Revolution in the making

By ROBIN BAILEY

Two new processes that could have a huge impact on the way this country builds boats are being introduced to the industry next week.

Together they could revolutionise the way both aluminium and GRP (fibreglass) boats are made and involve big cost savings.

The systems will be one of the main talking points at the third annual New Zealand Marine Industry Conference at the Formosa Country Club, near Pine Harbour in Auckland on April 10 and 11.

A British expert takes the floor on day one. Dr Tim Searle is commercial manager of the Advanced Composites Manufacturing Centre at the University of Plymouth. He will be telling delegates about a technique called the resin infusion process, which has the potential to change the way in which GRP boats and components are manufactured, making them faster and more cost-effective to produce.

Dr Searle's introduction will be followed by a panel discussion on the implications of resin infusion chaired by Richard Downs-Honey, managing director of the leading New Zealand composites company Hi Modulus, who heads the Boating Industries Association suppliers group.

Others taking part include Cabot Lyman, of the United States-based company Lyman Marine, which uses resin infusion to build 27m to 30m custom boats and Bill Barry Cotter, founder of the hugely successful Riviera Group in Australia.

Day two will see aluminium boatbuilders paying attention as Dr Zhan Chen, senior lecturer at the Auckland University of Technology Faculty of Science and Engineering, talks about and demonstrates the friction stir welding process.

The solid-state joining process was invented in Britain in 1991. Since then it has been used in a range of commercial applications, including shipbuilding, the aerospace industry, and in Japan for building bullet trains.

Dr Chen, as a manufacturing/welding researcher, was at the forefront of developing the technology at Tohoku University and has been continuing his work at AUT.

Friction stir welding overcomes a problem encountered traditionally which results in a high level of distortion during welding of aluminium alloys. Solidification cracking, in the weld metal and in the partially melted zone, is a serious problem, particularly for high-strength aluminium alloys but because no melting is required, distortion and cracking are minimised.

This means the process has the potential to dramatically reduce the time it takes to build the luxurious superyachts New Zealand is turning out in increasing numbers.

A good example is the Henderson-based company Alloy Yachts, already a world leader in the construction of superyachts. Any improvement in the way these boats can be built will have a huge impact for the company and for our national economy as most are built for export.

Delegates will also be brought up to date on the implications of the new Trade New Zealand/Industry New Zealand rebirth as New Zealand Trade and Enterprise and what impact the change will have on the marine industry. The move is part of the Government's strategy to grow a portfolio of world-class sectors and businesses that are internationally competitive with sustained and profitable foreign earnings.

The new agency is designed to contribute to a supportive environment for economic growth, enhance industry and entrepreneurial capability and contribute to increased exports from, and investment in, New Zealand. The plan is to establish a global network with nine offices in New Zealand and three internationally.

A couple of the Auckland delegates and at least one from the South Island say they will have some serious questions for the men from the ministry who will be explaining the new agency. Which is as it should be.

* Organised by the Boating Industries Association, the conference is being sponsored by High Modulus, Technology New Zealand, the Boating Industry Training Organisation and Industry New Zealand, with assistance from Electrics Afloat Ltd, Electronic Navigation Limited, Power and Marine, NZ Yachting Developments and Tenob Marine Wholesale.