Success story:
Pickling and Passivation of Stainless Steel
- Company: Important company in the industrial sector of GAS
- Country: Portugal
- Need: Pickling and passivation of welds on stainless steel pipes.
- Substances to be removed: Blackened layer on the weld.
- Material and dimensions of the parts to be processed: Various sizes and geometries.
- Installation: Two 12,000-litre tanks with sufficient ultrasound power to complete the job in the required time.
- Processes for pickling and passivation of stainless steel: Ultrasonic pickling and passive weld passivation and rinsing.
Success story: Pickling and Passivation of Stainless Steel
The Importance of Pickling and Passivation of Stainless Steel
The pickling and passivation of stainless steel is an essential process in industrial sectors such as the chemical, food and pharmaceutical industries. These techniques ensure the removal of contaminants, oxides and welding residues, leaving a clean, passivated and corrosion resistant surface.
In this article, we present a successful case where ultrasonic tanks were installed to optimise these processes, enabling whitening welds and significantly improve process times and final product quality.
The Challenge: Ensuring Uniform and Efficient Stripping
The company, dedicated to the manufacture of stainless steel components in the gas industry, faced recurring problems:
- Blackened welds and non-uniform.
- Traces of rust and contamination on welded parts.
- Inconsistent results when using manual pickling methods.
- High operating costs due to time and chemicals used.
In addition, the need to meet stringent quality standards in the industry required more efficient and environmentally friendly processes.
The Solution: Ultrasonic Vessels for Pickling and Passivation
TAfter analysing the specific needs of the company, an ultrasonic tank system was implemented, designed for:
- Delete welding residues and bleach surfaces.
- Precision pickling of large and complex parts.
- Reducing the use of chemicals and exposure of workers through ultrasonic action.
Pre-testing of stainless steel pickling on pipe welds
Prior to procurement, a pre-test of stainless steel pickling of different tubes was carried out to verify the uniform bleaching of the weld, the uniformity of the result and the speed of the process.
In the following images, we show the quality of solder pickling and passivation following tests carried out in a ultrasonic cleaning machine "on the ground, achieving a whitening and weld uniformity excellent.
IMAGES of the pre-testing process
Design of customised stainless steel pickling solution using ultrasonic system
We detail the scope and approach of the ultrasonic installation project for pickling and passivation.
On the basis of our technical expertise and experience, the Ultrasonic power to be installed was based on a power/litre ratio calculated according to the tank dimensions required by the customer.
From IBERKLEENfor a valid reaction in this type of stainless steel pickling processWe recommend a ratio of x W / litre of liquid.
Based on this ratio, we dimension the tank for the pickling operation.
The dimensions proposed by the client were 4000 x 2000 x 1500 mm.
As they are not large in volume or physical mass, we considered that 200 mm of free liquid neck in height would be sufficient, so the number of litres in the tanks was 12,000 litres.
In order to guarantee a long service life, the tanks are made of an acid-proof polymer.
The second strong point to highlight is the ambivalence of the project.
By offering a solution with individual ultrasonic emitters, they can be used in different tanks and processes.
For example: In the future, the customer can create a 1000 litre tank, fit it with 4 emitters and use it for a degreasing process prior to painting or whatever surface finish is required.
The pre-installation design
In order to make a proposal as close to reality as possible, in addition to the stainless steel pickling and passivation tests, we made 3D models and renders of the solution so that the client could see the final result.
Main features of the installed system
- Adapted frequency: optimised to whiten the weld and give it uniformity without damaging the surface.
- Thermal control: guarantees the stability of the pickling solution.
- Compatibility with specific passivating agents: to achieve a uniform protective layer.
Results Achieved: Improved Productivity and Quality
The implementation of the ultrasonic vatting system brought immediate benefits
- Reduction of processing timePickling and passivation were completed in 90% less time compared to traditional methods.
- Savings on chemicalsThe efficiency of the system reduced the consumption of pickling and passivating solutions by 30%.
- Improved finishThe parts had a homogeneous surface, free of oxides and with a glossy, passivated finish.
- Regulatory complianceThe solution met the quality and environmental requirements of the industry.
Advantages of Ultrasonic Pickling and Passivation
- Uniform bleaching of weldsIdeal for visible or aesthetically demanding components.
- Compatibility with different partsFrom small precision parts to larger structures.
- Waste reduction: Reduced generation of chemical waste.
- SustainabilityA more environmentally friendly process.
Result: Innovation and Efficiency in the Stainless Steel Pickling Process
This case demonstrates how ultrasonic tanks are an effective solution for the pickling and passivation of stainless steelhelping companies to improve their production processes and meet the most demanding quality standards.
If your company is looking to optimise processes such as whitening welds or improve the finish of metal parts, don't hesitate to explore our solutions of ultrasonic cleaning.
Interested in innovative solutions for stainless steel pickling?
Contact us to find out how our ultrasonic tanks can transform your industrial processes.