Highfield boats Quality Presentation · ISO 1421 - Tensile strength test Sample size: 50mm*200mm....

Highfield 2014 World Conference

Highfield boats

Quality Presentation


1. Raw material qualification

1. Fabrics

2. Assemblies

3. Powder coating

4. Accessories

5. Aluminum

2. Quality control on production


Fabric

1) Tensile strength test (ISO 1421)

2) Tear strength test (ISO 4674)

3) Adhesion to textile strength test (ISO 2411)


ISO 1421 - Tensile strength test

Sample size: 50mm*200mm.

Perform tensile test, after breaking record the maximum value.

ISO 6185: 2000N / 5cm

Mehler: 2500N / 5cm

ORCA: 3000N / 5cm

HF standard: 2200N / 5cm


ISO 4674 - Tear strength test

Sample is size is 50mm*200mm.

Fabric sample needs to be cut in the center, 100mm long

Do the tensile test, after tearing to termination record the maximum value.

ISO 6185: 75N

Mehler: 120N

ORCA: 200N

HF standard: 120N


ISO 2411 - Adhesion to

textile strength test

Separate thecoating layerwith cutter

Glue 50mm*200mm samples together.

Let the assembly cure for 48 hours.

Separate the coating layer with cutter and record the average value.

ISO 6185: 80N / 5cm

Mehler: 100N / 5cm

ORCA: 150N / 5cm



Assemblies

1) Bonding strength test (ISO 2411)

2) Seam strength test (ISO 6185)

3) Heat test (ISO 6185)

4) Air tightness test (ISO 6185)

5) Bonding of fabric to powder coated aluminium

6) Chemlock


ISO 2411- Bonding strength test

Glue 50mm*200m samples together.

Let the assembly cure for 48 hours.

Do the peel test and record the average value.

ISO 6185: 80N / 5cm

HF standard:

Mehler: 200N / 5cm

ORCA: 170N / 5cm


ISO 6185 - Seam strength test

Join two pieces of material together in the same manner as used in the boat

construction to form a 50 mm wide test piece.

Apply a static load at 60 ℃ over a period of 4 h.

Butt connection

Single overlap connection


ISO 6185 - Heat test

Sample tube is inflated to 1.2 times working pressure.

Placed in a heat chamber, set at 60℃, for a period of 6h. Test air tightness.

There should be no slipping or other failure at any part of seam.


ISO 6185 - Air tightness test

The boat is inflated to a 1.2 times design working pressure for 30min.

Pressure is reset to design working pressure for a further 30min period.

Following a test period of 24h, the pressure drop shall not be greater than 20%

in any compartment.


Bonding of fabric to hull

Glue fabric to the aluminium powder coated panel.

Do the peel test to measure the adhesion value. Record the average value.



Chemlock

Polish the aluminium panel and paint the aluminium with Chemlock.

Let the Chemlock dry.

Fabric and hull material are assembled by gluing using PVC or Hypalon glues.



Powder coating

1) Coating thickness (ISO 2178)

2) Impact test (ISO 2409)

3) Cross cut test (ISO 2409)

4) Solvent resistence test (Qualicoat)

5) Salt water boiling test (BS EN 12206-1-2004)


ISO 2178 - Coating thickness

We use the gauge to make sure the thickness of powder coating is qualified.

HF standard: 60-80um


ISO2409 - Impact test

Test panel is placed under a die. A weight of 1kg is released from 50cm high.

Impacted areas are examined for cracking.


ISO 2409 - Cross cut test

Scribe parallel lines. Apply sticky tape remove slowly.

Results should be no lifting of the cured powder between scribe lines.


Solvent resistence test

Apply petrol or solvents (MEK, toluene, acetone) on the test panels.

After 10 minutes assess the test panels for blister, delamination or loss of

gloss.


BS EN 12206-1-2004 – Salt water boiling test

Test panels are longitudinally scribed and stand vertically in a pressure cooker.

Keep heating for 2 hours at a pressure of 1 bar (100kPa).

Examine samples for blisters, delamination.


Accessories

1) UV test (ISO 4892)

2) Salt spray test (ISO 9227)

3) Strength test of handle, rope and D-ring (ISO 6185)


ISO 4892 - UV test

Sample panel is exposed to a specific UV lamp for accelerating weathering

test.

A 1000 hours of exposure can simulate a natural exposure of a few years.


ISO 9227 - Salt spray test

This is an accelerated ageing test to check corrosion resistance.

Sample panels are exposed to a salt spray machine during a defined period,

temperature and humidity.


Assemble handles, rope and D-ring on the tube.

After 3 days strength tests are performed.

Record the maximum value after accessories separated from tube.

ISO 6185

- Strength test of handle, rope and D-ring

ISO 6185: 1,500N

HF standard: 2,000N


Aluminium

1) Chemical analysis of aluminium

2) Bending test


Chemical Analysis for aluminium

A sample of aluminium is taken from every batch and sent to an independent

lab for chemical decomposition.


Bending test

The flexibility of the aluminium needs to be verified on every batch.

We make sample 100*100mm. Press a 90 deg angle, then flatten. Repeat the

process and record the number of times before cracking appears.

With this simple process we can check the resilience of the material.


Quality inspection on production

1) Aluminium hull

2) Fabric tube

3) Whole boat

4) Water tightness

5) Packing


Aluminium hull

Quality supervisor check the boat after each process (cutting, pressing,

assembly, welding, sanding, treatment, powder coating).

Record the result on the table.

Hulls that pass inspection are stamped on the transom.


Aluminium hull

A 200*50mm sample panel is attached together with the hull during the pre-

treatment and powder coated processes.

Tests are performed on the sample panel to check the quality of the powder

coating (impact test, cross cut test and solvent resistance).

Record the result on the table for traceability.

Keep the sample panel in archives.


Aluminium hull

Measure the coating thickness on 12 different locations of the hull.

Record the data on the table and get the average to check whether the coating

thickness is satisfying.

1

4 6

32

5

7 811 12

109


Fabric tube

Tube can be made only if humidity is below 70% and temperature between

15°C. to 30°C. After the tube is completed each compartment is tested to verify the air

tightness of the chambers and baffles.

Tube air tightness test is performed.

Tube is brushed with soapy water on the seams to check potential leaks.


Whole boat

Quality supervisor checks every boat’s quality about glue situation, taping,

rubbing strake, accessories, packing and so on.

Record the result on the table and signature on the program card.

Program card is used for traceability. It records who and when did what on the

boat.


Water tightness

Boats are filled with water after the tube has been attached to the hull.

Water is kept in the boat for at least 5 min to make sure there is no leak.

Record the result on the table.

If leaks are found, they are fixed and the boat is tested again.


Final QC

Every boat is inspected following the quality inspection plan

Quality Inspection Sheet for OM

Date:

Order

number:

Model:

Hull/Serial

NO.:

NO. Description of inspection OK NG Remarks

Hull 1 Quality of weld fillet and buffing

2 Color of powder coating

3 Presence of stains on the hull (glue, solvent)

4 Quality of powder coating (gloss, thickness, dust)

5 Deformation or damage on hull

6 Hull is flat

7 No drilling after painting

8 Quality of transom cheeks

9 Bow locker fit for tube

10 Quality of fuel tank

11 Fuel tank is secured to the hull poperly

12 Fuel outlet is not touching deck lid

13Sender and connectors can be accessed from the small

lids

14 Model of fuel filler15 Installation of fuel hoses

16 Cover of fuel tank matching with deck

17 All screws are useful and have washers18 Make sure strakes are flat and 5deg down angle19 Transom welding20 Fitting of accessories (positon, size)

Tube

21 Material

22 Color

23 Stains

24 Scratches

25 Wrinkles on the seams

26 Regular cutting edges

27 Qualiy of the logo (flat)

28 Quality of adhesion/welded of the seams

Rubbing strake

29 Model

30 Position

31 Damage / scratches

32 Stains

33 Regular cutting edges

34 Quality of adhesion to tube

Accessories

35 Material and color

36 Model

37 Position and edge

38 Bubbles (air or stains) under the accessories

39 Stains

40 Damage / scratches

41 Quality of adhesion to tube

42 Nylon drain plug can be screwed and unscrewed

43 Quality of elephant trunk + rope and cleats

44 Motor plates (position, rivets)

Anti skid

45 Position, edge, adhesion(no bubbles) on the hull

Equipments

46 Consoles and seats' model and quality

47 Wooden shelf and foam for protecting

48 Position and adhesion of CE plate 49 All equipments are packed (oars, bags etc.)

Date:

Signat

ure:


After packing

After boats are packed, 5% of the boats will randomly be opened for inspection

Highfield boats Quality Presentation · ISO 1421 - Tensile strength test Sample size: 50mm*200mm....

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Transcript of Highfield boats Quality Presentation · ISO 1421 - Tensile strength test Sample size: 50mm*200mm....