VDA 19.1 & ISO 16232
Contamination of components can cause serious damage and impair the functionality and reliability of critical systems, e.g. in the automotive industry. VDA 19 was published in Germany in 2004 to prevent problems caused by particulate contamination on function-related automotive components; the current version is VDA 19.1.
Table of contents
- VDA 19.1 and ISO 16232 briefly explained
- Why do you need VDA 19.1 and ISO 16232?
- Where are the standards applied?
- The development of the standards: revision of VDA 19 and ISO 16232 2007
- VDA 19.1 and ISO 16232 for residual dirt analysis at Quality Analysis
- ISO 16232 and VDA 19.1 – basic methods and procedures
- VDA 19.1 and ISO 16232 in summary
VDA 19.1 and ISO 16232 briefly explained
VDA 19.1 and ISO 16232 are central standards for the verification of the technical cleanliness of components and assemblies in the automotive industry. While VDA 19.1 was published by the German Association of the Automotive Industry and is a German standard, ISO 16232 is its international counterpart. In terms of content, both standards cover exactly the same framework and are therefore comparable in relation to methods and processes.
Why do you need VDA 19.1 and ISO 16232?
Around the turn of the millennium, technical developments in the automotive sector led to an increase in damage caused by residual dirt. This aspect affected anti-lock braking systems and direct injection systems in diesel vehicles, for example. These sensitive systems react to the smallest contamination with malfunctions, increased wear and, in the worst case, total failure. This situation gave rise to the need for standardised requirements for clean manufacture and verification of compliance with the required cleanliness standards.
Standardised norms for technical cleanliness verification
In response to this need, VDA 19.1 and ISO 16232 were developed as standards for quality assurance in the automotive industry. They provide detailed guidelines for technical cleanliness inspection, focussing on the amount of contamination, particle size and the conditions under which components are manufactured and inspected.
The standardisation of these inspection processes ensures high component quality. There are several advantages: on the one hand, the standards ensure that the inspections are undertaken to a high standard with precise and consistent results. On the other hand, they help to reduce the risk of defects and complaints by providing clear guidelines and criteria for cleanliness inspection.
Where are the standards applied?
The standards VDA 19.1 and ISO 16232 are used in the automotive industry and in many other sectors. The inspection processes are primarily applied in the German automotive industry to ensure the cleanliness and reliability of components.
Use of the standards in different sectors
In addition to the automotive industry, VDA 19.1 is also frequently used in other sectors that place similarly high demands on technical cleanliness verification, such as the aerospace industry and medical technology.
ISO 16232 is internationally orientated and is used worldwide in the automotive industry. It specifies the cleanliness requirements for components and systems in road vehicles and, like VDA 19.1, is also applicable in other industrial sectors that have comparable requirements on the cleanliness of components and systems.
Typical applications for both standards are the initial inspection and evaluation of new components, the inspection of incoming and outgoing components, as well as quality control and monitoring of cleanliness-related manufacturing processes such as cleaning, surface treatment and assembly processes.
VDA 19.1 and ISO 16232: specific application examples
The standards VDA 19.1 and ISO 16232 are used in various areas of the automotive industry. These applications include inspecting the cleanliness of components such as engine components, transmission parts, fuel systems, hydraulic systems and much more. Clean manufacture of these parts is crucial for ensuring their functionality and service life. Liquids such as fuels, lubricants and coolants can also be checked for contamination. In addition, the cleanliness of environments such as production facilities, assembly areas and cleanrooms can be monitored in accordance with the standard.
The development of the standards: revision of VDA 19 and ISO 16232 2007
The original VDA 19 and ISO 16232 were initially introduced to establish consistent standards for the evaluation and inspection of particle contamination. Since then, both standards have undergone revisions aimed at adapting the requirements to the state-of-the-art and better fulfilling the needs of the automotive industry.
Introduction of new particle size classes and parameters for decay curves
Key developments include the introduction of new particle size classes. Originally, the standards focussed on smaller particle sizes, however the revisions extended these classifications to cover particle sizes up to 3000 µm. This extension permits more comprehensive analysis and reporting of larger particles, which can also have a significant impact on the functionality and reliability of components. In addition, start parameters for decay curves were specified; these parameters are crucial for maximising extraction efficiency and achieving consistent results during particle extraction.
Specification of the fibre criteria and expansion of permissible extraction and analytical methods
In the original standard, the criteria for the evaluation of fibres were less detailed, which could lead to uncertainties during analysis. The revised standard now specifies clear criteria for the identification and evaluation of fibres, increasing the accuracy and reliability of the analyses. Additional permissible extraction and analytical methods were also introduced. These new methods offer more flexibility and allow users to select the methods best suited to their specific requirements.
The new methods include optical particle size determination, RAMAN and FTIR spectroscopy as well as micro-computed tomography. These methods significantly expand the possibilities for analysing and evaluating particles and help to enhance understanding of the causes of contamination and develop targeted measures to improve cleanliness.
VDA 19.1 and ISO 16232 for residual dirt analysis
at Quality Analysis
In our laboratories we analyse both very small function-related components with a size of a few millimetres, as well as entire assemblies and systems with a weight of up to 2,000 kilograms. With our comprehensive analytical methods, we guarantee you the highest quality and reliability during residual dirt analysis. We also support you by evaluating particle traps and stamps for environmental monitoring and ensuring cleanliness during assembly.
- Analyses in accordance with VDA 19/19.1, ISO 16232 as well as numerous customer standards and specifications
- Particle extraction by means of spraying, flooding, rinsing, agitating, suction and ultrasound
- Class 8 cleanroom in accordance with ISO 14644 for the highest cleanliness standards
- Accredited test laboratory for technical cleanliness verification in accordance with DIN EN ISO/IEC 17025
ISO 16232 and VDA 19.1 – basic methods and procedures
The standards ISO 16232 and VDA 19.1 provide detailed instructions for undertaking cleanliness inspections as are crucial for technical cleanliness verification in the automotive industry and other sectors. These standards include various methods for extracting and analysing particles; these methods are undertaken in several steps. In this way the precision and reliability of the results is ensured.
Methods for particle extraction in accordance with ISO 16232 and VDA 19.1
Particle extraction from component surfaces on filter membranes is the first step in cleanliness inspection. The standards describe several methods:
1
Spraying
With the spraying method, a solvent-based cleaning medium or an aqueous solution is sprayed over the component surface to detach particles. This method is particularly effective for removing loosely adhering particles.
2
Rinsing
Similar to spraying, rinsing directs the medium over the surface or through the channels and cavities in the component; this technique is ideal for extracting particles in areas that are difficult to access.
3
Ultrasound
For the ultrasonic process, the component is placed in an ultrasonic bath with solvent. The ultrasonic waves detach the particles from the surface and from internal cavities. This method is very effective for firmly adhering particles.
4
Agitating
During agitation, the object is filled with test liquid, tightly sealed and subjected to oscillatory movements in a shaker. In this way, particles are detached from the internal control surfaces and transferred into the liquid. Particles in shadow zones or undercuts can also be extracted in this manner.
5
Suction
During air extraction in an ESD protection zone, suction is applied to components manually or using a robot. The advantage: particles can be extracted without the addition of a liquid – useful for certain sensitive components, such as air filters and electronic components for reuse.
Techniques for particle analysis in accordance with ISO 16232 and VDA 19.1
1
Gravimetry
Gravimetry is a method for determining the total mass of particles collected on a filter. For this purpose, the weight of the filter membrane used is measured to obtain an overview of the total amount of contamination.
2
State-of-the-art microscopy methods
Using reflected light microscopy the particles on the filter membrane are made visible and automatically classified by size and gloss level. The gloss level is differentiated into "metallic gloss", "non-metallic gloss" and "fibres".
3
Further analyses
Advanced analytical methods are used to analyse the particles in more detail. Scanning electron microscopy with EDX (SEM-EDX) provides a high-resolution assessment of the particle surface and structure; it is used to analyse the shape, size and composition of the particles. RAMAN spectroscopy and FTIR spectroscopy are methods for the chemical analysis of particles. They help to determine the material composition of the particles and provide information about the origin of the contamination.
VDA 19.1 and ISO 16232 in summary
VDA 19.1 and ISO 16232 are key standards for technical cleanliness verification in the automotive industry. They provide detailed instructions for particle extraction and analysis to safeguard the functionality and reliability of components. Originally introduced in 2004 and revised in 2007, the standards include new particle size classes, start parameters for decay curves and extended extraction and analytical methods. These standards are applied worldwide in the automotive industry and other sectors to ensure a high level of quality and the highest possible component and part reliability.
