AC 7101.3C 材料实验室Nadcap审核准则 - 力学性能检测

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161Thorn Hill Road

Warrendale, PA 15086-7527

AUDIT CRITERIA

AC 7101/3 REV . C

Issued 1993-05

Revised 2011-05

Superseding AC7101/3 REV. B

TO BE USED ON AUDITS CONDUCTED ON OR AFTER AUGUST 28, 2011

Nadcap

AUDIT CRITERIA FOR MATERIALS TESTING LABORATORIES

MECHANICAL TESTING

1.0 SCOPE

This checklist supplements PRI AC7101/1. This checklist applies to suppliers seeking Nadcap

accreditation for Materials Testing Laboratories - Mechanical Testing. It is intended to establish the criteria for acceptable methods used in Mechanical Testing.

2.0 GENERAL INFORMATION

2.1 Laboratory 2.2 Laboratory Contact 2.3 Auditor 2.4 Initial Accreditation Re-accreditation Follow-up

NOTE:

The Bold section in this document represent the interpretations for each section of this checklist. Items noted with a single asterisk(*) are additional Nadcap requirements.

NOTE:

Applicable definitions can be found in AC7101/1 General Requirements for Laboratories. 2.5 Equipment and Capability Matrix is attached. YES NO Attach equipment and capability matrix (include all equipment used for test types for which laboratory is to be accredited).

Minimum information in matrix shall include: Number of test frames, basic description of each test frame (including control mode capabilities), Load Ranges, extensometers, non ambient temperature capabilities, Controllers (including test software with revision), specialty equipment.

3.0 PROCEDURES AND DOCUMENTS

3.1 Reference Documents – A list of specific ASTM, ISO and other standards is found in checklist AC7101/1.

3.1.1 The laboratory has the applicable testing standards. YES NO

3.1.2 The laboratory uses the latest applicable standards or as specified by customer. YES NO

AUDITOR NOTE: Verify revision of standard used for each test type to be accredited.

3.2

Laboratory Procedures – Laboratory has a system of written procedures for test types performed.

YES NO Written procedures are required which are detailed to be followed for the specific test requirement to be used and specific test to be performed, and shall conform to the applicable test standard.

AUDITOR

NOTE: Verify written procedure for each test type to be accredited.

4.0 PERSONNEL AND TRAINING

4.1 Verify personnel training for at least one Mechanical Testing test type.

Test Type ___________________________________ Equipment operated ___________________________________

4.2 Training is documented. YES NO 4.3 Training includes any methods specified in laboratory procedures. YES NO

5.0 FACILITIES AND EQUIPMENT

Refer to Capability and Equipment List if needed. 5.1

Ambient facility temperature and humidity are monitored and documented as required by individual test requirements.

YES NO For short term tests, a minumim of a single measurement shall be made within ? hour of the start of the test (e.g. application of force to the specimen) and documented. Short term testing is defined as testing that lasts one hour or less.

For long term tests, measurements shall be made at time intervals no greater then every half hour commencing within 30 minutes of the time of load application. Long term testing is defined as testing having a duration of more than one hour.

Humidity shall be monitored and recorded when required by customer or standard.

It is the intent of this requirement that the ambient temperature is measured in close proximity to the testing equipment; however that Nadcap MTLTG recognizes that this is often not practical. The temperature sensor should be in the general area of the test equipment and placed so as to avoid drafts and other airflow (i.e. do not place directly under a heat source or air conditioning register).

5.1.1 Laboratory has a procedure for monitoring and recording ambient laboratory conditions.

YES NO

5.2 Laboratory has a written preventive maintenance plan in place. YES NO 5.2.1 The preventive maintenance plan is followed and logged. YES NO

5.3

Facility operations affecting specific testing – The laboratory procedures require notification of customers in the event of interruption due to power outage, or equipment failure that has an effect on the test results.

YES NO

If testing is interrupted due to power outage, equipment failure, etc. and the testing was not invalidated, testing records shall indicate the following: Date and time of interruption, description of malfunction, and corrective action taken, if required.

6.0 CALIBRATION/VERIFICATION

6.1 Equipment calibration/verification frequency is in accordance with Table 1 below. YES NO

Note all deviations from requirements.

Laboratories performing testing to ASTM based requirements shall use ASTM based calibrations. Laboratories performing testing to ISO based requirements shall use ISO based calibrations. Laboratories performing both types of testing shall have both types of calibrations.

TABLE 1 – Calibration/Verification Schedule

(Maximum Frequencies when not defined by standard methods or supplier requiements) (a),(e)

Code Test Type

Load Cell (c) Extensometer (d) Displacement (stroke) Crosshead/actuator Speed

STATIC TESTS A Room Temp. Tensile

1 year 1 year 1 year 1 year B Elev. Temp. Tensile 1 year 1 year 1 year 1 year C Stress Rupture (b) N/A N/A N/A XA Creep

(b) 1 year (f)

N/A N/A CYCLIC TESTS

O Load Control (High Cycle) Fatigue

1 year N/A N/A N/A Y Strain Control (Low Cycle) Fatigue

1 year 6 months N/A N/A P Fracture Toughness 1 year 6 months N/A N/A XE Crack Propagation 1 year COD gauge 6 months

N/A N/A

IMPACT – TYPE N 1 year (g)

1 year – Lateral Expansion gauge

N/A N/A

NOTE:

(a) Pull rod and adapter inspection takes place in individual test sections. (b) Weights: 5 years. Accuracy ± 0.5 %.

Load Frame – Lever Arm: 1 year. Accuracy ± 1.0%. See Table 2.

(c) Calibrate Load Cells in accordance with ASTM E4 or EN ISO 7500-1 Class 1 or better.

(d) Extensometers are calibrated for a particular system (i.e. the extensometer, cabling and signal conditioning must be included

and stay together as a unit). For the determination of all test types, the calibration shall be to at least Class B2 of ASTM E83 or at least Class 1 of EN ISO 9513 with the following exception: For the determination of Young’s Modulus of Elasticity, when required, Class B1 of ASTM E83 or Class 0.5 of EN ISO 9513 shall be used. Calibration of the Crack Opening Displacement (COD) gauge for fracture mechanics with the testing standard.

(e) Test machine alignment is considered a verification, not a calibration (i.e. it does not have a National Standards traceable

source) and is thus not addressed in the calibration section.

(f) For Creep indicators, the creep arms (sometimes referred to as “extensometer”) are required to have a visual inspection prior to

TABLE 2 – General Equipment Calibration Schedule

GENERAL EQUIPMENT REQUIRED FREQUENCY

(maximum)

Test temperature measurement Instruments and Recorders 3 Months

Laboratory Ambient Temperature/humidity measuring

Instruments

1 Year

Micrometers/Calipers 6

Months Creep Indicators (electronic – e.g. LVDT, Digital Glass Scale,

Capacitance, Digital Dial Indicators)

1 Year (Class B-2)

Creep Indicators (mechanical)

(This includes dial indicators.)

1 Month

Optical Comparator 1 Year

Oscilloscopes 1

Year Torque Testing Equipment 1 Year

Gauge Blocks 1 Year

Timers (rupture testing) – 0.1 Hr 1 Year

Load Frame – Lever Arm (Note “b” table 1) 1 Year

Weights (Note “b” table 1) 5 Year

All other Sensors and Instruments All other instruments shall be calibrated at an appropriate interval to ensure integrity of the test measurements.

Calibration cycles may be extended as defined by the NCSL (National Conference of Standards Laboratories), Recommended Practice 1, or other recognized statistical review process to support the extended time interval. Calibration frequencies defined by standard methods or supplier requirements shall not be extended. Calibration extension shall be allowed only if documented historical data and standard calibration practices substantiate the extension of calibration frequencies.

AUDITOR

NOTE:

Include documentation on all calibration extensions used.

7.0 TEST MACHINE AND TEST SPECIMEN ALIGNMENT

Proof of alignment capability is required for tests using axial loading. Calibration of elevated temperature test equipment may be performed at room temperature due to strain gauge temperature limitations.

Alignment verification for static testing is intended to be performed when the test machine is first set up and upon any major repairs from damage that might influence axiality of test load application.

Alignment verification for dynamic testing is far more likely to have an influence on test results and is intended to be performed upon setup of a particular gripping assembly (or program) as well as periodically during a dynamic fatigue testing program.

The intent of the test machine alignment check is to verify that the major components of the test machine load train are in alignment. Typically, the major components of a load train consist of a load cell, an actuator or crosshead, load rod or grip mounts, load rods and grips or grip bodies (creep and stress rupture machines do not require a load cell if calibrated dead weights are used). Reverification does not need to be performed upon the removal of the gripping mechanisms or specimen interface portions of the grips. These mechanisms include tapered wedges, collets, end cap housings, pins and clevises, anti-buckling supports, and threaded adapters. These mechanisms are typically characterized and identified by the fact that they are by design intended to routinely be inserted and removed from the grip bodies or load rods during normal operation of the grip.

7.1 Required

Capability

Laboratory demonstrates alignment capability for test frames used in Nadcap testing. YES NO

Maximum bending capability as calculated in accordance with ASTM E1012 shall be

demonstrated as follows:

Static Tests: 10% (requirement comes from ASTM test standards for static testing).

Dynamic (Cyclic) Tests: 5% (requirement comes from ASTM standards for dynamic

testing).

Acceptable alternate criteria - all gauges of each set within 100 micro strain of

average of that set for readings below 2000 micro strain.

Note – revision of ASTM E1012 will better clarify the alternate criteria. This document will be revised when that information becomes available.

Static and dynamic test equipment used in tension shall have an alignment verification performed in tension. Dynamic test equipment used in compression shall have an alignment verification performed in compression. Dynamic test equipment used in both tension and compression shall have an alignment verification performed in both tension and compression.

Note: there are no alignment requirements for static compression testing.

When bending calculations result in values greater than the stated requirements in 7.1, test equipment may be used at lower strain levels (i.e. below 2000 microstrain), if the bending calculation also includes a fixed strain gauge comparison, where the gauges are all within 100 microstrain of the average at the applied test forces of interest. A current revision of ASTM E1012 will better clarify the alternate criteria. This document will be revised when that information becomes available.

7.1.1 Loads During Evaluation

7.1.1.1 Static Test Alignment Verification

For static testing, an operational check that covers the general force range used for testing. Alignment verification shall include a minimum of three data points. Recommended data points at 10%, 20% and 40% of the load cell range or test machine capacity. Test set-up shall include the test machine and all rigid components of the load train assembly. Alternately, the alignment verification may be based on either of the following: ?The lowest maximum load as follows:

o Tensile tests – Lowest load required for yield strength determination

o Constant load tests – lowest load for producing specified stress.

?A customer requested loading regime

7.1.1.2 Dynamic (cyclic) Test Alignment Verification

Cyclic tests: verification shall cover the range used in normal testing without causing permanent deformation to the alignment through the lower strain or load levels to be used in testing are acceptable for higher strain or load levels.

?For negative R testing, verification in both tension and compression shall be used.

?For R=0, the data point at zero load (grips clamped) adequately represents the lowest peak stress or strain.

?For positive R testing, loads shall cover the entire test range.

Test set-up shall include the test machine and grips. Calibration is performed under static load conditions, but

7.2 Alignment verification for uniaxial testing is in accordance with ASTM E1012, using

YES NO the strain gauge method.

The test machine alignment verification includes zeroing the strain gauge readings with the specimen hanging

free, a data point with the grips engaged at zero applied force (i.e. a clamped at zero load point), a bending

calculation at the lowest force range used on the machine (for reporting or establishing test results or

conditions) and shall include at least two additional bending calculations at higher applied force levels. For the

clamped at zero applied force data point, bending calculations are not necessary.

NO 7.3 Alignment Specimens – meets guidelines of ASTM E10231012. YES Calibration Specimen(s): Bars shall represent the typical reduced section lengths to be tested. A strain gauge set

comprises axial strain gauges located at either 90° or 120° intervals around the circumference of the specimen

reduced section. The number of sets is as defined in ASTM E 1012.

For static testing where a number of test sample configurations are used, any standard ASTM E8 specimen may

be used provided that no more than one adapter coupling is used on each end of the specimen to connect to

machine pull rods.

7.4 Alignment Frequencies are acceptable. YES NO

7.4.1 Static Testing Machines (those used in sections 11,12 and 15 of this checklist) - upon

setup, if the equipment is moved or if any damage occurs to the machine from

unexpected events.

7.4.2 Dynamic Testing Machines (those used in testing covered in sections 17, 18, 19 and

21) - every 6 months or when changing test setups for new specimen geometry

(whichever comes first). Note - if testing is underway when an alignment verification is

due, the test may be allowed to run to completion before the alignment verification is

performed.

7.5 Alignment Verification Records YES NO

Alignment verification records may be curves showing % bending as a function of the applied load, or they may

be tabular listing of data points (3 minimum for tension and 3 minimum for compression).

For Clevis loaded specimen testing such as CT specimens for crack growth or fracture toughness, a test

machine alignment verification using dimensional measurements or setup gauges (Machine Alignment as

defined in ASTM E1012) is acceptable (may be done to internal procedure). For this case, a specimen alignment

using a standard uniaxial specimen (eliminating the clevises) is also acceptable.

8.0 INCOMING SPECIMEN INSPECTION AND MATERIAL CONTROL

8.1 Incoming test specimens receive a general quality inspection. All specimens have

YES NO specific identification.

Machined test specimens may enter the testing area either from in house (captive) machine shop or from an

outside (independent) supplier. Either method requires quality inspections of the specimens. This includes: ?Measurement of dimensions that are used in the calculation of test results

?Visual inspection

?Verification of specimen identification

Nadcap MTL Task Group recognizes that inspection may be best performed in a facility other than the laboratory

(e.g. machine shop or inspection area). It is the expectation that the inspection will be performed using the best

8.2 The laboratory inspection procedure requires inspection to the specimen drawing or customer requirement. YES NO

8.2.1 Inspect and record dimensions that are used in the calculation of test results for all specimens. YES NO

8.3 Describe quality inspection methods: YES NO

Same inspection methods applied to ALL specimen types. Different inspection methods applied to different specimen types. Requires process control (SPC). Audits process control.

8.4 For CYCLIC TESTS (Codes O, Y) and when required by standard, the machining source is qualified to Specimen Preparation Code Z1 for Low Stress Grinding and Specimen Preparation Code Z2 for Low Stress Grinding and Polishing.

YES NO

8.5 Non-cyclic specimen machining is controlled (e.g. Drawing/Procedure/Machining Guidelines). YES NO

Testing laboratory performs its own specimen machining.

8.6

Outside specimen machining source(s) comply with the Nadcap requirements

regarding specimen machining, and are listed on AC7101/1 Figure 3 with test codes and specimen types. If outside specimen machining sources are not accredited to AC7101/7, then laboratory has a procedure for verifying the outside specimen machining source is compliant with AC7101/7. YES NO

AUDITOR

NOTE: Be sure AC7101/1 lists machining sources.

9.0 TEMPERATURE MEASUREMENT

9.1 Thermocouples (T/Cs) Thermocouple selection shall be according to ASTM E230. Thermocouple tolerances (correction factors or deviations) shall meet the special tolerances for base metal thermocouples and the standard tolerances for noble metal thermocouples. List types and uses: ___________________________________________________________________ 9.1.1

Control and recording thermocouples shall have a calibration certificate that identifies

the source of the calibration data, nominal calibration temperatures, actual calibration temperature readings, and calibration technique for each calibration temperature traceable to NIST (or other National Standardization body). Calibration technique shall comply with ASTM E220 or other recognized standard.

YES NO

Thermocouples shall not be used outside the calibration range. Extrapolation of correction factors shall not be performed. Calibration temperature intervals shall be within the following:

?Noble metal (e.g. type R, S) thermocouples: 200°F (111°C) Requirement from AMS 2750

?Base metal (e.g. type K, N) thermocouples: 100°F (56°C) Requirements meet suggested ASTM E220 of every 200 degrees F and AMS 2750D requirement of not to exceed 250 degrees F

Thermocouples produced from calibrated rolls may be used in lieu of individually calibrated thermocouples. Rolls up to and including 1000 ft (305 meters) in length may be sampled at one end; rolls over 1000 ft (305 meters) shall be sampled at both ends of the roll and at 2000 ft (610 meter) increments. Calibrations shall be performed per ASTM E220.

The difference between correction factors at opposite ends of rolls shall not exceed 2o F (1.1o C). It is permissible to divide the roll into shorter length rolls when the end-to-end tolerance is exceeded. These then become individual rolls and require their own calibration and correction factors.

It is permissible to use thermocouples that have been calibrated individually.

Non expendable thermocouples and devices that are used for purposes other than to record test temperatures (i.e. furnace over-temp thermocouples) are exempt from calibration requirements.

Non expendable thermocouples and devices that record data (i.e. laboratory ambient temperature monitor thermocouples) shall be calibrated and are limited to use below 500o F (260o C). This includes thermocouples that are used for cryogenic testing applications.

AUDITOR NOTE:Review at least one calibration report for every T/C type material used. Attach each report reviewed.

9.1.2 Correction factors (deviations) are applied to all non ambient temperature testing. YES NO Thermocouple correction factors shall not exceed + 2o F (+1.1°C) or 0.4% of the reading, whichever is greater.

For thermocouples produced from rolls calibrated at each end, the correction factor shall be the average of the values at each end.

Thermocouple correction factors and recording/display equipment correction factors shall be applied algebraically to each non room temperature test. These may be applied either manually or with an automated control system.

For additional information on applying Thermocouple Correction Factors, please see example located under Public Documents section of Materials Testing Laboratories within eAuditNet.

AUDITOR NOTE:Review test and work instruction to verify that correction factors were calculated and applied correctly.

9.1.3 Thermocouples are only be used within ranges defined in ASTM E230. YES NO Temperature measurements for testing outside these temperatures require customer approval.

AUDITOR

NOTE:

Verify laboratory work instructions for this requirement.

9.1.4 Control T/Cs are of equivalent or better precision, accuracy, and durability to YES NO

9.1.5 Requirements specific to Types K and N Thermocouples. YES NO Requirements for type N thermocouples are the same as for type K thermocouples except that Type N thermocouples shall not be used above 2000°F (1093°C).

9.1.5.1 T/C wires are not twisted prior to the weld bead or the crimp tips. YES NO

9.1.5.2 For long duration, high temperature tests, the procedure addresses T/C degradation. YES NO

Wire stability for all long term testing (greater than 25 Hr for temperature measurement) above 1600°F (871°C) shall be determined by the comparison method of ASTM E 220. The exposure temperature shall equal or exceed the maximum temperature at which the wire will be used; exposure time shall be the greater of the standard minimum or 25 hours. If the standard minimum is unknown, the exposure time for stability shall be limited to 150 Hr. The wire is acceptable provided the indicated temperature does not drift more than 5°F (3°C) during exposure.

For additional information on applying Thermocouple Correction Factors, please see example located under Public Documents section of Materials Testing Laboratories within eAuditNet.

YES NO 9.1.5.3 T/Cs are not re-used unless all heat affected wire and all kinked wire have been

removed and a new junction made.

The laboratory shall have a procedure addressing reuse of type K thermocouples. Thermocouples shall not be re-used unless all wire previously exposed at temperatures above 1000°F (538°C) has been removed and a new junction made. For reuse of type K thermocouples at any non ambient temperature, kinked wire and any damaged junctions shall be removed and replaced.

This requirement is intended to apply to recording and control thermocouples.

9.1.6 Requirements Specific to Noble metal Thermocouples

YES NO N/A 9.1.6.1 The laboratory has a procedure addressing use and reuse of type R, S and B

thermocouples. This shall include any recalibration periods used.

Recalibration requirements are as follows:

?For temperatures at or below 1112o F (600o C) – 4 years

?For temperatures from 1112 o F (600o C) to 1472o F (800o C) – 2 years

?For temperatures above 1472o F (800o C)- 1 year

?Note – these come from ISO 204.

Type B thermocouples shall not be used below 1600°F (593°C).

Type R and S thermocouples shall not be used above 2700°F (1482°C).

Temperature measurements for testing above this temperature require customer approval.

Type R and S thermocouple junctions - Welded junctions in Types “R” and “S” may be used as long as welding processes prevent contact with foreign metal vapor (e.g. laser welding or arc welding with inert gas).

9.1.7 Thermocouple selection and use complies with requirements. YES NO

Thermocouples (T/C) shall be selected in accordance with customer criteria. Bare wire thermocouples are preferred although if the lab can prove that all requirements of this standard are met Mineral insulated metal

Traceability information for control and recording T/Cs used for elevated and cryogenic temperature tests shall be maintained in laboratory records.

9.1.7.1 Thermocouple attachment methods comply with requirements. YES NO Thermocouple attachment methods shall be in accordance with the test standard or with customer criteria. If no specific criteria are provided, use ASTM E633 for creep and stress rupture (this also may be used for tensile testing).

Thermocouple attachment by welding directly on the gauge section of the specimen is prohibited. Methods of attachment are test type and material type dependent. Specific thermocouple attachment requirements are described in the specific test sections. Revision note – be sure this is included.

The T/C junction shall be in intimate contact with the test specimen.

The contact between the thermocouple junction and the test piece shall be shielded from radiation effects of the furnace elements. This may either be done through furnace design, where a high temperature material blocks the direct radiation from the furnace elements or by the use of high temperature insulation applied directly to the external surface of the contact point, also blocking direct radiation from the furnace elements.

If used, Mineral insulated metal sheathed (MIMS) thermocouple junctions shall be grounded to the sheath for acceptable intimate contact. Procedures shall identify standard attachment practice.

9.2 Thermocouple extension wire use conforms to requirements. YES NO Extension wire shall conform to ASTM E230 or other recognized standard.

Extension wire shall not be spliced. Connectors, plugs, jacks and terminal strips are permitted if they are the compatible type, i.e. they have thermoelectric properties conforming to the characteristics of the corresponding thermocouple type – ASTM E1129 may be used as a guide for round-pin connectors.

9.3 Temperature measurement instrumentation conforms to requirements. YES NO Output of thermocouples shall be converted to temperature through the use of readouts, recorders and controllers. These shall be calibrated against a standard traceable to NIST (or other National Standardization body).

Calibration accuracy requirements for readouts, recorders and controllers shall be +2°F (or for laboratories using SI temperature units +1 °C is acceptable).

Readouts, recorders and controllers shall be digital with a minimum readability to 1°F or 1o C.

10.0 TEST CERTIFICATES, REPORTS AND RECORDS

Test Certificates, Test Reports and Test Records are defined in AC7101/1. Additional report requirements are contained within AC7006 and ISO17025.

This section is intended to audit the overall method used by the laboratory for establishing how results are reported. Audit checks of specific reports are included in the various test sections of AC7101/3.

In the case of a laboratory sharing raw test data with a customer for purposes other than generating a report, this data is not considered a report in and of itself.

10.1 Test records include all pertinent information from the test. YES NO

It is the intent of the Nadcap MTL TG that a test Certificate/Report can be recreated using information contained in the Test Record.

Test records shall include customer required information, items from the following list required by standard and other information from which reported results are determined:

?Stress/strain or load/displacement curve or data (tensile), and creep curve or data (creep-rupture), from which values may be determined.

?Equipment identification, including testing machine, extensometer, furnace, and thermocouples.

?Measured test temperature and time, including ramp, soak, and test.

?Measured specimen critical dimensions.

?Invalid test results, and reason for invalidation

?Ambient temperature

?Reason for replacement of specimens

?Extensometer attachment method

?Test operator

?Test date or and start date, time and duration of test (multiple day tests)

?Test load and lever ratio (rupture)

?Incremental loading curves, if required (creep-rupture)

?Initial shoulder diameter, notch diameter, and notch radius (notched-rupture test)

?Test atmosphere, if different than laboratory air.

10.2 Test Certificates/ Reports include mandatory reporting information. YES NO

Test certificates/reports shall include standard/specification and customer required information and applicable items from the following list:

?Results that are required by the customer (typically UTS, 0.2% Yield Strength, %elongation, %creep, life, absorbed energy, lateral expansion, fracture appearance, etc.).

?Specimen identification

?Material identification

?Specified test temperature

?Heat treat condition if applicable

?Specimen type or reference to specimen type (e.g. drawing, ASTM E8, etc.)

?Stress (rupture)

?Uploaded or discontinued tests (rupture)

?Fracture location, if outside of center half of gauge length (tensile, rupture)

?Standard/source of requirements

10.3 Rounding – Lab procedures are governed by a standardized approach to rounding. YES NO

It is the intent of the MTL Task Group to allow rounding as per the test standard used. Unless otherwise specified in the test standard, numerical values are rounded in accordance with ASTM E29.

11.0 TENSILE TESTING (Codes A and B) N/A

11.1 Check which are being accredited.

A – Room Temperature Tensile

B – Elevated Temperature Tensile, to a maximum temperature of _______ .

There are several tensile test methods covered under tensile testing. The certification issued to the laboratory

will list the methods for which the laboratory is approved.

11.2 Round robin completed per AC7101/1. YES NO

11.3 Facilities and Equipment (Specific to Tensile Test)

11.3.1 Test machine calibrations meet the requirements in table 1 at frequencies indicated. YES NO

11.3.2 Test machine alignment verification meets the static testing requirements provided in

section 7 of AC7101/3.

YES NO

Verification is required for frame and grips after installation of the frame, and when alignment is suspect (e.g. movement of machine, multiple radius failures, etc.).

11.3.3 Ambient conditions – Testing is conducted between 50°F (10°C) and 100°F (38°C)

unless otherwise specified in the applicable standard.

YES NO

11.3.4 Tensile equipment has the capability to perform at the rates and in the control mode

required for the test standard.

YES NO

11.3.4.1 For testing to ASTM B557 (aluminum or magnesium alloys), strain rate control is not

required. Tensile equipment has the capability to run in a displacement control mode

and the lab has the capability to determine a displacement rate based on the rate of

stressing defined in ASTM B557.

YES NO

11.3.4.2 For all other tensile testing certifications, tensile equipment has capability to perform a

test in strain rate control at a controlled strain rate of 0.003 to 0.007 per minute

through yield, with a controlled crosshead speed of 0.04 to 0.06 per minute times the

nominal length of the reduced section until rupture.

YES NO

11.3.5 If elevated temperature tensile tests are performed, furnaces are:

Circulating hot air

Resistance

Other type approved during customer certification

Number of zones in each furnace:

_________________________________________

11.3.5.1 For elevated temperature testing, induction heating prohibited/not used for Tensile

Testing unless permitted by customer. YES NO

11.3.5.2 For elevated temperature testing, sufficient thermocouples are used to assure that the

uniformity of the temperature gradient along the reduced section of the test piece

conforms to the following:

For ≤ 1000° C ± 3°C (1800°F ± 5°F); For >1000°C ± 6°C (1800°F ± 10°F).

YES NO

11.3.5.3 Furnace design and practice prevents specimen over-temperature outside the

measured section.

YES NO

Specimen shall be in the approximate center of the furnace and operated in such a manner so as to prevent the areas outside the gauge section to be hotter than the gauge section.

11.3.6 Extensometers – Appropriate extensometer is used. YES NO Extensometer is rated to at least Class B2 of ASTM E83 or at least Class 1 of EN ISO 9513 for standard tensile testing. For the determination of Young’s Modulus of Elasticity, when required, Class B1 of ASTM E83 or Class 0.5 of EN ISO 9513 shall be used.

Non-contact extensometers are subject to the same requirements as contact extensometers. The strain measurement method shall use measurement points as close as practical to the gauge length used for elongation measurement. If non contact extensometers are used, Laboratory records shall show comparison and stability studies to compare with contact extensometers.

11.4 Tensile Testing Procedures

AUDITOR NOTE: Verify test procedure is in accordance with applicable standards and that procedures are followed (witness test).

11.4.1Appropriate test procedures are being used. YES NO Tensile testing shall be performed in accordance with one of the test standards listed in AC 7101/1, unless otherwise specified.

11.4.1.1Room Temperature Tensile YES NO AUDITOR

NOTE:

List standard used: _________________________________________________

11.4.1.2Elevated Temperature Tensile YES NO AUDITOR

NOTE:

List standard used: _________________________________________________

Other procedures are acceptable if required by customer.

Other written procedure(s): Describe below:

____________________________________________________________________

11.4.2 Adapters and pull bars are visually inspected before and after each test program. YES NO

The inspection may be performed by the test technician to verify that the adapters and bars are in good working condition and are suitable for performing the test. There is no need to record the inspection.

11.4.3 Specimens are inspected in accordance with AC7101/3 section 8. YES NO 11.4.3.1 Specimens are visually inspected for surface damage immediately prior to testing. YES NO 11.4.4 Laboratory procedures guide extensometer selection. YES NO The laboratory shall have a procedure that describes the method of choosing an appropriate extensometer type, size and attachment method.

11.4.4.1 The Extensometer is attached directly to the reduced section of the Specimen unless otherwise approved by customer requirements.

YES NO

Contact extensometers shall be attached to the gauge section used for elongation measurement unless otherwise approved by customer requirements and shall be as close as practical to the gauge length used for elongation measurement. Extensometers may be attached to the grip section of the specimen, to grips or adapters when not prohibited by customer requirements; however, this is not recommended. This also requires the use of an “effective gauge length” as described in ASTM E21.

AUDITOR

NOTE: Indicate if extensometer is attached to points outside the gauge section.

Shoulder attachment is used.

Contact extensometers may be removed at any point after yield to prevent damage to the extensometer.

11.4.5 For elevated temperature testing, the specimen is soaked at temperature for 30 minutes minimum.

YES NO

11.4.6 Correct testing speed is used. YES NO 11.4.6.1 For tensile testing to ASTM B557 (or AMS 2355) the test speed up to the specified yield strength is corresponds to a stress rate of less than 100,000 psi/min. Test speed after yield does not exceed 0.5 in/in gauge length per minute.

YES NO

11.4.6.2 For all testing not covered by ASTM B557 (or AMS 2355) - unless otherwise specified, testing speeds for both Room Temperature and Elevated Temperature Tensile tests are a controlled strain rate of 0.003 to 0.007 per minute through yield, with a controlled crosshead speed of 0.04 to 0.06 per minute times the nominal length of the reduced section until rupture.

YES NO

There are several other test speed and control mode callouts in related test standards. These are acceptable only if the material specification/standard or the customer requirements specifically call them out.

11.4.7 Tensile Testing Curves are reviewed as part of the testing process. YES NO All tensile curves shall be reviewed. The laboratory shall provide training to operators on identification of invalid tensile curves.

11.4.8 Laboratory procedures define the method of calculation of each result and measurement accuracy.

YES NO

11.4.9 Tensile Strength (alternately known as Ultimate Tensile Strength) is calculated using the formula: (Maximum Load) (Original Cross-Sectional Area).

YES NO

11.4.10 Yield Strength is measured at 0.2% Offset, unless otherwise specified. YES NO

Indicate if other than 0.2% offset method used.

AUDITOR

NOTE:

When offset Yield Strength determination is performed, the laboratory shall have a procedure for determining this manually or electronically. The procedure shall take into account initial and subsequent nonlinearity and other imperfections in the stress strain (load displacement) curve. Curves from which Yield Strength has been automatically determined via software shall be reviewed and changes to incorrectly calculated Yield Strength made.

YES NO 11.4.11 Both Percent Elongation and the relationship of the gauge length to test piece cross

section dimensions (Proportionality) are measured and reported in accordance with

the material specification/standard or customer requirement.

*Autographic measurement (elongation at fracture as defined in ASTM E8) is acceptable if it includes only the plastic portion of the strain (i.e. elastic strain is subtracted out of total strain). Extensometer must meet the gauge marking restrictions (i.e. 4X dia. for ASTM, 5X dia. for ISO testing) shown in 12.2.11.1 of AC7101/3.

For cases of low ductility or when the data acquisition does not have enough resolution to correctly determine plastic strain at fracture, then the traditional method of fitting the ends together and measuring the final gauge length shall be used.

11.4.11.1 Acceptable Elongation marking method used (punch, scribe or ink mark). YES NO

In order to accurately measure elongation to a multiple of the gauge length, a method of marking the gauge length shall be used. Acceptable methods are punches, scribe marks, or ink marks, provided the marking is readable after completion of the test. Fractures that occur on the gauge marks shall be indicated as such on the report. Specimens that fail on or outside the gauge marks and fail to meet the property requirements may be invalidated (elongation only).

When customer requirements prohibit the use of gauge marks or materials are sensitive to gauge marks, the adjusted gauge method described in ASTM E21 may be used. Records shall include the actual gauge length that was used.

Elongation calculated using the adjusted gauge length method will typically be lower than when calculated using the 4D or 5D method, as the gauge length will be longer than 4D or 5D.

11.4.12 Reduction of Area is determined in accordance with the test standard. YES NO

11.4.13 Test data is reported per AC7101/3 section 11. YES NO

YES NO 11.4.14 Rounding of test results per appropriate test standard required in procedure and

demonstrated in job audit.

Rounding for data from Room Temperature Tensile per ASTM E8, EN2002-1, EN10002, ISO 6892 or BS4A4. Rounding for data from Elevated Temperature Tensile per ASTM E21, ISO 2002-2 or ISO 783. Rounding of data not established in the test standards per ASTM E29.

11.5 Specific Reporting Requirements meet the following requirement. YES NO

11.5.1 As a minimum the report includes the following:

(unless any of these are by specification/standard not required for the specific test)

NO Temperature YES

11.5.1.2 Test

Strength YES NO 11.5.1.3 Yield

NO strength YES

11.5.1.4 Ultimate

11.5.1.5 Elongation YES NO 11.5.1.6 Reduction of area YES NO Specific reporting requirements are often supplied by the customer and take precedent over the list above when applicable.

12.0 STRESS RUPTURE AND CREEP TESTING (Codes C and XA) N/A

C = Stress Rupture (S/R). Questions apply to S/R. Creep (C/R). XA = Creep Only.

12.1 Check which tests are being accredited:

Room Temperature S/R only

___________________

Elevated Temperature S/R to maximum temperature of ________________________

Creep to maximum temperature of

________________________________

12.2 Round robin completed per AC7101/1. YES NO

12.2.1 Facilities and Equipment (Specific to Stress and Creep Rupture Testing)

12.2.1.1 Test machine calibrations meet the requirements in table 1 at frequencies indicated. YES NO

YES NO 12.2.1.2 Test machine alignment verification meets the static testing requirements provided in

section 7 of AC7101/3.

Verification is required for frame and grips after installation of the frame, and when alignment is suspect (e.g. movement of machine, multiple radius failures, etc.).

YES NO 12.2.1.3 For creep testing only, shifts in ambient temperature are accounted for in strain

measurement.

Laboratory may address this through one of the following methods:

?Extensometer stability data showing no effect on strain measurement with normal shift in ambient temperature.

?ASTM E139 requirements – Extensometer readings should be taken only when ambient temperature is within ± 5 degrees F of the ambient temperature at the start of the test.

? A temperature correction applied when the ambient temperature exceeds ± 5 degrees F of the ambient temperature at the start of the test as described in ASTM E139.

?Record ambient temperature concurrently with creep data. Assess whether ambient temperature exceeds ASTM E139-06 requirements and determine whether the creep curve is affected at times

required by specification/standard.

12.2.1.4 Furnaces

are: YES NO Circulating hot air

Resistance

Other type approved during customer certification

Number of zones in each furnace:

_________________________________________

12.2.1.4.1 Induction heating prohibited/not used for Stress Rupture or Creep Testing unless

permitted by customer.

YES NO

AUDITOR

NOTE:

Indicate if induction heating is used.

12.2.1.4.2 Furnace design and practice prevents specimen over-temperature outside the

measured section.

YES NO

Specimen shall be in the approximate center of the furnace and operated in such a manner so as to prevent the areas outside the gauge section to be hotter than the gauge section.

12.2.1.5 Specimen temperature measurement

12.2.1.5.1 Laboratory procedures define the number, location, and attachment method of

thermocouples that are attached to the specimen.

YES NO 12.2.1.5.2 The number of thermocouples meets the customer requirements. YES NO

Laboratories should be able to provide evidence of the source of customer requirements. If no customer requirements exist, the laboratory shall define the minimum number of thermocouples. ASTM E139 requires three (3) thermocouples for specimens with ≥ 50 mm reduced section and two (2) thermocouples for specimens with < 50 mm reduced section length. It is recognized that it may be difficult to attach two (2) thermocouples to extremely small specimens, so engineering judgment may be required.

12.2.1.5.3 The minimum and maximum Indicated specimen temperature tolerances during soak

and testing meet customer requirements.

YES NO

Most customer requirements revert to ATSM E139 temperature tolerances. ASTM E139 tolerances are: For a nominal temperature ≤1000°C (1800°F) the tolerance shall be ± 2°C (± 3°F); for a nominal temperature > 1000°C (1800°F) the tolerance shall be ± 3°C (± 5°F). The material specification/standard or other customer requirements may differ.

12.2.1.5.4 The laboratory has a procedure that provides requirements for review and disposition

of tests with occurrences of indicated temperature that are outside of the customer-

required tolerances.

YES NO

It is recognized that temperature deviations may occur during rupture testing. At minimum, the laboratory should have a procedure that provides guidance or instructions for common occurrences and/or requires review and disposition by a Metallurgist or equivalent. Additional guidance is provided in ASTM E139.

12.2.1.5.5 Extensometers – Appropriate extensometer system is used. YES NO

Many creep extensometers are different from other mechanical test extensometers in that they use a frame that attaches to the specimen (usually outside the gauge section). This frame is often referred to as the Creep Arm Assembly with the attachment to the specimen at the Creep Arms. These require a functional inspection before every test (e.g. assembly slides smoothly) but not a calibration. The strain sensor attaches to the creep arm assembly and is the element of the system that requires calibration to AC7101/3 Tables 1 and 2. Other extensometers are acceptable as long as they meet AC7101/3 Table 1 and 2 requirements.

12.3 Stress Rupture and Creep Testing Procedures

AUDITOR

NOTE:

Verify test procedure is in accordance with applicable standards and that procedures are followed (witness test). 12.3.1 Appropriate test procedures are being used. YES NO

Stress Rupture and Creep testing shall be performed in accordance with one of the test standards listed in AC7101/1, unless otherwise specified.

AUDITOR

NOTE:

Stress Rupture Testing – List standard used:______________________________

AUDITOR

NOTE:

Notched Stress Rupture Testing – List standard used:_______________________

AUDITOR

NOTE: Creep Testing – List standard used:_____________________________________

Other procedures are acceptable if required by customer. Other written procedure(s). Describe:_______________________________________

12.3.2 Creep arms, adapters and pull bars are visually inspected before and after each test program.

YES NO

The inspection may be performed by the test technician to verify that the adapters and bars are in good working condition and are suitable for performing the test. There is no need to record the inspection.

12.3.3 Specimens are inspected in accordance with AC7101/3 section 8. YES NO 12.3.3.1 For the case of Notch Stress Rupture testing, root radius is measured to the nearest 0.0005 in (0.01 mm) prior to testing. (ASTM E292 Notch).

YES NO

12.3.3.2 For the case of Notch Stress Rupture, notch profile is verified using a 10X minimum magnification (e.g. optical comparator).

YES NO

12.3.3.3 Specimens are visually inspected for surface damage immediately prior to testing. Note magnification if used. ______________________________________________

YES NO

12.3.4 Laboratory procedures guide extensometer selection. YES NO

The laboratory shall have a procedure that describes the method of choosing an appropriate extensometer type, size and attachment method.

12.3.4.1 Laboratory performs pre-test functionality check of strain measurement components (extensometer, mechanisms for clamping to specimen and strain measurement YES NO

12.3.4.2 Method of Extensometer attachment is documented (Code XA). YES NO

Most creep extensometers are not attached directly to the gauge section of the specimen and require the use of an “Effective Gauge Length” measurement as defined in ASTM E139. Attachment directly to the specimen gauge section is acceptable.

12.3.4.3 Correction factor used for shoulder attachment. YES NO

12.3.5 Specimen soaked at temperature not less than 1 hour. (ASTM E139) YES NO

Soak time shall be recorded on test report if other than 1 hour.

YES NO 12.3.5.1 Maximum time that the specimen is held at temperature before test load applied is 24

Hr.

The intent of the Nadcap MTLTG is that tests are started immediately upon completion of the soak. While it is recognized that this is not always possible, the load application should not be delayed.

12.3.6 Care is taken in applying the test load, in order to prevent shock loads or overloading. YES NO

Describe loading technique. (ASTM E139) __________________________________

12.3.7 Creep Testing Curves are reviewed as part of the testing process. YES NO

All creep curves shall be reviewed. The laboratory shall provide training to operators on identification of invalid creep curves.

YES NO 12.3.8 Laboratory procedures define the method of calculation of each result and

measurement accuracy.

12.3.9 Both Percent Elongation and the relationship of the gauge length to test piece cross

YES NO section dimensions (Proportionality) are measured and reported in accordance with

the material specification/standard or customer requirement.

Unless otherwise specified, elongation shall be measured after fracture.

12.3.9.1 Acceptable Elongation marking method used (punch, scribe or ink mark). YES NO

In order to accurately measure elongation to a multiple of the gauge length, a method of marking the gauge length shall be used. Acceptable methods are punches, scribe marks, or ink marks, provided the marking is readable after completion of the test. Fractures that occur on the gauge marks shall be indicated as such on the report. Specimens that fail on or outside the gauge marks and fail to meet the property requirements may be invalidated.

When customer requirements prohibit the use of gauge marks or materials are sensitive to gauge marks, the adjusted gauge method described in ASTM E139 may be used. Records shall include the actual gauge length that was used.

Elongation calculated using the adjusted gauge length method will typically be lower than when calculated using the 4D or 5D method, as the gauge length will be longer than 4D or 5D.

12.3.10 Reduction of Area is determined in accordance with the test standard. YES NO AUDITOR ROA is not always required by material specifications/standard. If this is the case of

12.4 Specific Reporting Requirements meet the following requirement. YES NO

12.4.1 As a minimum the report includes the following:

(unless any of these are by specification/standard not required for the specific test)

12.4.1.1 Specimen

ID YES NO 12.4.1.2 Test

Temperature YES

NO 12.4.1.3 Test

Duration YES NO

12.4.1.4 Times to strain levels indicated in customer PO YES NO

12.4.1.5 Elongation YES NO 12.4.1.6 Reduction of area YES NO Specific reporting requirements are often supplied by the customer and take precedent over the list above when applicable.

13.0 BEND

TESTING(Code XN) N/A

There are no calibration, alignment or round robin requirements for Bend Testing.

13.1 Facilities and Equipment (Specific to Bend Testing)

13.1.1 Ambient conditions for ISO 7438 testing only. Testing is conducted between 50°F

(10°C) and 95°F (35°C) unless otherwise specified in the applicable standard.

YES NO

13.1.2 Controlled conditions for ISO 7438 testing only. Testing is conducted between 64°F

(18°C) and 82°F (28°C).

YES NO There are no specified ambient conditions for testing to ASTM E290.

13.2 Bend Testing Procedures

AUDITOR NOTE:Verify test procedure is in accordance with applicable standards and that procedures are followed (witness test).

13.2.1 Appropriate test procedures are being used. YES NO

Bend Testing shall be performed in accordance with one of the test standards listed in AC7101/1, unless otherwise specified.

AUDITOR

NOTE:

List standard used: __________________________________________________

Other procedures are acceptable if required by customer.

Other written procedure(s). Describe: ______________________________________

13.2.2 Bend Test methods used are in accordance with customer requirements. YES NO