introduction to vda-19.1 and iso-16232

Introduction to VDA-19.1 and ISO-16232

Dr. Sebastian Wex

Cleanliness control Particular contamination

∙ 76689 Karlsdorf-Neuthard ∙ Germany©

Particulate and Filmic Contamination Go Together

2

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

http://www.rjl-microanalytic.de/


Oil/ Grease

Particulate Contamination

Typical Contaminants Found on Component Surface

3

Contamination Categories

Minerals Metals Salts Organic

hard soft

Filmic



ISO-16232 and VDA-19.1 are the Most Common Directives World-Wide

4

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



Three-Step Approach Standardized in VDA-19.1 and ISO-16232

5

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)




6


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



Rinsing with Pressurised Liquid Jet

7

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]



Rinsing with Pressurised Liquid Jet

8

Particle Extraction



Ultrasonic Vibration

9

Particle Extraction


• Frequency 35-40 kHz

• Power density 10 Watts/liter

• Duration 30-60 sec


Application

[VDA-19.1] [Sonorex][Hydac]

Small parts in beaker

Single components

Small parts in basket



Ultrasonic Vibration

10

Particle Extraction



Internal Rinsing by Liquid Flow

11

Particle Extraction


• Volume flow 1-20 l/min (turbulent)

• Duration 15-60 sec

• Pulsation, reversal of direction


Application

[VDA-19.1] [Sartorius][Hydac]

Bores, feedthroughs Pipes, tubes

Coolers, housings



Agitation by Shaking

12

Particle Extraction


• Volume filling 40-50%

• Amplitude 30 cm, Frequency 1 Hz

• Time 15-60 sec


Application

[VDA-19.1]

Containers Pressure tanks

Large tubes Small components

Do not!




13



Standard analysis

Extended analysis


AgitationUltrasound

Air jet extraction


Analysis filtration

1

2

3


Gravimetric



Micro-CT LIBS



Direct-Filtration

Analysis filtration

14

analysis filter

filtration funnel

Vacuum source

Filter holder

Cleaning cabinet

[Hydac]

[VDA-19]



Deposition of Contaminants on a Membrane by Vacuum Filtration

15

Analysis Filtration

Laboratory equipment for vacuum filtration

Vacuum source

Filter holder

Filtration funnel

Analysis filter

Vacuum flask



Vacuum Filtration Unit

16

Analysis Filtration



Preparation for filter analysis

17

Drying of Membrane



Well-prepared membrane

Analysis filtration

18




19



Standard analysis

Extended analysis


AgitationUltrasound

Air jet extraction


Analysis filtration

1

2

3


Gravimetric



Micro-CT LIBS



Typical Requirements from the Customer

20

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



Determination of Particle weight

21

Gravimetry



Determination of Particle Size and Number By Microscope or Scanner

22

Standard Analysis

Particle size

Standard Analysis> 50 µm

[Leica]

[Zeiss]

[RJL]



Typical Cleanliness Report on Three Pages

23

Standard Analysis



Light-optical analysis using a light microscope or scanner

24

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



Excellent Correlation of MicroQuick and Five Light Microscopes (6/2014)

25

Comparison to Light Microscopy

MicroQuick (green bar)others: Leica, Zeiss, Jomesa



Determination of Particle Material by SEM-EDX

26

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]



Aspex Automated Feature Analysis (AFA) im Video

Automatische Partikelanalyse

27

Steels

Coatings

Non-ferrous metals

Abrasive Minerals

Cleaner



Karlsruhe

Analysis Services & Instruments | From One Source

28

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


introduction to vda-19.1 and iso-16232

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