DELPHI DX552500 Surface Cleaning of Metal Components

Delphi is a leading global supplier of mobile electronics and transportation systems. The standard “DELPHI DX552500 Surface cleaning of metal components” developed by this organization describes the cleaning requirements for die castings, stampings, extrusions and other metal components that are not coated after forming.

The specification number shown in the title is a general number for the various surface cleanliness requirements of metal components supplied to Delphi. The table titled “Cleanliness requirement” given in the standard contains the specification numbers to be used on the drawings and reflects the basic requirements of the specification. Namely,

• Delphi specification number DX552501: Ionic contamination test required, maximum foreign particle size 127 microns, adhesion test unnecessary
• Delphi specification number DX552502: Ionic contamination test required, maximum foreign particle size 254 microns, adhesion test unnecessary
• Delphi specification number DX552503: Ionic contamination test required, maximum foreign particle size 508 microns, adhesion test unnecessary
• Delphi specification number DX552504: Ionic contamination test required, maximum foreign particle size 127 microns, adhesion test required
• Delphi specification number DX552505: Ionic contamination test required, maximum foreign particle size 254 microns, adhesion test required
• Delphi specification number DX552506: Ionic contamination test required, maximum foreign particle size 508 microns, adhesion test required

Special requirements shown on the part drawing take precedence over any requirements in this specification or may be in addition to the requirements of this specification.

All materials supplied to this standard must comply with the requirements listed in standard DX000005.

The requirements in this standard are explained as follows:

• Adhesion test (DX900423): The metal component shall show more than 900423 percent cohesion failure when tested according to the DX90 standard.
• Ionic contamination: All metal components controlled according to this standard shall meet the ionic contamination levels specified in the table provided in the standard when tested according to IPC-TM-650 Section 2.3.28.2. Namely,
  • Chloride contamination limit, maximum 0,75 µg/cm2
  • Bromide contamination limit, maximum 1,0 µg/cm2
  • Sodium contamination limit, maximum 2,0 µg/cm2
  • Total inorganic contamination limit, maximum 30,8 µg/cm2

The supplier shall include the ions listed in the table provided in the standard as part of the total inorganic calculation. This requirement is for PPAP only and is not a process control requirement.

• Foreign particle size: All components checked to this standard shall be free of surface loose particles larger than the size specified in the table described above when tested according to method C defined in “ASTM F303-02 Standard Practices for Sampling Particulates in Aviation Fluids and Components.” The cleaning process used on Delphi components shall be capable of screening and filtering all particles larger than the specified size.

Metal surfaces must be frequently cleaned before subsequent operations to remove undesirable substances such as pigmented drawing compounds, unpigmented oil and grease, chips and cutting fluids, polishing and buffing compounds, rust and scale, and various contaminants.

In industrial manufacturing, maintaining high-quality components ensures longevity and reliability. Surface cleanliness is a key factor affecting the quality and longevity of industrial components. Surface cleanliness refers to the level of contaminants on the surface of components and is a critical factor in ensuring their safety, reliability and integrity. Various substances such as rust, corrosion and other residues can contaminate the surface of industrial equipment. These contaminants reduce the ability of the equipment to perform at its optimum, resulting in downtime, repair costs and deterioration of functionality.

Ionic contamination testing detects ionic residues left over from the manufacturing and soldering process and is often a requirement to ensure ionic cleanliness before conformal coating is applied to printed circuit boards.

The ionic contamination test method is considered a critical quality and process control tool. International standards state that assemblies should be cleaned to a maximum of 1,5 µg/cm2 sodium chloride equivalent.

Among the numerous tests, measurements, analyses and evaluation studies that our organization has carried out for businesses in various sectors, it also provides testing services defined in the “DELPHI DX552500 Surface cleaning of metal components” standard with its trained and expert staff and advanced technological equipment.