Removing Rust & Corrosion from Moulding Tool - Case Study
Customers Criteria: To remove burn marks and rust from mould tool
Component: Moulding tool
Material: Tool Steel
Contamination prior to cleaning: Burn Marks, Rust
Total number off: 2
Number off per run: 1
| Ultrasonic Cleaner | Cleaning Agent | Temperature(s) | Concentration |
|---|---|---|---|
| Kemet 12 Ultrasonic Cleaner | Solvit 3 | 40°C | 10% |
Process for cleaning mould tool
Allow the ultrasonic to heat up to temperature, then place the part into the basket and run a cycle of 10 minutes manually dunking after 5 to remove any loose debris. Do not leave the part in the ultrasonic for to long as this may start to blacken and discolour the part.
Etched effect: None
Before cleaning moulding tool
After cleaning moulding tool
Customers Criteria: Free from all contamination
Component: Plastic injection moulds tools
Material: Tool Steel
Contamination prior to cleaning: Plastic injection residue, corrosion
| Ultrasonic Cleaner | Cleaning Agent | Temperature(s) | Concentration |
|---|---|---|---|
| Kemet 30 | Solvit 3 | 40°C | 10% |
| Kemet 30 | DI water + Korrostop 5000 | 50°C | 0.1% |
| Versa 120 Dryer | N/A | 65°C | 100% |
Quickest way to remove rust
Due to the moulds being heavily contaminated with corrosion an acidic product is required; Solvit 3 was used due to its high de-oxidizing and degreasing properties. All tanks were degassed for 10 minutes and allowed to reach the required temperature before cleaning. All tools had a total cleaning time of 20 minutes in the ultrasonic using the sweep mode to ensure a thorough clean. Next the tools were rinsed in deionised water with a 0.1% concentration of a corrosion additive Korrostop 5000. Korrostop 5000 is used to protect steel against corrosion and does not leave any film that could disturb the following operations. Next the tools were dried in a hot air dryer unit for 20 minutes at 70°C. Note: Increased concentration and process time may produce a better result.
Before removing rust
After removing rust
Customers Criteria: Remove all contamination
Component: Tool
Material: Tool Steel
Contamination prior to cleaning: Grease, dirt, burn marks & plastic extrusion
Number off per run: 1
| Ultrasonic Cleaner | Cleaning Agent | Temperature(s) | Concentration |
|---|---|---|---|
| Versa 120 | H14 | 50°C | 10% |
| Versa 120 | De-ionised water | 50°C | 100% |
| Versa 120 Dryer | N/A | 70°C | 5 minutes |
Process for removing grease, dirt, burn marks & plastic extrusion
The tool was placed into the basket and then submerged into the tank and set for a cycle time of 10 minutes. As soon as the Sonics are turned on you can see the contamination being removed. After the wash cycle the parts have to be rinsed to neutralize any left on cleaning agent and contamination. Finally the parts were dried in the Versa hot air dryer set at 70°C for 5 minutes.
% Satisfactorily Cleaned: 100%
Before cleaning
After cleaning
