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Pierburg PN 02 035-Part Cleanliness Classification-01 03 2017-Aktuell
Pierburg PN 02 035-Part Cleanliness Classification-01 03 2017-Aktuell
1 Area of Application 2
2 Scope 2
3 General 2
3.1 Determination of the actual condition 2
3.2 Escalation 2
3.3 Process chain for definition of cleanliness requirements 3
4 Terms and Definitions 3
4.1 Pollution 3
4.2 Particle 3
4.3 Cleanliness requirements 3
4.4 Cleanliness Level 3
4.5 Residue weight (M) 3
4.6 Particle size 3
4.7 Particle quantity 4
4.8 Cleanliness inspection 4
4.9 Wetted area / Control Area (Ac) 4
4.10 Extraction method 4
4.11 Qualification test 4
4.12 Decay curve 4
5 Cleanliness classes (SK) 5
5.1 Definition 5
5.2 Size classes for particles 5
6 Functional assessment of the parts or components 7
7 Documentation of the cleanliness requirements 7
8 Cleanliness inspection 9
8.1 Procedure of qualification tests 9
8.1.1 Blank value 10
8.1.2 Declining criterion 11
8.1.3 Determination of the inspection specifications 12
8.1.4 Validity of the qualification test 12
8.2 Performing the routine tests 13
8.2.1 Sampling, packaging and transport of units under inspection 13
8.2.2 Verification of blind value during routine tests 13
8.2.3 Extraction of the particulate load 14
8.2.4 Filtration 14
8.2.5 Drying 14
8.2.6 Analysis 15
8.3 Documentation 15
9 Evaluation of surface energy 16
10 Further applicable documents 16
11 Updates 17
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Part Cleanliness PN 02.035
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2 Scope
This specification describes cleanliness classes to be kept with regard to particulate pollution, as
well as methods of collection and analysis of the residual contamination to be performed in the
cleanliness inspection of the parts, subassembly and single components. It describes also how to
define technical cleanliness demands in the engineering documents. The requirements are
generally valid as long as not otherwise specified on engineering documentation (e.g. drawing,
TL’s).
For simplification reasons, in the following standard only the word part is used. This includes parts
as well as subassemblies and single components.
3 General
If part or components does not provide any indications for the allocation of the cleanliness class,
the allocation can be based on experience. For this purpose, the degree of contamination of the
predecessor or similar device or component is documented. The cleanliness class for the new part
or component may be derived from this data. Moreover, all the failures in the field and in the
process which were due to contamination have to be taken into account.
Note: This approach requires the tolerances, the operational requirements and the functions of the
devices or components in question to be comparable!
3.2 Escalation
If achieved cleanliness class is out of specification than Technical Cleanliness (TC) inspection shall
be repeated under following conditions:
Inspection of randomly chosen one component in finished condition if previous TC inspection
results were within the specification (results are not older than 6 months).
Inspection of randomly chosen two components in finished condition if any TC inspection results
are not available.
Corrective action is taken if results of this verification measurement is negative, means cleanliness
level is out of specification.
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4.1 Pollution
Pollution consists of particles contaminating after their completion and impairing or preventing the
subsequent manufacturing process or the correct performance of the component or subassembly.
4.2 Particle
Particles are elements of solid matter, fibres and fibrous of metals, plastics, minerals, rubbers or
salts. Pasty elements are not counted among particles.
The potential danger of a particle is often related to the particle size and particle hardness. An
evaluation of the particle hardness is very complex. The popular optical microscopy can only
distinguish between “shiny” (metallic) material or “not shiny” (non-metallic) materials.
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Illustration 3: Wetted area example for vacuum pump marked with blue color.
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Division Mechatronics defines cleanliness classes for parts in order to have a clear allocation to
particle size classes to the relevant permissible degrees of contamination (see table 1)
5.1 Definition
The permissible level of residual contamination and the permissible type of particles are defined
according to the function of the component.
ISO 16 232 define grades of contamination which allow the logarithmic indication of the number of
particles per particle size class. The number is related to standardized area of 1000 cm². If the area
is smaller or greater than 1000 cm², an appropriate conversion has to be made. For parts
significantly smaller than the required 1000 cm², an adequate No. of parts has to be analyzed to
reach a surface area of 1000 cm² at minimum. Usage of smaller areas has to be aligned with
responsible Quality Department.
Cleanliness level
size
size x [µm] a b a b a b a b a b a b
class
E 50 =x< 100 5 7 5 7 5 7 6 8 6 8 9 10
F 100 =x< 150 2 5 2 5 2 5 4 7 4 7 8 9
G 150 =x< 200 2 5 2 5 2 5 4 7 4 7 8 9
H 200 =x< 400 1 2 1 2 1 2 2 5 2 5 5 7
I 400 =x< 600 00 0 00 0 00 0 0 3 0 3 4 4
J 600 =x< 1000 00 0 00 0 00 0 0 3 0 3 4 4
K 1000 =x< 00 0 00 0 00 0 0 3 0 3 4 4
Table 1 Cleanliness classes for metallic and non-metalic particles in accordance with ISO 16232-10
- Particle are standardized with starting size of 50 µm, starting with this size it is possible with standard
cleanliness test procedure to measure particle size. Classification with smaller particle size should be
avoided (size classes A-D).
*) Requirements related to fibers should be defined, if necessary, acc. to particular application
separately and mentioned on the drawing.
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Table 2 Amount of particles for each cleanliness level in accordance with ISO 16232-10
The entire volume of extraction liquid used to extract particles from the test components is filtered
on a membrane filter and the separated particles are counted and sized using microscopic
techniques.
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The best method of allocating cleanliness classes is the functional assessment, taking into
account:
Customer demands, especially at the interfaces (e.g. pneumatic connections)
The function of the part and evaluation of the effect of foreign particles on the function
The determination of the part areas to be included in the test, thus the actual surface
Media involved (oil, water, air, etc.)
Claims analysis
The careful analysis an assessment of the function can be the base for the definition of meaningful
cleanliness classes for parts or components. In doing so, the residual contamination limits have to
be coordinated for components working together.
The documentation of the requirements must be clear described on the drawing with help of
cleanliness class or the component cleanliness code (e.g. see below).
SK 2/ 0,7 / -
SK 3/ - / -
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3. Example for information on the classification according to ISO 16232 in case if standard req.
cannot be used:
4. In case of need for translation of current description of cleanliness requirements acc. to new
standard, please see below example for such translation:
Current drawing description:
CLEANING REQUIREMENTS:
GRANULOMETRY:
o
- N of particles bigger than 400 µm < 130/1000 cm²
o
- N of particles bigger than 150 µm < 2000/1000 cm²
o
- N of particles bigger than 50 µm < 250000/1000 cm²
o
- N of particles bigger than 1000 µm is allowed
GRAVIMETRY: LEVEL < 25 mg/1000 cm²
SURFACE OF THE PART: 218,7 cm²
PARTICLES MASS: 5,5 mg max.
In certain cases, for instance components for electronic assemblies, the permissible degree of
contamination has to be related to special material properties of the particles, such as conductivity
or hardness. In this case, this shall be made visible by special indication.
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This chapter describes methods for the determination of the technical cleanliness of components. It
includes methods allowing quantitative statements (e.g. relative to mass/ size) regarding the
particulate load. This information is required, for example, for:
To determine the particulate cleanliness condition of a test object, the test object shall be subjected
to a test cleaning process whereby the cleaned off particles are contained and analysed.
The selection of the extraction method depends, among other factors, on the material of the test
object, the type of contamination, the component size and the work piece part to be tested.
No objective evidence (such as, for example, of the capability of measuring and monitoring
equipment) of the capability of extraction methods can be provided according to statistical rules.
Already after the first extraction process, the degree of particle contamination of the test object is
reduced significantly in accordance with the target. Multiple measurements on the same test object
are not conducive to verifying the reproducibility of the extraction
The objective of the cleanliness test is to clean off any particles adhering to the component during
the extraction "completely" and to achieve a "decay" of the contamination. The effect of the
extraction is therefore decisive for whether the cleanliness of the component can be judged
correctly. It is therefore of great importance.
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The contamination present in the whole test system (test container, filter holder, lines, rinsing fluid
and air) which cannot be further reduced despite thorough precleaning, is called "blank value".
Illustration 4 indicates that the particle load of a test object cannot be completely removed despite
multiple cleaning processes and cannot be brought below the blank value. The cleanliness of all
components used during test cleaning therefore plays a major role and has to be taken into
consideration.
During cleanliness test, the blank value shall be significantly below an impairing level relative to
the cleanliness limit specification of the test object. Where this is not the case, no significant
statement can be made regarding the real component cleanliness.
Where the blank value is at an impairing level, suitable measures shall be taken to bring the test
cleaning systems to a lower blank value level (finer filtration of the rinsing fluid, filtration of the air
etc.).
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Example:
Requirement: M = 6 mg; L ≤ 800 µm
Permissible blank value: M = 0,6 mg; L ≤ 400 µm
As no absolute detection method for the real particle load exists at present, decay measurements
are of essential relevance. By repeating identical test steps on one component (multiple sample
of the same component), it is possible to detect whether the particle load separated each time is
reduced from test step to test step and whether the extraction method is therefore applicable.
The component is cleaned up to 6x in all using pre-determined parameters, whereby the
separated contaminant load is determined by separate measurements in each case and
visualized in an decay curve (see illustration 5).
n
Declining criterion: Cn ≤ 0,1∑Ci (n≤6)
i=1
Cleanliness level
10% Line
blind value
1 2 3 4 5 6
Number of tests
Illustration 5: Measured cleanliness level on repeated tests of one component („decay behaviour“)
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Where the declining criterion is not fulfilled, the selected method or the inspection specifications
were not suitable for "completely" cleaning off the particular load. This is normally also reflected
in a very flat shape of the decay curve. If the validation criterion has not been achieved, a new
qualification test with modified inspection specifications / method shall be carried out. If the
declining criterion cannot be achieved even after several attempts, the orderer shall be informed
accordingly and the further procedure joinly agreed.
From the decay curve, e.g. the amount of fluid required for a spraying process and the exposure
time required for ultrasonic treatment can be derived.
If the test starts on the basis of a fluid volume used or a given ultrasonic exposure time, the
diagram will give a quick indication of how many cleaning passes are required for a good result
and for fulfilling the declining criterion. During the routine test, these parameters shall then be
used.
The qualification test is valid if it was possible to fulfil the declining criterion. The results shall be
documented as objective evidence and submitted to the orderer if required. In case of any
relevant modifications to the component or manufacturing method, a further qualification test
may be required.
Product group specific qualification tests are generally sufficiently. The result is the derivation of
the inspection specification to be used for the routine test (refer chapter 8.1.3). The qualification
test must not be confused with the routine test procedure.
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Note illustration 4 for the test procedure. The routine test shall only be conducted when the unit
under inspection is prepared and the method has been qualified.
When carrying out specimen sampling, ensure that the unit under inspection is not
contaminated with additional external particles or with particles that may be removed from the
part itself by the removal process.
The term "packaging of the units under inspection" covers all packaging components coming
into contact with the unit under inspection or located in its direct vicinity. In principle has the
series packaging to be used. The transport routes must be kept short and the units under
inspection may not be exposed to vibration during transport in order to avoid falsification of the
test.
From case to case it is reasonable to check the blind value before performing the routine test.
Thereby is the evidence for a well-conditioned inspection equipment given. The determination of
the blind value has to be performed according to chapter 8.1.1.
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Extraction is the thorough separation of the particulate load from the defined areas of a unit
under inspection using a suitable fluid, an adequate quantity of fluid and an optimum extraction
time (acoustic irradiation time). These parameters depend on the unit under inspection and the
type of contamination. The above-specified parameters are defined and documented in the
inspection specifications within the framework of qualification of the extraction method.
In general a cold cleaner for application at ambient temperature has to be used as an inspection
fluid. In general only approved substances are allowed.
In the case of small parts the quantity of samples must assure a total residue weight of all units
under inspection M ≥ 3mg or alternatively a control area AC ≥ 200 cm². If applicable a control
area of AC ≈ 1000 cm² should be used during a gravimetric analysis. With a smaller control area
and a following scaling to 1000cm² the measuring inaccuracy and the blind value are also
multiplied. This leads to imprecise results.
8.2.4 Filtration
The fluid containing the particulate load is filtered to separate the particles from the extraction
fluid.
If nothing else is agreed, a filter with a mesh size of 20µm or smaller must be used. Where
appropriate a filter cascade (e.g. 20µm and 100µm filter) might be useful to get a better
separation of big and small particle. This makes a following analysis easier.
It is recommended to filter the extraction fluid with a 5µm filter (or smaller) before using the fluid.
8.2.5 Drying
The filter must be preconditioned before usage. In particular the filter is wetted with inspection
fluid. Then the filter is dried in a drying oven before and after filtration and then cooled in an
exsiccator to room temperature. Temperature of drying and duration of drying depend on the
species of the filter and the fluid. The drying is completed when a constant weight has been
reached. Therefore a repeating drying and weighing procedure is necessary.
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• Analysis is performed by
• determination of the weight constant of the filter before and after extraction,
• calculating the weight difference,
• measuring and if applicable counting the particles and
• converting to the control area AC.
• if applicable material analysis
8.3 Documentation
The documentation of cleanliness test is a very important step. The repetition of tests can only
be faultless replicated if all conditions of previous test are exactly adhered. A precise and clear
recording is essentially required.
Cleanliness
requirements per
product /
component
Result
documentation
of routine tests
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Testing of surface energy can be used as optional/ alternative quick cleanliness check for e.g.
incoming inspection of components.
The surface energy is one decisive criterion for the adhesion of e.g. printing ink on any non-metallic
or metallic surface => what give also direct indication for surface cleanliness. Apart of some
exceptions the general rules is: The higher the surface energy of material is, the better is the
adhesion of anything meant to be fixed to this surface. Surface contamination (e.g. grease or oil,
finger prints) might be reason for a low surface energy.
Verification of surface energy can be applied with help of ink (recommended) or pen (not
recommended => higher risk for contamination of pen felt, what caused, that pen cannot be used
any more =>wrong verification results).
A stroke of the ink leaves a full line on the material; if the line of ink stays unchanged for at least 2
seconds on the material’s surface without turning into drops, the surface energy of the material is
the same or higher than the surface tension of the ink (see example pictures below).
The measurement range of the ink must correspond to the minimum permissible drawing value for
surface tension (e.g. min. permissible surface tension of 36 mN/m. What is typical value for
contamination with rolling oil, must be verified with test ink 36 mN/m).
Pictures (example for OK and NOK surface energy ink test results)
OK NOK
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11 Updates
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