AC7102-2 B AL heat treating for nadcap

PRI operating procedures provide that "This report is published by PRI to advance the state of technical, engineering, and quality sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user."PRI invites your written comments and suggestions.Copyright 2009 Performance Review Institute. All rights reserved. t-frm-15 21-May-08161Thorn Hill RoadWarrendale, PA 15086-7527AUDIT CRITERIAAC7102/2 REV . BIssued 2006-10Revised 2009-8Superseding AC7102/2 Rev. ABaselineNadcap AUDIT CRITERIA For ALUMINUM HEAT TREATINGTO BE USED FOR AUDITS CONDUCTED ON OR AFTER JANUARY 31, 20101. Facilities 1.1 Are the heat treating equipment and instruments for the heat treatment ofaluminum alloys in accordance with all the customers’ requirements?YES NO 1.2 Do the heat treating facilities possess the correct temperature uniformity,instrument accuracy and resolution for the heat treating of aluminum alloys in accordance with all the customers’ requirements?YES NO 2. Control of Heating Environment above 400F (200C) NA2.1 Are the furnaces used above 400F (200C) designed and operated such that theproducts of combustion that could contaminate the load do not enter the heat treating furnaces for finished parts?YES NO2.2 When required, is there a procedure that includes the use of protective compounds(ammonium or sodium fluoborate, or other equivalent moisture reducingcompound), or the replacement of protective compounds with the monthly check for high temperature oxidation?YES NO NA2.2.1 Are there records indicating that the procedure is followed? YES NO NA3. Salt Baths NA3.1 Does certification exist to document compliance to material specification for gradeof salt required by applicable heat treating specification?YES NO3.2 Do the records indicate that each salt bath is tested periodically for pH inaccordance with the applicable heat treating specification? YES NO4. Racks, Fixtures and Baskets NAYES NO4.1 Do the procedures and records indicate that specially designed racks and fixturesare used for the specific parts they are designed for?YES NO4.2 Do the procedures specify that racks, fixtures and/or baskets shall be free fromentrapped quenchant?4.3 Are there procedures, racking sketches or other means to ensure that parts areYES NOspaced adequately to ensure adequate circulation of the heating medium andquenchant?NO 4.4 Is there evidence that the procedures are being followed? YESYES NO4.5 Do the racks, fixtures and baskets appear to be in good condition and suitable fortheir intended use?System NA5. Quench5.1 Are the quench mechanisms and other mechanical equipment (hoists, trucks,YES NOrollers, etc.) operational and capable of meeting the maximum quench delayprovisions of the specifications?5.2 Do the procedures and records indicate that quench delay requirements are metYES NOfor each individual load?6. Spray Quench/Forced Air Quench NA6.1 Is the spray or forced air quenching only used on those alloys and product formsYES NOwhen allowed by the governing specification?YES NO6.2 Are there records to document the qualification of spray and/or forced airquenching equipment?YES NO6.3 Are the periodic electrical conductivity tests performed to verify the effectiveness ofthe spray and/or forced air quench as required by the governing specification?YES NO6.4 Is there a maintenance plan in place to assure that nozzles and jets are notblocked and are oriented at the same position as qualified?YES NO6.5 Is the tensile testing performed at the correct frequency (i.e. qualification, lot,periodic, etc.) as required by the governing specification?7. QuenchantControl NAYES NO7.1 Do the procedures specify how quenchant temperature is to be controlled anddocumented?YES NO7.2 Do the records on or traceable to the traveler demonstrate that quenchants havebeen at the specified temperature before and after the parts were quenched?7.3 Do the procedures and observations indicate that quenchant agitation and/orYES NOagitation of the parts during quenching conform to applicable specifications?8. Water/Polymer Quenchant Solutions NA8.1 Is there a vendor’s qualification report on file, including certificates for each lot,YES NOwhich demonstrates that the polymer quenchant solutions being used foraluminum alloys conforms to the requirements of AMS 3025 and/or applicablecustomers’ specifications?8.2 Is there a system in place that ensures that the quenching in water/polymerYES NOsolution is only used when permitted by the particular customer and specificationfor the specific alloy and metal thickness?8.3 Is there a procedure that specifies that all the water/polymer quenchant solutionsYES NOare checked for concentration by a method and at frequencies required by thecustomer?8.4 Are there records to document that all the water/polymer quenchant solutions haveYES NObeen checked for concentration by a method and at frequencies required by thecustomer?YES NO8.5 If the concentration is checked by the refractive index, is the refractometerperiodically calibrated using standard solutions?9. Water/Polymer Quenchant used in conjunction with the Salt Baths NA9.1 Is there a method to ensure that the water/polymer quenchant solutions, used inYES NOconjunction with the salt baths are checked weekly for salt contamination usingcalibrated known solutions?9.1.1 Do the records show that the contamination does not exceed 6%? YES NO10. Refrigeration NA10.1 Do procedures address cooling requirements after quench? YES NO10.1.1 Are there records to show that the cooling after quench is in compliance withYES NOcustomer requirements specified in procedures or shop planning?YES NO10.2 Do procedures specify the requirements for time/temperature limits for retention ofthe “As Quenched” condition?10.3 Do procedures address the recording of the temperature in each refrigeration orYES NOcold storage unit?NO 10.4 Do the records indicate that the procedures are followed? YES11. HandlingFasteners NAYES NO 11.1 Do procedures address the customers’ requirements for special handling of thefasteners after quenching?12. Aluminum Solution Heat Treating Furnaces with the Heat Source in Walls NA 12.1 Are radiant tubes and/or electric heating elements shielded or positioned toYES NO prevent the radiation heating of parts?12.2 Are the radiation tests made in accordance with AMS 2750 prior to initialYES NO production use and after any repair or adjustments that might alter radiationcharacteristics?Testing NA 13. Conductivity13.1 Conductivity Inspector / Operator Training13.1.1 Are the personnel that perform conductivity testing trained andYES NO qualified/certified per the internal procedure that meets the applicablecustomers’ specifications?YES NO 13.1.1.1 Do procedures require personnel performing tests to demonstrate operationand standardization as part of qualification?13.1.2 Do records indicate that personnel performing conductivity are trained toYES NO supplier procedures?13.2. Calibration of Conductivity Test Equipment NANote: As it applies to this section, calibration is defined as the periodicinstrument calibration to national standards.YES NO 13.2.1 Do records indicate the conductivity measurement instrument meetcustomer requirements for accuracy, readability, and repeatability?13.2.1.1 Do procedures define the required instrument accuracy, readability,YES NO repeatability per customer requirements?13.2.2 Do records indicate the instrument calibration oscillator frequency meetYES NO customer requirements?13.2.2.1 Do procedures define the instrument oscillator frequency settings forYES NO calibration per customer requirements?13.2.3 Do records indicate calibrations are performed at the required testYES NO intervals per customer requirements?YES NO13.2.3.1 Do procedures define the required calibration intervals (period betweencalibrations) per customer requirements?13.2.4 Do procedures address calibration standards and their accuracy? YES NO13.2.4.1 Do records indicate calibration standard conformance? YES NO13.2.4.2 Are the working and/or laboratory standard calibration blocks properlyYES NO maintained, protected from damage and available in appropriate IACS (MS/m –MegaSiemens/meter) ranges for the material inspected or instruments to becalibrated?YES NO NA 13.2.4.3 If used at the supplier, do the laboratory standard calibration blocks have valuesassigned in accordance with ASTM B-193, or the values for the laboratorystandard calibration blocks assigned by an independent agency usingstandards traceable to a national standard?13.3 Standardization of Conductivity Test EquipmentNote: As it applies to this section, Standardization is defined as the in-useworking verification performed by operators.YES NO13.3.1 Do supplier procedures and/or work instructions require operatorstandardization upon start of testing and define a re-standardization intervalthereafter?YES NO13.3.1.1 Does the defined standardization test interval comply with customerrequirements?13.3.2 Are working standards properly maintained and protected from damage? YES NOYES NO13.3.2.1 Are working standards available in the appropriate IACS (MS/m) ranges for thematerial inspected and the instruments to be calibrated?YES NO13.3.2.2 Do procedures define the appropriate IACS (MS/m) ranges in accordance withcustomer requirements?13.4 Performance of Conductivity Testing13.4.1 Is there controlled documentation (procedure, job traveler, drawing, etc.) tospecify the following?a. The selection and number of test locations?YES NOb. Effect and control of thin gauge and / or clad aluminum?YES NOYES NOc. Effect and control of curvature, edge effect, minimum surfacearea, and other part geometry concerns?d. Operating frequency and probe size?YES NOe. Test instrument, standard, and part temperature stabilization?YES NOf. Sample Size YES NO13.4.2 Are acceptance criteria accurately flowed down to the inspector/operator? YES NO13.4.3 Does documented objective evidence show conductivity meetsYES NO acceptance criteria?YES NO 13.4.4 Are the tested values recorded individually or as a range for the lot (not as anaverage)?13.4.5 Auditor shall verify the following: YES NOa. Operators are performing standardizations at instrument start-upYES NO and frequency defined.b. Tests are taken at sufficient locations, including extremes of metalYES NO thickness.c. Apparent conductivity tables are properly utilized for clad and thinYES NO gauge alloys.d. Controls on curvature, edge effect, and/or minimum surface area areYES NO observed during testing.e. Test instrument, standards and parts are stabilized to the sameYES NO temperature before testing.f. The oscillator frequency of the conductivity instrument isYES NO appropriate for the apparent conductivity tables being utilized; aswell as the material form & thickness being tested.g. Number of parts tested conforms to requirements (e.g. sample size)?YES NO14. Testing NA 14.1 Do the procedures identify the periodic testing required by customer to verify theYES NO aluminum heat treating (e.g. monthly quench effectiveness testing - tensiletesting, eutectic melting, intergranular corrosion, clad diffusion, etc.)?YES NO 14.2 Is there objective evidence that the supplier’s periodic testing is performed perthe procedures and the customers’ requirements?YES NO14.3 Are the specifications required sample sizes (or 100%) and acceptance rangesfor hardness testing or conductivity testing of each order of parts listed on theplanning or on the controlled media traceable to the individual part number?15. Compliance Audits of Completed Heat Treating Jobs15.1 The Auditor shall complete the long form job audits based on the supplier’s heattreating capabilities. In some cases, no aluminum long job audits may berequired. For a supplier that performs only aluminum heat treating, two (2) longform job audits are required.16. Abbreviated Job Audits Checklist16.1 The Auditor shall complete short form job audits based on the supplier’s heattreating capabilities. Usually, a minimum of two (2) job audits will be required foranyone seeking aluminum heat treating accreditation. For a supplier that performsonly aluminum heat treating, a minimum of eight (8) job audits are required,preferably for in-process parts. When sufficient in-process jobs cannot bewitnessed, completed jobs may be substituted.。