Precision and Performance: Maximizing Efficiency in Motorsport Testing Solutions
In the ever-evolving world of motorsports, innovation drives not only speed but also safety. Carbon-fibre composites, known for their lightweight strength, have become a cornerstone of this high-performance industry.
With a relentless focus on boosting vehicular performance and enhancing safety, it’s no wonder why technologies developed in this high-stakes environment often become the gold standard. At the heart of this evolution lies our client, Crosby Composites, a leader in advanced carbon-fibre products, whose ambition is to push the boundaries of composite manufacturing while maintaining impeccable safety and quality standards. They had a need for carbon fibre chamber leak testing equipment.
Carbon-fibre composites are indispensable in motorsports due to their unparalleled combination of strength and lightweight properties. But even the finest materials demand rigorous testing to ensure reliability under extreme conditions. That’s where ATEQ UK stepped in, offering cutting-edge leak testing solutions that maximize efficiency without compromising precision.
Motorsport Carbon Fibre Composites Leak Detection
Crosby Composites faced a unique challenge: testing the integrity of a large-volume carbon-fibre chamber, exceeding 50 litres, fitted with numerous blinding ports and complex insulations. The chamber required the highest precision leak testing to ensure that no performance issues would arise from undetected leaks.
However, the chamber’s size, combined with the material’s flexibility, created variations in pressure and temperature, further complicating the process. Crosby Composites turned to ATEQ UK for a non-destructive testing method that could provide reliable, accurate results. They needed a reliable leak detection system (Leak Detectors) that could conduct accurate leak testing of the test chamber.
To meet Crosby Composites’ needs, we approached this challenge with a 4-phase Design Thinking framework, blending technical expertise with engineering precision to solve the challenges they faced. This collaborative process between Crosby Composites and ATEQ UK was designed to ensure a solution that would meet and exceed the client’s expectations.
Phase 1 Discover (Feasibility Study):
We began by collaborating closely with Crosby Composites’ engineers to gain a deep understanding of their specific requirements. Our team conducted detailed feasibility studies to assess the complexities of large-volume leak testing. Together, we identified critical points of failure, and our team proposed a tailored plan for equipment installation at the production site, ensuring optimal results.
Phase 2 Define (Selecting Leak Testing equipment):
Initial discussions revealed that the instrument Crosby Composites originally requested wouldn’t meet the demands of testing such a large, flexible chamber. Our team recommended the F670LV—an advanced leak detection system designed to conduct leak testing on large volumes with short fill time. This solution offered greater precision and ensured Crosby Composites’ carbon-fibre chambers would meet the strictest quality standards.
Phase 3 Develop (Component Pressure Optimisation):
During the commissioning process, our engineers worked hand-in-hand with Crosby Composites’ team. Our team identified several leaks from the chamber’s blanking plates, requiring immediate attention. The leak rates were higher than the optimal level. Upon detecting several leaks from the chamber’s blanking plates, we provided on-site, hands-on guidance, demonstrating how to create a positive test pressure program.
We suggested conducting a preliminary bubble test to manually locate and seal the larger leaks before proceeding with vacuum decay pressure testing using the F670LV. This step-by-step process of visual leak testing allows Crosby Composites to isolate and resolve significant leaks early, paving the way for successful high-resolution leak testing.
Phase 4 Deliver (Quality Control and Commissioning):
After thorough adjustments, we successfully conducted the leak tests, ensuring the carbon fibre chamber met the specified rejection levels. Crosby Composites was
impressed with our hands-on support and proactive problem-solving approach, ensuring their components were ready for high-performance motorsport applications.
By partnering with Crosby Composites, we not only ensured their carbon-fibre components met stringent performance standards but also improved overall
production line efficiency. Defects were significantly reduced, as leaks were detected and addressed earlier in the process.
Key factors behind this success included:
• Precision Technology: Advanced leak testing systems ensured precise and efficient testing of carbon-fibre components, significantly reducing operational
costs.
• Expert Guidance: On-site support facilitated effective leak detection and resolution during the commissioning process, fostering a highly collaborative
culture.
• Enhanced Performance: Leak-free components helped maintain the high-performance standards, critical for motorsport applications.
Together, we helped Crosby Composites accelerate toward its goals of delivering world-class carbon-fibre solutions while upholding the rigorous standards demanded by the motorsports industry.
