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What is Ultrasonic?
Sound can be defined simply as a vibration. All sounds are produced by things that vibrate and all things that vibrate generate a sound, and the level of a vibration determines its range. The lowest vibration level has a lower range and the higher level has a higher range. Therefore, the range is directly connected to the vibration rate. When this rate of vibration, or cycle, is expressed per unit of time (seconds), it is called frequency. The frequency can be expressed in Hertz (Hz) which is the number of cycles per second, for example: 1Hz = 1 cycle per second. Most men can hear sounds from 10Hz to 16,000Hz (16kHz), but some women can hear up to 19,000Hz (19kHz), so sounds that exceed this frequency can not be heard by the human ear. Because of this fact that frequencies above 20,000 Hz (20 kHz) are called Ultrasonic. While frequencies above 20,000 Hz (20 kHz) are not used for oral communication between humans, they are used in a wide application of uses that make life easier for men. As an example we can mention the manufacture of Sonars, fish shoal detectors, cracking machines in metal parts, welding equipment in thermoplastics and metals, cell separators, ultrasonic cleaning equipment and a multitude of applications, being the The main focus here is the extensive application of Ultrasonic Cleaners, which is one of the areas where Ultrasonic is most applicable in the industrial environment. A large part of the manufacturing and service companies has a constant need for varied cleanings in parts and components, with levels of demand established by standards, linked to a cost compatible with the process, free of risks to human health and the environment. environment. Ultrasonic Cleaning is often the answer to all of these needs!

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How did Ultrasonic cleaning come about?
Research reports that during World War II the first occurrence that triggered the actual discovery. Accidentally, an object emitting high-frequency sounds (radio communication) fell into the water during its use, causing the formation of bubbles that caught the attention of the serviceman who used the radio when picking it up in the puddle of water. Which were later called cavitation. It was later noted that a high-frequency vibration in a liquid medium promotes the immediate formation of millions of tiny bubbles (or cavities) that collapse when they encounter an obstacle within the liquid.

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What is basically "Ultrasonic Cleaner" (Ultrasonic Cleaner or Ultrasonic Cleaning)?
Ultrasonic Cleaning is based on the transformation of electrical energy into mechanical energy, causing within a liquid solution a phenomenon called Cavitation. Ultrasonic cleaning equipment generally consists of an oscillator circuit, power circuit (electronics), Piezoelectric Transducer and a tank (tank) for a suitable liquid solution (detergent / degreaser). The main peculiarity of this type of cleaning technique is the penetration into cracks, holes, porosities, removing the dirt in a homogeneous way, where human access would be impossible by any other method.

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What is a Piezoelectric Transducer?
The Piezoelectric Transducer is the component responsible for transforming electrical energy into mechanical energy through the vibration emitted by it in response to the oscillator circuit and the power circuit. The main component of the transducer is its piezoelectric ceramic (PZT). PZT is a component that presents variations in its dimensions, when an electric field is applied to it at high frequency. This phenomenon is called piezoelectricity and the materials that present it are called piezoelectric.

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What is and how is cavitation produced?
Cavitation is the rapid formation of micro-bubbles within a liquid solution, generated by the high frequency of Ultrasonic. These bubbles are formed by millions and the collapse of millions of tiny bubbles (or cavities) inside a liquid promote mechanical action. Cavitation is produced by the alternation of waves of high and low pressures, which are generated by Ultrasonic. During the low pressure phase, these bubbles grow in microscopic size until they reach the high pressure stage, in which they are compressed and imploded. These cavities occur along the liquid. The effect of thousands of implosions per second makes the Ultrasonic cleaning process very powerful, and the result can be observed at the microscopic level.

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Cavitation Helpful:
Useful cavitation happens after removal of existing gases in the cleaning solution, where a void will be left in the formed bubbles. Bubble collapses happen when the pressure wave hits the wall of the bubble. The energy released by this collapse is converted into heating and kinetic energy, generating high temperatures in microscopic proportions in the liquid solution. This energy will help the detergent to break the bonds between the parts and the dirt. Cavitation cleans effectively because it attacks dirt and contaminants (molecular level), raising the temperature of the liquid increases the rate of chemical reactivity, which consequently also increases Cavitation. In order to obtain a good level of Cavitation, it is important to observe: temperature, surface tension, viscosity, density, time of exposure to cleaning and frequency of the Ultrasonic ideal for the type of cleaning to be performed. By controlling these factors, choosing the right cleaning detergent, using the right temperature and the right equipment, will ensure a good cleaning result.

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What is degassing and how is it made?
Degassing is the initial removal of gases present in the solution. Useful cavitation occurs after these gases are removed from the cleaning solution and a void is left in the blisters that are formed below. The operation of Ultrasonic itself will be responsible for removing these gases, depending on the time of operation without parts inside the tank. As the liquid solution is degassed with the Ultrasonic in operation, the sound emitted will increase beyond the modification that is taking place on the surface of the liquid. These are aspects (audible and visual) that can aid in the identification of the degassing process.

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How to get the right Ultrasonic cleaning equipment?
There are many important things to consider when purchasing an Ultrasonic Cleaner that is efficient for every need. The most important decisions to be made are to choose the ideal cleaning solution, the right temperature (depending on the liquid and parts), the Ultrasonic frequency (25/33/40/135 KHz) and the ideal size of the equipment .

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Can Ultrasonic Cleaning Damage My Parts?
Ultrasonic cleaning is considered safe in most of its applications, and there are restrictions in some cases to the time of application of the same and the frequency of Ultrasonic, depending on the materials to be cleaned. If the parts remain for a very long period (hours) exposed to Ultrasonic Cleaning and the material is fragile, damages may be generated. To avoid any similar occurrence, one must choose a company capable of developing the ideal equipment and the ideal process, so that success is complete. CTA do Brasil has Expertise and several "success cases" to format to its client all the necessary conditions to obtain good results. In order to understand the difference in Ultrasonic frequencies as a function of the cleaning and the material of the parts, it is important to understand that the frequency determines the size of the cavitation bubbles and as the frequency increases the cavitation bubbles decrease from Size, making the cleaning thinner and as the frequency decreases the cavitation bubbles increase in size, making cleaning more aggressive.

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What is "direct" and "indirect" cleaning?
Direct cleaning occurs when the parts to be cleaned are immersed directly into the ultrasonic tank solution, through the aid of stainless steel baskets or special supports. Indirect cleaning occurs when the parts are placed inside a separate container, such as a glass backer filled with the proper cleaning solution, if the tank is filled with water only. In the case of indirect cleaning the ultrasound will occur through a process of transfer of the vibration generated by the tank, which in turn will transfer the vibration to the wall of the backer, thus generating cavitation inside the same. Usually this type of cleaning applies to small parts such as dental implants and the like.

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What kind of solution should I use?
The liquid solution (detergent or degreaser) plays a very important role in the set of actions to have a good result. There are products suitable for use in ultrasonic cleaning, emphasizing that improper chemicals can impair the operation of Ultrasonic and damage the equipment in cases where extremely aggressive chemicals are used, which is not in keeping with the environmental conditions currently being sought. CTA do Brasil is able to guide its clients in the decision making of which will be the best product to be used for each need that involves the application of ultrasonic cleaning, besides having some products formulated specifically to work with good results in the processes Of Ultrasonic.

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What kind of solution should I not use?
Never use corrosive or flammable liquids, because with the release of gases, existing in the solution, at the beginning of the cycle the risk of explosions may occur through some type of spark. In addition, acids should not be used, applied directly to the tank, as this will damage the equipment.

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When should the solutions be replaced?
The solution should be replaced when a drop in cleaning performance is noticed, or when the solution is visibly contaminated. A supply of clean solution at each cleaning is not normally required, especially if the equipment is equipped with a Filtration Recirculation system. There are optional peripherals to recirculate the liquid, passing it through a filter, which increases its durability and cleaning efficiency.

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Why should I obey the solution level in the tank?
The level of solution must always be maintained according to the levels established by the existing baskets or supports, aiming at the better functioning of the equipment, as low levels of solution can provide changes in the characteristics of the liquid environment, generating a change in the frequency of the system, And may even damage the equipment if the level is too low or non-existent (total lack of liquid = empty tank). The level of the solution must be observed in a double direction, especially in equipment that has a heating system, due to the high evaporation rate of the liquid. Level control systems can be incorporated into equipment as well, in order to protect parts that can not be idle, such as Ultrasonic, pumps and electrical resistances. CTA has these resources for the equipment it manufactures, but in smaller equipment and considered as an accessory.

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How long should the cleaning time be?
The cleaning time varies according to the following conditions: Type of contaminants to be removed; Concentration of cleaning solution; Process temperature; Geometry of parts and components to be cleaned; Materials of parts and components to be cleaned; Degree of cleaning required by the process or by standards.

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What is the purpose of using an integrated heating system?
The heating is applied depending on the type of solution to be used and depending on the level of dirt of the parts to be cleaned, but the heating being used in conjunction with a hot working solution, added to the mechanical action promoted by Ultrasonic always Results improvement.

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How to know if the equipment is producing cavitation correctly?
If you are not getting proper cleaning, it may be because a wrong solution, improperly-rated equipment, undesirable temperature, and short-cycle cleaning cycle have been chosen. However, if all of these steps are followed and the doubt persists as to the operation of your equipment, there are some tests that can be performed, the Aluminum Foil Drilling Test (AFDT), which is the best cost-benefit ratio.

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How to run the AFDT?
Cut a piece of aluminum foil, these used in the kitchen, in the size of 100 X 50mm. Holding it at one end, dip the other end into the water in the tank of the working Ultrasonic device, positioning it in various parts of the tank and observe. After a few seconds the sheet of aluminum foil should be perforated through the cavitation, thus showing that the equipment is perfectly functioning. If the aluminum foil is not perforated, it will be characterized that the equipment has some problem. Perform this test initially only with water in the tank and after confirming the operation, you can repeat the test with the chemical solution that will be used in Ultrasonic and if you do not obtain the same results with the chemical solution, you would have concluded that the chemical solution is inadequate, Impairing the operation of Ultrasonic.

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What is the purpose of using baskets, backers and pallets?
It is not advisable to deposit parts to be cleaned directly on the bottom or against the side walls of the tank, since Ultrasonic Transducers are generally applied in these areas, and this may damage the Transducers as well as impair cavitation and consequently cleaning Of the parts. These accessories also facilitate the handling of parts to be cleaned.

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What is the ideal temperature for good cleaning?
Heat usually increases and speeds up the cleaning process, and most solutions that are designed to work hot are usually used between 50 and 60 ° C. There are cases in which the temperature plays a primary role in cleaning and Ultrasonic can be operated up to 90 ° C.

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Why is there a need for a rinse after cleaning?
Rinse is recommended so that any type of chemical residue from the cleaning step can be removed, which may damage the part and the process. The rinsing also exerts the function of removing residues that are only deposited on the part, but already they are completely disaggregated of the same by the action of the Ultrasonic.