Quality Control and Inspection in our Manufacturing Process

Primary Designs prides its self on superior quality, an exhaust failure could cost a race or even a championship, because of this we operate a very strict quality control system through all stages of our business, from the purchasing of raw materials through to manufacture and shipping. Having these systems in place is essential to working in the highest end of the motorsport industry.

Quality Control

Fluorescent Penetrant Inspection (FPI)

FPI is a type of dye penetrant inspection and a non-destructive test (NDT) where a fluorescent dye is applied to the surface of a non-porous metal, in our case the surface of an exhaust component, in order to detect any surface breaking defects that could later lead to a potential failure.

This method is suitable for all non-porous metals such as:

  • Inconel
  • Titanium
  • Stainless Steel
  • Steel
  • Aluminium
  • 3D printed components
  • Castings

The process involves the part being thoroughly cleaned and then being dipped in a tank containing fluorescent dye, this dye works it’s way into any flaws or defects on the surface of the component. Excess dye is removed and a developer is then applied, a white powder based substance that acts as a contrasting background against any flaws that may be detected. Finally the part is inspected under a UV light in a dark room and any defects that held the fluorescent dye will be illuminated.

Any defects that have been identified can be repaired or replaced and will go through the whole FPI process again until they pass inspection.

CMM Inspection

In order to manufacture exhausts to the high level of accuracy required to work with and supply top level race teams, it is not only important to have a strict inspection procedure at the end of manufacturing but also at the start of the process. With the use of our FARO Fusion portable coordinate measuring machine (CMM) we can not only inspect the final product but we can also inspect the manufacturing jigs to an accuracy of 0.061mm before the manufacturing process even starts.

Most of our jigs are now created from CAD around a 3D model of the exhaust and then CNC machined from Aluminium and Steel. Where a CAD model of the jig is available they can then be assembled and inspected using the FaroArm. This process can also be used for exhaust components and full exhaust systems where CAD models are available.

Important faces, positions and critical areas on the exhaust can be measured and using FARO CAM2 Measure, FARO’s own software, a full report can be automatically produced detailing any critical inspection data such as:

  • Hole Positions
  • Face relationships
  • Flatness
  • Circularity
  • Deviation from tolerances

Traceability and Part Marking

In accordance with ISO 9001:2015, all of our finished exhaust components are part marked with a unique job number. This unique number, with the use of our ERP software and quality management system, allows us to trace our products back to their corresponding quality documents such as; raw material mill certificates, inspection reports and even manufacture and delivery dates.

Products, if requested, can also be marked with any other information such as; the customer part number, batch number and serial number, using one of our 3 types of part marking:

  • Laser etching
  • Electro-Chemical Etching
  • Dot peen marking

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