrasonic cleaning quickly cleans metal parts, helping to reduce energy usage and saving you time and money.
- Versatility
- Ultrasonic cleaners can remove various contaminants including oil, grease, metal shavings, dirt, sand, paint, carbon, oxides, and many other particles from a wide range of surfaces.
- Gentleness
- Unlike abrasive or mechanical cleaning, ultrasonic cleaners use gentle cavitation to clean without damaging parts, making them safe for sensitive items like microchips in electronics.
- Energy Efficiency
- Ultrasonic cleaners consume less energy compared to traditional parts washers. They typically use a single efficient motor, unlike older machines with multiple motors, ensuring lower power consumption. Ultrasonic washing machines are built for optimal energy use.
- Reliability
- Ultrasonic cleaning is reliable as the system has no moving or rotating parts. This simple design ensures consistent and dependable operation for parts washing.
- Small Parts Cleaning
- Ultrasonic cleaners excel at washing small or hard-to-reach parts that are difficult to clean with standard methods. They effectively clean inside passageways, cracks, holes, and tiny openings. Ultrasonic cleaning machines are ideal for intricate components.
Process of Ultrasonic Cleaners
Ultrasonic cleaners remove dirt and contaminants from small parts using high-frequency sound waves, typically around 18 kHz, which cause cavitation. Cavitation is the creation and collapse of tiny bubbles in the cleaning liquid. These bubbles dislodge and lift away particles from surfaces and crevices that are otherwise hard to access. Common contaminants removed by ultrasonic cleaning include sludge, polishing compounds, mold release agents, and oil.
Ultrasonic cleaning equipment is widely used for cleaning jewelry, watches, electronic parts, medical and dental tools, precision instruments, heat exchangers, and firearms.
- Design of Ultrasonic Cleaners
- Every ultrasonic cleaning system includes at least an ultrasonic transducer, a generator, and a tank (immersion tank).
- Transducers convert electrical energy into high-frequency mechanical vibrations. The generator supplies the necessary power to the transducer. The transducer is either mounted on the side of the tank or submerged inside it. The tank holds the items to be cleaned and the cleaning solution. The transducer emits ultrasonic waves into the tank, causing cavitation within the liquid.
- The tank contains a cleaning solution that can be hot water, an aqueous-based solution, or a solvent used for vapor cleaning. Each cleaning medium is suited for different applications. As the solution forms bubbles, these bubbles implode and scrub the parts clean. Materials commonly cleaned this way include stainless steel, iron, aluminuml, copper, brass, plastics, molded rubber, wood, and absorbent cloth.
- Materials of Ultrasonic Cleaners
- Most ultrasonic cleaner components, especially the tank, are made from stainless steel for corrosion resistance and long-term durability.
- Ultrasonic cleaning systems can be customized in many ways. For example, adding a square wave signal can create a multi-frequency system for cleaning different contaminants. Upgrades like digital controls, wheels for mobility, or battery power are also available depending on your needs.
- Before cleaning, parts are lowered into the tank. The system is activated via digital controls or knobs. Cavitation in the ultrasonic bath releases energy and heat, ensuring the cleaning solution reaches all surfaces of the parts, even hidden areas.
- Ultrasonic cleaners deliver unmatched cleaning quality, reaching every surface more thoroughly and efficiently than other cleaning technologies.
Types of Ultrasonic Cleaners
There are many types of ultrasonic cleaners, often categorized by their intended use. Examples include ultrasonic blind cleaners, ultrasonic jewelry cleaners, golf club cleaners, gun cleaners, and ultrasonic degreasers.
Ultrasonic blind cleaners are designed specifically to remove dirt, grease, fingerprints, and nicotine from blinds and shades. Jewelry cleaners are built for cleaning jewelry, golf club cleaners for golf clubs, and ultrasonic gun cleaners for firearms. Ultrasonic degreasers remove grease from automotive and industrial parts. Other options include industrial ultrasonic cleaners, immersible ultrasonic cleaners, and fully-automated ultrasonic cleaning systems.
Industrial ultrasonic cleaners use high-frequency sound waves to remove dirt and debris from objects. They work with specialized cleaning solutions and often include a powerful electric heater for enhanced performance. Immersible ultrasonic cleaners are flexible and easy to install, offering durable and convenient operation.
Fully-automated ultrasonic cleaners improve pre-assembly cleaning, reduce solvent use by up to ninety percent, and use heat pump thermal transfer to minimize solvent evaporation. Diagnostic controls and computerized transporters ensure consistent, high-quality cleaning results.
- Benchtop Cleaners
- Used to wash small parts. They have a small footprint and are often rested on a counter or table.
- Golf Club Cleaners
- Clean golf clubs quickly and thoroughly. They are widely used at golf courses for players to use.
- Immersion Cleaning
- Takes place in a tank using an aqueous solution. In this process, it is the cavitation that releases the contaminant from its base host.
- Industrial Ultrasonic Cleaners
- Large-capacity parts cleaners that use sound waves which produce cavitation to clean, degrease and sterilize products in manufacturing applications.
- Tabletop Cleaners
- Used to wash small parts. As the name indicates, they are small enough to sit upon a table.
- Tank Cleaners
- Do not require a lot of complicated machinery. Generally, they are built in a rectangular shape, holding 100 gallons or less.
- Ultrasonic Blind Cleaners
- Equipment designed to clean window blinds utilizing ultrasonic cleaning techniques. They provide for a very thorough cleaning, removing allergens like dust, pollen, soot and nicotine, as well as any other accumulated grime.
- Ultrasonic Cleaning
- A process that uses ultrasonic sound waves to clean.
- Ultrasonic Cleaning Equipment
- Uses millions of tiny bubbles to scrub.
- Ultrasonic Cleaning Solution
- Used in ultrasonic parts cleaners as an important part of the cleaning process, since water alone is not effective at cleaning the dirty part or product.
- Ultrasonic Cleaning Systems
- Use sound waves to clean, degrease and sterilize products, parts and machine components of grease, dirt, wax, lubricants, oil and other contaminants.
- Ultrasonic Degreasers
- Used to clean critical parts by incorporating both ultrasonic immersion cleaning and conventional vapor degreasing.
- Ultrasonic Jewelry Cleaners
- Use ultrasonic frequencies to clean cracks and crevices in jewelry that are difficult or impossible for traditional cleaning methods to reach.
- Ultrasonic Parts Cleaners
- Underwater cleaning systems that use high frequency sound waves to clean parts with hard surfaces.
- Ultrasonic Tanks
- The components of ultrasonic cleaners that hold the water, cleaning solution and parts to be cleaned.
- Ultrasonic Vapor Degreasing Equipment
- Uses solvents in an environmentally-safe chamber. The vapor and ultrasonic agitation work together to clean parts.
- Ultrasonic Transducers
- The power source of larger cleaning systems that convert electrical energy from a generator into mechanical energy, or sound vibrations, which cause cavitation.
- Ultrasonic Washers
- Use ultrasound waves and special fluids to clean jewelry, surgical instruments, and golf clubs.
Installation of Ultrasonic Cleaners
Ultrasonic cleaners can be installed in several locations, such as on a table, within a frame, mounted next to walls fitted with transducers, or used as a self-contained unit.
Wherever you position your cleaner, ensure it is near a grounded electrical outlet. Before plugging in, confirm that the outlet’s voltage and your cleaner’s power requirements are compatible.
Standards and Specifications of Ultrasonic Cleaners
The standards you follow depend on your application as well as industry and government regulations. For example, ultrasonic cleaners used for medical parts must comply with FDA standards, while those cleaning military equipment may need to meet Mil-Specs. For optimal results, ensure your system and procedures adhere to guidelines from organizations such as ISO, ASTM, and NIST.
Things to Consider When Choosing Ultrasonic Cleaners
Begin by considering what items you need to clean, including their size, shape, and volume. This will help you determine the appropriate tank size for your ultrasonic cleaning equipment, which is available in a wide range of capacities.
Also factor in your application’s demands. For heavy-duty cleaning, select high-capacity ultrasonic cleaners, as they are more robust than standard units.
The type of cleaning solution is also important. Solutions can be alkaline, acidic, or neutral. Alkaline cleaners work well for hard metals like stainless steel, but may damage non-ferrous or softer metals like aluminum. For ferrous metals, use a water-based solution with a rust inhibitor. Neutral pH cleaners are best for delicate components such as copper wires and fine metal layers, and are commonly used in ultrasonic jewelry cleaners.
To ensure you get the optimal cleaning system for your needs, choose a manufacturer willing to meet your specific requirements, budget, and timeline. For a list of reputable manufacturers, see the companies featured above.
Proper Care for Ultrasonic Cleaners
When operated correctly, ultrasonic cleaners typically require minimal maintenance. The most important step is to follow best practices and regularly inspect for any signs of defects.
One common mistake is placing parts directly on the bottom of the tank, which can damage the transducers. Always use a basket to hold items. The most frequent issue with used ultrasonic cleaners is heat damage, as transducers generate heat that must be dissipated in the liquid. Running the cleaner with insufficient solvent can damage the bond between transducers and the tank, stopping cavitation. Check for discoloration on the housing as a sign of heat damage.
To further improve the performance and lifespan of your ultrasonic cleaning equipment, maintain the correct temperature, watt density, and output frequency (standard units operate at 40 kHz). The right cleaning solution and proper settings maximize equipment longevity.
Accessories of Ultrasonic Cleaners
Ultrasonic washers generally require few accessories due to their straightforward operation. However, optional accessories are available to suit specific applications, such as extra sinks, casters for mobility, hinged or insulated lids, and containment baskets.
Ultrasonic Cleaners Terms
- Acoustic/Acoustics
- Pertaining to the energy of sound waves and the science and application of acoustic energy.
- Acoustic Streaming
- Currents flowing in one direction through a fluid because of sonic waves, like the action of a transducer in ultrasonic cleaning.
- Agitation
- Rotation of components that allows cleaning solution and cavitation to remove contaminants.
- Amplification
- Mechanical amplitude rising from both ends of an acoustic element. Amplification could be negative or positive.
- Aqueous Cleaning
- The use of water-based solutions for the cleansing process.
- Basket
- Small-parts container composed of mesh or containing holes.
- Blind Hole
- An air pocket in a component where the cleaning solution cannot reach and the cavitation process cannot occur.
- Cavitation
- Cleansing bubbles caused by ultrasonic waves in liquid, which create negative pressure.
- Cascade Rinse
- The succession of rinses used for the washed part(s). Water flows in a direction opposite of the flow of the parts, which allows for exposure to cleaner water throughout the process.
- Centrifugal Drying
- Using a basket that spins to enable the water and contaminants to separate from the surface of the cleansed part(s).
- Cleaning Solution
- Water-based detergent or organic solvents that provide an intense amount of cavitation energy.
- Cleanliness Check
- A water break testing process used to determine if the components are free of oil and other contaminants. A surface quality monitor takes measurement for thin films of contaminants.
- Closed-loop System
- A system in which wastewater is recycled once it has been treated and purified so it can be recirculated through the wash and rinse tanks in an aqueous cleaning system.
- Continuous Wave
- Acoustic wave used in ultrasonic cleaning. Parts exposure to this wave occurs throughout the full process.
- Critical Cleaning
- The cleanest stage possible for the components to experience. Cleanliness is essential for the use of the product.
- Diaphragm
- A device that generates vibrations.
- Dryer
- The device used in the process of removing moisture from components.
- Electrode
- The component that provides electrical energy at the preferred ultrasonic frequency to the transducer. Electrodes are typically thin metal plates.
- Generator
- Also known as the "power supply," it is the equipment component that provides energy and control to the converter or transducer of an ultrasonic device or system which is electronically run.
- Hertz (Hz)
- A measurement unit for frequency equal to cycles per second (cps). One Hertz is the same as one cps.
- Horn
- A common element of amplification that is equipped with a tip in a probe for ultrasonic systems.
- Kilohertz (KHz)
- A unit of measurement for frequency equal to one thousand cycles per second (cps).
- Immersion Cleaning
- Cleaning components by submerging them in an aqueous cleaning solution.
- Load Requirement
- A factor that affects the construction of the tank, generator choice and cleansing solution volume.
- Loop
- Point of maximum amplitude.
- Node
- Fixed point of minimum amplitude.
- Piezoelectric Transducer
- A ceramic crystal between two strips of tin. Voltage taken through the tin will displace through the ceramic crystal, and the diaphragm attached to the transducer then creates a pressure movement that makes a wave through the aqueous solution in the tank.
- Probe
- Specific to ultrasonics only, it refers to the converter, horn and tip system that receives power from a generator and performs work.
- Rinse
- Using clean water or solution to remove residual detergent.
- Somewhat Critical Cleaning
- The cleaning level that is lower than critical cleaning. Aesthetic or quality problems could occur if not cleaned well.
- Somewhat Industrial Cleaning
- Not as imperative as the cleanliness of critical or somewhat critical, but still poses an aesthetic or quality problem if not cleaned well enough.
- Sonic
- Pertaining to the velocity of speed of sound in contrast to ultrasonic. Labeling cleaning devices as sonic does not indicate that it is ultrasonic with cavitation, just that it vibrates components.
- Surface Quality Monitor
- Measures film depth of contaminants left on the cleaned part.
- Tanks
- Containers to hold the solution and part(s), usually rectangular in shape and manufactured in almost any size.
- Ultrasonic Transducer
- Component that receives electrical energy from the generator or power supply and converts it into mechanical vibrations.
- Ultrasonic Generator
- Converts the frequency of standard electric into high frequency needed to create ultrasonic vibrations.
- Vertical Agitation
- An up-and-down motion in an aqueous solution, in which spray blasts clean the submerged parts. Vertical agitation is a powerful cleaning method for parts containing blind holes or intricate passages.
- Water Break Test
- Determines if oil is no longer present on the cleaned part.
