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As storage density increases at a rate of 100% per year or more, disk drive manufacturing processes continue to be pushed to support this ongoing challenge. Increased cleanliness contributes significantly to the ability to provide increased storage density as flying heights are decreased and disk surfaces become more and more complex and delicate. Already, unimaginably small particles appear as "boulders" to the disc drive mechanism. This course explores the cleaning process from top to bottom starting out with a look at what is behind the need to clean. The nature and sources of contaminants are discussed in detail along with the properties that make them difficult to remove. The course continues on to explore the various substrates that require cleaning and the cleaning chemistries and processes best suited for removing specific types of contamination. Solvent, aqueous and semi-aqueous chemistries are explained along with the mechanics of various cleaning processes and hardware. Heavy emphasis is placed on ultrasonic cleaning and how it may be best applied with control and without the risk of part damage especially on increasingly sensitive HSA's. Finally, ways to measure cleaning effectiveness and provide process control of cleaning to assure that it is efficient and consistent over time are presented. Other topics covered will include manufacturing for cleanability including ways to simplify and minimize the need to clean, understanding cleaning hardware and its application in disk drive cleaning, and the relative costs of cleaning using various technologies and chemistries. This knowledge provides a basis for understanding the various cleaning processes used in disk drive manufacturing.
 

Cleaning Overview Trends in the Industry What Needs Cleaning Why Do Things Get Dirty When Do We Clean How Clean is Clean What Goes Wrong The Risk of Overcleaning What is Cleaning Substrates and Surfaces Contaminants Breaking Bonds Chemical Cleaning Mechanical Cleaning Cleaning Synergisms Capturing and Removing Contaminants Ultrasonics Cavitation and Implosion Degassing Ultrasonic Parameters Sweep, Power, Duty Cycle Frequency and its Effects Monitoring Ultrasonic Performance Eliminating Part Damage Chemistry Solvent Chemistry Aqueous Chemistry Blends and Mixtures Semi-Aqueous Solvent Wash Water Rinse How Chemistry Works to Clean Evaluating and Selecting Chemistry Toxicity

Aqueous Cleaning Where Water Works and Why The Role of Mechanical Boost Benefits and Pitfalls Process Parameters DI and RO Water Rinsing Drying Solvent Cleaning Where Solvent Works and Why Vapor Degreasers Liquid Immersion Systems Solvent Rinsing Maintaining Solvent Purity Azeotrope Systems Co-Solvents Environmental Issues Alternative Cleaning Methods Present and Future Potential CO2 Snow Super-Critical CO2 Laser Plasma Disk Drive Cleaning Issues Parts and Materials Contaminants Engineer for Cleanability Efficiency What's Unique Cleaning System Design Customize for Disk Cleaning System Features and Controls Capital Costs Operating Costs Process Control and Verification Cleaning Effectiveness Automation

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