International standards for uniform cleanliness testing

The topic of "Technical Cleanliness" is becoming increasingly important for companies in the automotive industry: even a single small contaminant on a component caused by particles can lead to serious vehicle faults. Therefore, it is necessary for the entire industry to verify the cleanliness level of all vehicle components using clearly defined methods. For Germany, there is already a fixed set of rules – VDA 19.1. However, after the extensive revision in conjunction with the international guideline ISO 16232, it is no longer fully compatible. The Fraunhofer IPA now aims to create comparable standards worldwide with several automotive manufacturers and to revise the norm.

Already in 2001, the purity technologists at Fraunhofer IPA addressed the topic of "Technical Cleanliness in the Automotive Industry." The scientists developed the first version of VDA 19, which was valid until early 2015. "Until then, the contents of VDA 19 and the international counterpart ISO 16232 were still aligned," explains Dr. Markus Rochowicz, Group Leader of Cleanliness Technology at Fraunhofer IPA. However, between 2012 and 2014, the German standard was fundamentally revised. Since its reissue in early 2015, manufacturers have found it difficult to verify the technical cleanliness of their components in an internationally comparable manner. "More and more automotive manufacturers and suppliers are demanding a unified guideline," the expert states.

Strong network with experience in measurement technology

Now, the experts in cleanliness technology from Fraunhofer IPA are taking on this task. Together with companies from the automotive industry and measurement technology, the scientists want to adapt ISO 16232 to the German standard VDA 19.1. "Among others, Daimler, Mahle, Bosch, VW, and Zeiss are involved," Rochowicz informs. The group leader is pleased to have a strong network behind him. "When successful companies from Germany with many years of experience demand standards, the guideline quickly gains international acceptance," Rochowicz is convinced. Vehicle-producing countries around the world are also interested in the norm: "Companies from Japan, the USA, France, and Sweden have already expressed interest in participating in the standard," Rochowicz adds.

Fewer parameters and defined procedures

With the new guideline, the Stuttgart experts aim to ensure comparable international measurement results. "The problem with technical cleanliness is that it must be determined using multiple procedures in the laboratory," Rochowicz explains. Residual dirt from components is extracted, filtered, and then microscopically analyzed. "So far, there are neither clear guidelines for the procedure nor fixed values for parameters," Rochowicz notes. The result is measurement deviations of up to a factor of four – "a catastrophe for quality inspectors," Rochowicz emphasizes. A new ISO 16232 is intended to finally bring clarity: "We want to significantly limit the variety of parameters, as in VDA 19.1. Additionally, we specify how the measurement must be carried out. The revised standard should, for example, specify which extraction method to use, which filter, and how to set up the microscope," explains the group leader. The kick-off meeting of the consortium will take place on September 30, 2015, at Fraunhofer IPA in Stuttgart. Four meetings per year with international participation are planned. After twelve months, the team aims to publish a consensus-based foundational document for a new ISO 16232.