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.
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.
3D Scanning Inspection
To meet the high precision standards demanded by top-level race teams, it’s essential to implement rigorous inspection procedures not only at the end of the manufacturing process but also from the very beginning. By using our Creaform HandySCAN portable scanner, we can inspect not just the finished exhaust systems, but also the manufacturing jigs with an accuracy of 0.020mm/m³ before production begins.
All of our jigs are designed in CAD based on a 3D model of the exhaust, then CNC-machined from aluminium and steel. Using the CAD model as a guide, each jig is assembled and inspected using the HandySCAN to ensure dimensional accuracy. This process is also applied to individual exhaust components and complete systems where CAD models are available.
Key surfaces, positions, and critical features of the exhaust can be precisely measured. With Creaform’s industry-leading VXInspect software, a comprehensive inspection report is automatically generated, detailing all critical dimensional data such as:
- True position and other GD&T constraints
- Surfaces / deviation colour maps
- Flatness
- Part to CAD comparison
- Tolerance validation
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
