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Study on Remanufacturing Cleaning Technology in Mechanical Equipment

Remanufacturing Process

Chapter · January 2013

DOI: 10.1007/978-981-4451-48-2_105

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 Study on Remanufacturing Cleaning Technology in Mechanical Equipment
Remanufacturing Process
1 1 1 1 1,2
WeiWei Liu , Bin Zhang , Ming Zheng Li , Yanzeng Li , and Hong-Chao Zhang
1
Dalian University of Technology
2
Texas Tech University

Abstract
The cleaning technology plays an important role in product quality during the remanufacturing processing. The availability,
quality, remanufacturing cost and the remaining life of the remanufactured product will be directly influenced by various
cleaning methods and the corresponding cleaning quality. In the meantime, the introduction of cleaning also brings
contamination to the remanufacturing processing, which restricts its engineering application. Therefore, with the study of
cleaning methods those are suitable for remanufacturing process, the fundamental concepts of remanufacturing cleaning
technology were introduced in this paper, and the major cleaning technologies for each stage in the remanufacturing stage
were described, which is beneficial to find out the optimize cleaning method in actual production and realize the real green
remanufacturing.

Keywords:
Remanufacturing; Fouling; Cleaning Technology; Green Cleaning

1 INTRODUCTION remanufacturing has become a key strategy for sustainable

Green manufacture, environmental protection, sustainable
development and recycling have been drawing the world’s attention
in recent years. In this context, remanufacturing as a specific type of
recycling makes the fact that the used durable goods can be
repaired to be like-new realized [1]. Therefore, remanufacture
engineering has become the tendency and played a significant role
in the development of the advanced manufacturing technology.
Remanufacturing is such an industry that it concerns the high-tech
restoration and transformation of discarded mechanical and
electrical products, of which the scrapped parts will be redesigned
and remanufactured on the basis of performance failure analysis
and life assessment analysis so as to achieve or exceed the
qualities of new products. For this reason, remanufacturing is
environmentally friendly because it maintains the raw material,
saves the energy, reduces environmental pollution and preserves
the land from the disposal of waste materials. On the other hand,
remanufacturing contributes greatly to the social sustainable
development by creating new productive jobs. Consequently,
Cores ① Cleaning Disassembly
development [2].
The technological process of remanufacturing is shown in Figure.1.
It can be found that the core (the used/worn-out/broken products
that enter the remanufacturing process are referred to as ‘core’ [3].)
passes through a number of remanufacturing steps such as
disassembly, cleaning, inspection & sorting, reconditioning, testing,
reassembly and painting & packing. As can be seen from Figure.1,
cleaning is among the most demanding steps and is a particularly
essential process in remanufacturing because the quality of core
surface cleanliness directly determines the parts surface analysis
and the following process as surface inspection, reconditioning,
reassembly and painting processing. In the meantime,
remanufacturing cleaning is often the main source of pollution in the
remanufacturing process. And that is, the cost, quality and
environmental performance of remanufactured products are closely
related to the remanufacturing cleaning process. Therefore,
remanufacturing cleaning is a crucial step but is often neglected
during remanufacturing process optimization at present.
Remanufacturable
Inspection parts
② Cleaning & Sorting
③ Cleaning Reconditioning

Worn parts
Intact parts Nonremanufacturable
parts
Scrap Scrap

New parts Nonconforming

parts

Qualified
Remanufactured Painting & parts
Product Packing
⑤ Cleaning Test Reassembly ④ Cleaning Test

Figure 1: Common technological process of remanufacturing.

Cleaning in remanufacturing is an industrial process for the reduction
of the quantity of contaminations present in or on a component until
the specified cleanliness level has been reached in remanufacturing
process. The objectives of remanufacturing cleaning in each stage of
the remanufacturing process are different. Firstly, the purpose of core
pre-cleaning before disassembly is mainly to reduce the quantity of
contaminations outside the products. Secondly, by removing the
grease, scale deposit, rust, carbon deposition and the paintcoat
attached on the surface, and the cleaning after disassembly is
convenient for detecting the surface abrasion, micro crack or other
failure situations in order to make sure if remanufacture can be
applied and what kind of method can be employed. Thirdly, the
cleaning processes in other stages, such as the cleaning processes
before reconditioning, reassembly and painting, are performed to

20th CIRP International Conference on Life Cycle Engineering, Singapore, 2013

644 W. Liu et al.

remove surface contaminants (oils, greases, inorganic residues,
particulates, etc.) and to prepare surfaces for additional treatment
prior to subsequent steps. Many cleaning operations are critical to
the ultimate performance of remanufactured product. Inadequate or
inappropriate cleaning leads to unacceptable production yields or,
even worse, to product failure during use.
Remanufacturing cleaning is distinct from cleaning in maintenance
or cleaning in new production. Cleaning in maintenance
concentrates on the position of damage before repairing while
cleaning in remanufacturing is done for the whole mechanical parts
in order to make them meet the quality requirement after
remanufactured. Cleaning in new production is another case. Firstly,
the cleaning objects in new production process are changeless in
work piece size and material, and the contaminations are mainly the
residual metal cutting fluid, lubricating oil, antirust oil, polishing paste
and so on. By contrast, cleaning in remanufacturing is not so easy
that the objects are of great many types with different sizes and
materials and complex and long-termed surface fouling. Secondly,
cleaning in new production is performed at a high level. Due to high
standards of OEMs (Original Equipment Manufacturers), suppliers
have made great efforts to optimize cleaning processes. Also, the
ISO Standard 16232 on technical cleanliness gives recommenda-
tions for cleaning in new production steps. However, at present, in
strong contrast to the well-defined cleaning in new production
processes, cleaning in remanufacturing is mostly performed based
on the experience of the operator instead of knowledge based and
therefore often results in a lack of efficient solutions. So, cleaning in
remanufacturing has a great potential for optimizations and
innovations.
As can be seen from the above analysis, cleaning is an essential
step in the remanufacturing process, which lacks systematic
understanding yet. Therefore, the main purpose of this paper is to
establish a foundation for further study on remanufacturing cleaning,
about the establishment of knowledge base, process optimization,
innovations and related standardization.
The remainder of this paper is organized as follows. The
fundamental concepts and the basic elements of remanufacturing
cleaning technology are introduced in section 2. Section 3 gives a
brief introduction about the commonly used cleaning technologies
that are suitable for remanufacturing process and outlines the
development tendency of remanufacturing cleaning technology. The
principle of the selection of the cleaning methods at each stage in
the remanufacturing is described in section 4, and the final
conclusions are given in section 5.
2 BASIC ELEMENTS OF REMANUFACTURING CLEANING
By mechanical, physical, chemical or electrochemical means,
remanufacturing cleaning removes the grease, scale deposit, rust,
carbon deposition and the paintcoat attached on the core surface so
that the specified cleanliness level requirements can be reached. Four
basic elements are included for core remanufacturing cleaning:
cleaning object, core contamination, cleaning force and cleaning
medium. A synopsis to elaborate the four elements is given as follows.

Contaminant Position Components Characteristics

Easy to be removed, but difficult to

External deposits Outside surface of parts.
The surface contacted by
Residual lubrication oil parts and with lubricating
medium.
Combustor surface, air
Carbon
valve, piston head, piston
deposition
ring, spark plug.
Dust, oil sludge, etc.
Aged viscous oil, water, salt, product
of corrosion and deterioration on parts
surface.
Carboid and carbides, lubricating oil
and tar, a handful of oxygen acid, ash
content, etc.
clean thoroughly.
Complex components, furring,
which determines corresponding
cleaning methods.
Most of the components are
insoluble, which are difficult to be
removed.

Carbonized Film like Piston skirt, connecting

Carbon. Low strength, easy to be removed.
painting rod.
Sediment
Other Shell wall, crankshaft Lubricating oil, tar, a handful of Most of the components are
types of journal, oil pump, filters, carboid, carbides and ash content, insoluble, which are difficult to be
sediment lubricating oil passage. etc.. removed.

Scale deposit Cooling system. Calcium salt and magnesium salt, etc. Soluble in acid.

Insoluble in water and alkali, and

Rust The surfaces of part. Iron oxide, alumina, etc.
soluble in acid.
Metal debris, perspiration, and Adhesive force is small, and easy
Detection residues The whole part surface.
fingerprint, etc. to be removed.
Metal debris, polishing paste, abrasive
Adhesive force is not large, but
Residues of machining The whole part surface. paste, lubricating liquid, coolant liquid,
need to clean thoroughly.
etc.

Table 1: Contaminants of automotive products during remanufacturing process.

Study on Remanufacturing Cleaning Technology in Mechanical Equipment Remanufacturing Process 645

1. Cleaning object, the one which needs to be cleaned in a
remanufacturing process. For example, all sorts of machinery
parts, electronic components, etc. These parts and electronic
components are mainly made of metal, ceramic (containing
silicon compounds), plastic and etc. Different cleaning methods
should be employed, according to different cleaning objects
(different materials, shapes, and geometric dimension).
2. Core contaminant, a kind of “unpopular” deposits which are
deposited on the core surface because of the long-termed
effects of physical, chemical or biological during the core’s
service time (i.e., before remanufacturing process), or a kind of
fouling (such as residual metal cutting fluid, lubricating oil,
antirust oil, polishing paste, etc.) which is introduced during
remanufacturing process. Remanufacturing cleaning is therefore
a process of contamination removal from the core surface to
achieve the required cleanliness.
Taking automobile remanufacturing cores as examples, there are
varieties of core contaminant, which can be mainly divided into the
following categories as seen in Table 1.
3. Cleaning force, the force among cleaning objects,
contaminants and cleaning medium, which disperses steadily in
the cleaning medium during the cleaning processes to remove
the contaminants away from the part surface. The contaminant
molecules are combined by electrostatic or molecular attraction
forces so that they can be removed by overcoming those forces
in the cleaning process. Generally, the cleaning forces can be
classified into five categories, that is, 1) solvency force and
dispersion force, 2) surface active force, 3) enzyme force, 4)
chemical reaction force and 5) physical force, as described in
Table 2.

Type Interaction Way

Solvency force and dispersion Contaminants can be dissolved in water or organic solvent and then steadily dispersed into
force cleaning medium.

Comprehensive effects of wetting, permeating, emulsifying, scattering and solubilizing on the

Surface active force contaminants will be produced by lowering the interfacial tension between surfactants and
contaminations.

Organic contaminants (i.e., grease) can be resolved by hydrolysis reaction accelerated by the
Enzyme force
enzyme (a kind of biological molecule), which then disperse into cleaning medium.

Contaminants can be dispersed by the chemical reaction between chemical agent and
Chemical reaction force
contaminants, which then disperse into cleaning medium.

Contaminants will change their physical properties or decompose by thermal effect, which
Thermal effect
promotes the cleaning process.

Pressure Cleaning force generated by high pressure, medium pressure, negative pressure or vacuum.

Friction The contaminants on the surface can be removed by rushing to scraping.

Physical Abrasive force The contaminants on the surface can be removed by mechanical force.
force
The contaminants on the surface can be removed by the function of cavitations of ultrasonic
Ultrasound effect
wave in cleaning medium.

Electrolytic force The contaminants on the surface can be removed by electrolytic action

The atoms of organic contamination molecule absorb certain wavelength of ultraviolet light and
Ultraviolet ray
the priming effect causes the decomposition of contaminants molecules.

Table 2: Categories of cleaning force.

Cleaning medium Decontamination force Major ingredient Applicable contaminants

Solvent Dissolving force and dispersion force. Organic solvent. Oil and grease.

Adsorption, wetting, permeating,

Aqueous based cleaning Surfactant, detergent, Various contaminants
emulsifying, scattering and
fluid additive agent, etc. adsorbed on core surface.
solubilizing, etc.

Acid solution, alkali

Rust, saponified grease,
Chemical solvent Chemical reaction force. solution, oxidizing and
etc.
reducing agents, etc.

Solid particle Abrasive force, impact force. Various solid particles. Rust, paintcoat, etc.

Table 3: Common cleaning medium.

646
4. Cleaning medium, through which the cleaning environment is
offered and directly contacted with surfaces to be cleaned
during cleaning process. Cleaning medium plays a significant
role in the cleaning process, which is reflected in transmitting
the cleaning force and preventing re-adsorption of the
contaminants which have been detached. The common cleaning
mediums, with great varieties, are listed in table 3.
3 REMANUFACTURING CLEANING TECHNOLOGY AND
DEVELOPMENT TENDENCY
3.1 Current Situation of Remanufacturing Cleaning
Technology
Continuous development and improvement are required for
remanufacturing cleaning technology, cleaning methods as well as
cleaning equipments, which have few ideas to borrow from new
product manufacturing process. Different techniques and methods
depend on different purposes at different stages. Sometimes a
variety of methods are used simultaneously or successively. The
cleaning technologies which are under consideration for
remanufacturing cleaning are briefly introduced as follows.
1. Organic solvent cleaning technology. By means of soaking
the core in organic solvent or spraying organic solvent to the
object, the contaminations can be removed from the core
surface because of dissolution and chemical reaction [4].
However, there are some issues with this cleaning technology
such as waste liquid, which must be treated in a lifecycle in
manufacturing cleaning when environmental factor is taken into
account.
2. Jet cleaning technology. According to the mediums, this
technology includes classified as high-pressure water jet
cleaning [5], abrasive blasting cleaning [6] and dry ice blast
cleaning [7], etc. The grease, rust and other contaminations can
be removed from the core surface due to the physical interaction
of the accelerated mediums by compressed air or high pressure
water. However, there are some issues with such approach,
such as waste liquor treatment during the high-pressure water
jet cleaning, high cost of the dry ice blast cleaning and dust
pollution also in the abrasive blasting cleaning.
3. Thermal cleaning technology. By use of high temperature or
hot stream, oil or grease on the core surface will be evaporated
during the cleaning process. Therefore, this cleaning method is
suitable for hydrocarbon which does not contain chlorine and
fluorine, but not applicable for low melting point or flammable
metal parts. Even though, for this time-consuming and energy-
consuming process, a lot of improvements are still needed.
4. The Ultrasonic cleaning technology. Ultrasonic cleaning uses
high frequency (usually from 20-400 kHz) sound waves to
generate agitation in a liquid [8]. Cavitation bubbles induced by
the agitation will act on contaminants adhering to substrates like
metals, plastics, glass, rubber, and ceramics and cause the final
contaminant detachment. However, it is difficult to choose
proper cleaning parameters for different contaminants process
because to some extent surface corrosion will be produced once
the cleaning parameters are set improperly. Meanwhile, waste
liquor treatment is needed for environmental account. Therefore,
researches about high power, series and high reliability
ultrasonic power are required to optimize the cleaning process.
5. Electrolytic cleaning technology. Electrolytic cleaning is
derived from the release of bubbles [9] and it is not suitable for
non-ferrous metals such as copper, bronze, brass, pewter, tin or
W. Liu et al.
aluminum. Moreover, great amount of energy will be spent
during electrolytic cleaning process.
Definitely, there are still other ways to remove contaminants away
from core surface, such as ultraviolet radiation cleaning [10], plasma
cleaning [11], ion beam cleaning [12], laser cleaning [13],
supercritical fluid cleaning [14], biological enzyme cleaning [15], etc.
Current imperfection of remanufacturing cleaning is reflected as
follows in remanufacturing industry. 1) Contamination degree and
type are not classified before the cleaning process. 2) Necessary
cleanliness specifications are not set in advance before processing
the parts. 3) The utilization of cleaning machinery generally bases
on experience rather than systematic knowledge. 4) Various
technologies (e.g. shot basting, wet cleaning) are not tailored to the
needs of remanufacturing and cost drivers. 5) Cleanliness
measuring systems, methods or equipment is unknown while the
need of remanufactured parts is tightening. 6) Remanufacturing
cleaning is a bottleneck in the material flow. Dirty parts are gathered
to a large size in order to achieve a high operating ratio of the
machine. This, however, works against the trend of decreasing
batch sizes. High intermediate storages with correspondingly long
lead-times and high cost of inventory are consequences. 7)
Cleaning is the most environmentally unfriendly process in
remanufacturing as many hazardous cleaning agents are used
during the process.
3.2 Development Tendency of Remanufacturing Cleaning
Technology
Cleaning is one of vital process for remanufacturing of mechanical
equipment parts. It should follow the principle of high efficiency, low-
cost, energy efficiency, low-emissions of pollutants (including waste
gas, waste liquor and solid wastes). Presently, cleaning agents like
ozone depleting substance (ODS) and chlorofluorocarbon (CFC) are
widely used in cleaning industry, both of which have been phased
out under the Montreal Protocol because of their negative
environmental effect. Thus, the study of non-ODS cleaning solvents
is a development tendency of remanufacturing cleaning technology.
The selection principle of non-ODS cleaning solvents is listed as
follows: excellent cleaning abilities, appropriate cost performance
ratio, non-toxic and environmentally friendly. Consequently,
conventional chemical cleaning methods which use hazardous or
banned cleaning agents become unsuitable for remanufacturing
cleaning because of the environmental contamination. By contrast,
physical cleaning methods and the cleaning methods which use
environmentally friendly cleaning agents are widely used in virtue of
their unique advantage of less influence on environment.
In addition, with increasing demands of large-scale and efficient
mechanical equipment remanufacturing, the demand of low-cost
cleaning system in remanufacturing is also increasing. That greatly
accelerates the application of the latest semi-automatic and full
automatic cleaning equipments, such as cleaning production line
and cleaning robots, etc. Another development tendency of
remanufacturing cleaning technology is the study of composite
cleaning technology or hybrid cleaning system which is higher level
of automation, less cost and less environmental pollution.
Moreover, to find the best balance between environmental and
economical requirements is a major issue for remanufacturing
cleaning because cleaning process is one of the main pollution
sources in remanufacturing. In recent years, the biological
engineering as a kind of environmental friendly technology has
become a new trend in cleaning industry. The enzyme cleaning
technology, one of the most common biological engineering in
cleaning, might be used for a wide range of remanufacturing
cleaning applications.
Study on Remanufacturing Cleaning Technology in Mechanical Equipment Remanufacturing Process 647

Apart from the cleaning technologies mentioned above which need
to be improved or innovated, cleanliness detection and analysis
technologies for remanufacturing cores are going to require
improvement and innovation. This includes the reorganization of
contaminant degree and type before cleaning process, specification
definitions for technical component cleanliness, and measurement
of the technical component cleanliness and etc.
4 PRINCIPLES OF SELECTION
In remanufacturing cleaning process, several factors such as
maximum cleanliness, quality, time, cost and environmentally
friendly requirements should be taken into consideration when
cleaning methods and technological parameters are determined.
Generally, for optimizations in practice, the principles of remanu-
facturing cleaning methods selection at each stage are described as
follow.
1) Identify cleaning purposes and technical cleanliness
requirements. Table 4 represents five cleaning steps in each phase
of remanufacturing with different purposes for the subsequent
process as detection, machining or assemble. It can be seen that
the remanufacturing cleaning changes in each stage of the
remanufacturing process for different objectives.
2) Recognize the core contaminant type and its attachment manner,
and then choose the appropriate cleaning method and cleaning
agent.
3) According to the material, quantity, geometric dimensions of the
cores to be cleaned, choose the appropriate cleaning method and
cleaning agent. Meanwhile, make the comprehensive evaluation of
the cleaning agent damages to the part surface as well as cleaning
efficiency and cost.
4) According to the environmental requirements, make an evaluation
of energy consumption, discharge of wastes (including waste gas,
wastewater, waste oil and solid wastes) and make sure to decrease
resource consumption and degrade environment pollution.

No. Cleaning Contaminants Cleaning purse Requirements

Process

Pre-cleaning Deposits on the outside of equipments, Convenient for components and Roughly clean.
before such as dust, silt, grease, etc. parts disassemble and preventing
①
disassembly taking the contaminant into the
workshop.

Cleaning for Grease, rust, Carbon sediment, Convenient for detection of Surfaces of the
components residues of lubrication, scale deposit, remanufacturing properties. components and parts
②
and parts after paintings and etc. can be seen clearly.
disassembly

Cleaning before Residues produced during detection. Guarantee the machining quality of Rather clean.
③
reconditioning the remanufactured parts.

Cleaning before Machining residues such as rust, Guarantee the assemble quality of Very clean.
remanufactured cuttings abrasive material, grease, the manufactured parts.
④
parts assemble antirust oil and dust on standard
components and parts.

Cleaning before Grease and slag inclusions on Guarantee the painting protection Very clean.
⑤ remanufactured remanufactured part surface. of the manufactured parts and Nice
parts painting appearance.

Table 4: The cleaning process and requirements of automobile in each stage of remanufacturing process.

5 SUMMARY organic solvent cleaning technology, jetting cleaning technology,

Mechanical equipment products experience a fast development in
recent years. As an important process in remanufacturing,
remanufacturing cleaning has great effects on the quality of
remanufactured products as well as environmental benefits and
remanufacture cost. Actually, the pre-cleaning before disassembly,
the cleaning for cores after disassembly, the cleaning before
reconditioning, the cleaning before assemble and the cleaning
before painting are mainly included in remanufacturing cleaning.
Therefore, varieties of remanufacturing cleaning technologies, like
high temperature cleaning technology, ultrasonic cleaning
technology, electrolytic cleaning technology, and so on can be
applied to achieve different cleaning purpose. In spite of the
simplification and effectiveness of present remanufacturing cleaning
process, unified standards for cleanliness judgment and the
knowledge base of remanufacturing cleaning are insufficient.
Furthermore, problems such as secondary pollution, energy waste,
and low cleaning efficiency due to low levels of automation also
arise. Even so, the concentrated research of cleaning technologies
and cleaning equipments unquestionably leads remanufacturing
648
cleaning to be more effective, automated and environmental, which
also accelerates the establishment of relevant standards such as
enterprise standard, national standard or international standard.
6 ACKNOWLEDGMENTS
The authors thank the financial support offered by the national
program on key basic research project (973 Program) of China
(Granted No.2011CB013402) and the fundamental research funds
for the central universities of China (Granted No.DUT11RC(3)80).
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