Avoid cutting corners on quality

Tufnol Composites’ managing director, Roy Thomason examines the key areas to consider when purchasing laminates and resin-based composites and gives advice on ensuring the right product is selected to meet exacting requirements. There is much to consider when sourcing any composite product that is destined for use in a wide range of manufacturing applications. In view of the current economic climate, many budgets continue to be squeezed and some purchasing or production managers may be tempted to save a few pounds on cheaper, lower quality materials and components. Inevitably this will often prove to be a false economy in the long run. Alongside this, some suppliers claim to offer ‘equivalents’ of products from leading manufacturers’ brands – without possibly knowing the correct composition of that product. Indeed the definition of the word ‘equivalent’ is often used in the context of selling a product that is described as being comparable to a leading recognised quality branded product. While there is apparently no intention to mislead customers, calling something an ‘equivalent’ can lead to confusion for the equipment specifier and result in them purchasing something that isn’t quite what they thought it was. In the world of composite material development, all types and grades are manufactured using what, in many cases, is a closely guarded recipe. While it may be possible to make a reasonable guess or assumption on the resin systems and reinforcements used, products that are copies or imitate the original may be close in their make-up, but are they true equivalents? In addition to the make-up of the product itself, how can anyone be sure they have been manufactured to the same quality standard and gone through the same level of rigorous testing? These are important questions any product or equipment specifier would be advised to ask themselves before purchasing so called ‘me too’ products. There are currently many sectors, especially manufacturing, where the market continues to be challenging and production and operations managers and directors are increasingly under pressure to keep their spend to a minimum. It can be tempting to seek cheaper products and components, but this can come at a price and may cause failure during a process which in turn will result in downtime of the equipment, and in some cases costly loss of production. Ultimately, there is no substitute for going for the original equipment manufacturer every time to make sure a consistent and reliable performance is delivered. Some imports and cheaper products can present a number of problems for customers and these include the level of mechanical strength, electrical strength and in-service temperature. Products that are tested thoroughly and correctly will ensure the customers’ confidence in the products they are buying. For example, quality manufacturers such as Tufnol have their own in-house laboratories and facilities where products are extensively tested so customers can be supremely confident in the materials they are purchasing. In many cases, cheaper material will often fall down on mechanical strength, which in turn can lead to delamination and failure. Delamination can have catastrophic effects in most applications causing equipment to be shut down for repair and making it necessary for replacement products to be sought and fitted. This inevitably leads to expensive loss of production and downtime. A prime example of where materials promoted as ‘equivalent’ can fall well short is resistance to surface tracking. Electrical current will always try to find the shortest path and a material’s ability to resist surface tracking is measured and referred to as its Comparative Tracking Index (CTI). For example, one of Tufnol Composites’ high performance resin systems has been modified to give the superior epoxy cotton Grade 6F/45 a CTI of 800. Other materials which purport to be equivalents can only claim to achieve, at best, a figure that is only 75% of this value. The consequential difference in performance is vast. Products may well be made to meet the British Standard, but still may not be equivalent to the OEM product. This is because the same standard does not always mean it is the same product. So what should the specifier look for when selecting their composites products? Potentially top of the list is the experience of the manufacturer, and working with established companies who have an excellent reputation and proven track record with their customers is something that cannot be underestimated. Good business relationships are usually built on trust in the product and service received. It is important to work with a manufacturer that ensures a high standard of production and has quality assurance systems in place to ensure standards are not compromised. These systems are subjected to scrutiny and approval by independent authorities and government bodies such as BSI and UKAS, which helps to ensure that those purchasing and using equipment can be confident in the product and its manufacturing process. In addition to the relevant industry standards, receiving recognition from some of the world’s leading companies is another endorsement of quality that speaks volumes. For example, Tufnol holds ISO 9001:2008 and AS/EN 9100:2009 accreditation and approval has also been received from major international companies including BAE Systems, Rolls-Royce and AgustaWestland, to name but a few. Close examination of the material specification of the composite, and consideration of how it will perform to meet expectations, is vitally important. The best manufacturers will never only work on the principle that making a product simply to meet the relevant British or ISO standard is good enough. Embracing real technical creativity will always ensure the relevant specification is actually exceeded. In the same way designers of critical equipment used in the aerospace industry for example will build in a safety factor of plus one or plus two, so internal manufacturing specifications will be tailored in the same vein. This way, customers can have complete confidence in excellent in-service performance and total material reliability. When purchasing composites, confidence in the product and the manufacturer is key for complete peace of mind. If seeking a new component for a particular application, then working with the OEMs who have the experience and knowledge to help and advise in finding the best solution will pay dividends. When sourcing existing products, avoid the temptation to cut corners with inferior cheap imports and supposed ‘equivalents’ will also prove to be a wise move in the long run. www.tufnol.com