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Meeting the challenge
A better way to clean hard disk drives…
A major disk drive company required a dry and selective cleaning process to replace ultrasonic aqueous operations for cleaning disk drive components. CO2 composite spray cleaning was selected due to its ability to effectively remove microscopic particles and residues from partially assembled hard disk drive components. Fully-burdened cleaning costs were reduced between 60% and 85%, a $2,000,000 per year operating cost reduction.
A job shop machining company needed a viable PCD-coated tool turning process to replace a 3-hour Tungsten Carbide (WC) grinding operation using a diamond wheel. CO2 machining technology improved PCD-coated carbide insert life by greater than 10x (1000%) with 2x (200%) deeper cutting, and resulted in a better surface finish. CO2 machining enabled the turning of 90 HRC WC parts in 15 minutes, a 92% increase in productivity.
Cleaner commercial satellites…
A major aerospace company needed cleaner and faster manufacturing processes for preparing polymeric materials for its commercial spacecraft manufacturing operations. New supercritical fluid extraction processes were developed which successfully replaced solvent and thermal vacuum extraction processes for both military and commercial applications. Supercritical CO2 processes proved to be much faster, less costly, more effective and cleaner than solvent processes.
A ball point pen manufacturer required a precision cleaning system to replace hazardous perchloroethylene. After evaluating both conventional aqueous and closed-solvent degreasing alternatives, centrifugal liquid CO2 technology was selected due to its lowest energy costs and better cleaning performance. Another novelty of the system was the use of machining oil to remove gross chips from the product prior to degreasing. Following degreasing the machining oil was returned to the machining operations. Liquid CO2 degreasing reduced machined pen tip cleaning costs by more than $130,000 annually (fully-burdened), with a return on investment (ROI) of less than 24 months.
