Download - Introduction to VDA-19.1 and ISO-16232
Introduction to VDA-19.1 and ISO-16232
Dr. Sebastian Wex
Cleanliness control Particular contamination
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Particulate and Filmic Contamination Go Together
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Contaminants on Surface
Thin layer of oily, waxy or greasy compounds
Solid granular particles und fibersParticulate contamination :
Filmic contamination :
[VDA-19.1]
Particulate contamination Filmic contamination
Filmic contamination provides adhesion for particles
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Oil/ Grease
Particulate Contamination
Typical Contaminants Found on Component Surface
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Contamination Categories
Minerals Metals Salts Organic
hard soft
Filmic
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ISO-16232 and VDA-19.1 are the Most Common Directives World-Wide
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Standardized Cleanliness Testing
What is regulated in the norms?
• Selection of methods approved for testing
• How to apply and validate the test methods
What is not regulated?
• Which test method is suitable for a specific part
• Which cleanliness level to apply for a specific part
→ See customer requirement
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Three-Step Approach Standardized in VDA-19.1 and ISO-16232
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Cleanliness Testing Overview
Extraction of particles from component surface1
2
3
Filtration of contaminant particles on a membrane
Analysis of contaminant particles (mass, size, numbers and type)
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Three-Step Approach Standardized in VDA-19.1 and ISO-16232
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Cleanliness Testing Overview
Liquid extraction Air extraction
Standard analysis
Extended analysis
Pressure-rinsing Internal rinsing
AgitationUltrasound
Air jet extraction
Air throughflow extraction
Analysis filtration
1
2
3
Light optical from 50 µm
Gravimetric
Light optical from 5 µm SEM-EDX
Raman spectroscopy IR spectroscopy
Micro-CT LIBS
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Rinsing with Pressurised Liquid Jet
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Particle Extraction
Starting Parameters (ISO-16232)
• Volume flow: 1.5 l/min
• Fluid volume: 5 ml/cm2
• Distance: max. 15 cm
• Nozzle shape, diameter: round, 2.5 mm
Use cabinet or laboratory equipment
Application
Single components
Small parts
Large surfaces
Interior surfaces
[VDA-19.1][Hydac]
[C.Roth]
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Rinsing with Pressurised Liquid Jet
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Particle Extraction
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Ultrasonic Vibration
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Particle Extraction
Starting Parameters (ISO-16232)
• Frequency 35-40 kHz
• Power density 10 Watts/liter
• Duration 30-60 sec
Use cabinet or laboratory equipment
Application
[VDA-19.1] [Sonorex][Hydac]
Small parts in beaker
Single components
Small parts in basket
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Ultrasonic Vibration
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Particle Extraction
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Internal Rinsing by Liquid Flow
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Particle Extraction
Starting Parameters (ISO-16232)
• Volume flow 1-20 l/min (turbulent)
• Duration 15-60 sec
• Pulsation, reversal of direction
Use cabinet or laboratory equipment
Application
[VDA-19.1] [Sartorius][Hydac]
Bores, feedthroughs Pipes, tubes
Coolers, housings
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Agitation by Shaking
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Particle Extraction
Starting Parameters (ISO-16232)
• Volume filling 40-50%
• Amplitude 30 cm, Frequency 1 Hz
• Time 15-60 sec
Use cabinet or laboratory equipment
Application
[VDA-19.1]
Containers Pressure tanks
Large tubes Small components
Do not!
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Three-Step Approach Standardized in VDA-19.1 and ISO-16232
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Cleanliness Testing Overview
Liquid extraction Air extraction
Standard analysis
Extended analysis
Pressure-rinsing Internal rinsing
AgitationUltrasound
Air jet extraction
Air throughflow extraction
Analysis filtration
1
2
3
Light optical from 50 µm
Gravimetric
Light optical from 5 µm SEM-EDX
Raman spectroscopy IR spectroscopy
Micro-CT LIBS
∙ 76689 Karlsdorf-Neuthard ∙ Germany©
Direct-Filtration
Analysis filtration
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analysis filter
filtration funnel
Vacuum source
Filter holder
Cleaning cabinet
[Hydac]
[VDA-19]
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Deposition of Contaminants on a Membrane by Vacuum Filtration
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Analysis Filtration
Laboratory equipment for vacuum filtration
Vacuum source
Filter holder
Filtration funnel
Analysis filter
Vacuum flask
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Vacuum Filtration Unit
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Analysis Filtration
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Preparation for filter analysis
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Drying of Membrane
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Well-prepared membrane
Analysis filtration
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Three-Step Approach Standardized in VDA-19.1 and ISO-16232
19
Cleanliness Testing Overview
Liquid extraction Air extraction
Standard analysis
Extended analysis
Pressure-rinsing Internal rinsing
AgitationUltrasound
Air jet extraction
Air throughflow extraction
Analysis filtration
1
2
3
Light optical from 50 µm
Gravimetric
Light optical from 5 µm SEM-EDX
Raman spectroscopy IR spectroscopy
Micro-CT LIBS
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Typical Requirements from the Customer
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Cleanliness Specifications
Particle mass
Example:
Total particle mass less
than 5 mg per 1000 cm².
Particle size Particle material
Example:
No particles larger than
400 microns allowed, soft
fibers are tolerated.
Example:
No abrasive particles of
quartz, corundum, silicon
carbide allowed larger
than 100 µm.
test complexity – equipment cost
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Determination of Particle weight
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Gravimetry
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Determination of Particle Size and Number By Microscope or Scanner
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Standard Analysis
Particle size
Standard Analysis> 50 µm
[Leica]
[Zeiss]
[RJL]
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Typical Cleanliness Report on Three Pages
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Standard Analysis
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Light-optical analysis using a light microscope or scanner
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Comparison to Light Microscopy
particle scanner
• Particles > 25 µm
• fast (2 minutes + reporting)
• low investment, maintenance free
• Imaging of entire membrane
light microscope
• Particles > 5 µm (model dependant)
• widely used standard
• high image quality, variable magnification
• sequential analysis of fields, stitching
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Excellent Correlation of MicroQuick and Five Light Microscopes (6/2014)
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Comparison to Light Microscopy
MicroQuick (green bar)others: Leica, Zeiss, Jomesa
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Determination of Particle Material by SEM-EDX
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Identification of Metallic Particles
Electron Microscopy (SEM) with X-Ray Spectroscopy (EDX)
• automated measuring of particle size, number and material
• smallest particles from 0.5 µm
• Determination of origin of particles
X-ray energy (keV)
gezä
hlt
e R
ön
tgen
qu
ante
n
Peak-Height = Weight proportion
[FEI]
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Aspex Automated Feature Analysis (AFA) im Video
Automatische Partikelanalyse
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Steels
Coatings
Non-ferrous metals
Abrasive Minerals
Cleaner
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Karlsruhe
Analysis Services & Instruments | From One Source
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RJL Micro & Analytic GmbH
Contract Analyses
Particle Scanner (MicroQuick)Compact SEM-EDX (Coxem)X-Ray Micro & Nano-CT (Bruker)Digital 2D X-Ray Imaging (Kubtec)
Product Lines
Cleanliness TestingDetermination of Foreign ParticlesWith Accreditation DIN EN ISO/IEC 17025