High Temperature Impulse
filled with brake fluid is held in a convection oven at 295 ° F while being pressurized to 1,600 psi . A pressure cycling machine repeatedly increases the pressure in the hose from zero to 1600 psi within 2 seconds , holds it for 1 minute , and then quickly decreases the pressure back down to zero psi , also within 2 seconds . This full cycle is repeated 150 times ! At the completion of this , the line is removed from the oven and allowed to cool for 45 minutes , after which it must pass a 5,000 psi burst test . When designing a brake hose , the selection of materials must be such that their physical properties are not compromised by high temperatures . For example , if there is a durometer change , which would lead to softening in the presence of heat , the crimp joint may be compromised leading to failure of this test .
Salt Spray Chamber
End Fitting Corrosion Test
Most of us are familiar with this 24 hr salt spray test , which is designed to encourage rust and corrosion to form in a very short period of time . Its purpose is to validate that the materials and plating used on the end fittings will be protective enough to endure in corrosive and harsh environments . A hose assembly is suspended in the chamber and subjected to a 5 % salt solution made with distilled water . The temperature of the chamber is maintained at 95 ° F - hot and humid , a perfect environment for rust and corrosion . After 24 hours , the hose end fittings cannot show any base metal corrosion on the surface except where crimping or the application of labeling information has caused displacement of the protective coating .
Brake Fluid Compatibility Test
In order to test the hose ’ s chemical resistance , the hose is subjected to a temperature of 248 ° F for 70 hours while filled with SAE RM-66-05 compatibility fluid . After this , the hose is subjected to a 5,000 psi burst test .
Ozone Resistance
There are two components to this test . One is static and the other dynamic . For the static test , a brake hose assembly is exposed to ozone for 70 hours at 104 ° F - any cracks seen under 7X magnification are grounds for failure . For the dynamic test , the hose is cycle-flexed on a movable pin for 48 hours , after which it is also examined for cracks .
TECH EXTRA
Low Temperature Resistance
A brake hose is chilled to a temperature below -49 ° F for 70 hours . It is then bent around a mandrel and inspected for any cracking . It cannot have any cracks as seen without magnification .
Well , there you have it , a general description of “ The Torture Tests ,” which must be conducted in a very specific sequence . Any brake hose assembly manufacturer who can confidently and proudly state that they are in compliance with all the FMVSS-106 Standards has indeed earned the right to advertise their DOT compliance and compete fiercely in the marketplace . For Magnum Shielding , DOT compliance drives our quality standards and further reinforces our dedication to , and passion for , total customer satisfaction and safe riding . Our team strives to be the best at what we do and is committed to providing the industry with the highest quality innovative products that dealers have come to know and expect .
MAGNUM SHIELDING Pittsford , New York , USA
Tel : 585 381 8380 info @ magnumshielding . com www . magnumshielding . com www . AMDchampionship . com AMERICAN MOTORCYCLE DEALER - SEPTEMBER 2018 57