AC7102 Rev H Heat Treat

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AUDIT CRITERIA

AC7102 REV. H

Issued 1993-06 Revised: 2014-9 Superseding AC7102 Rev. G.

Baseline

Nadcap AUDIT CRITERIA for HEAT TREATING TO BE USED ON AUDITS CONDUCTED ON OR AFTER 11-May-2014

Editorial Revision: 14-May-2014 para 1.1.2, 3.2.1, 2.1, 2.2., 2.3, 2.4, 5.2, 5.2.1, 13.3.3 Editorial Revision: 11-Sept-2014 para 1.1.1, added AC7102/10

Editorial Revision: 23-Sept-2014 para 2.3, 7.3.1, 7.3.2, 7.3.3, 7.3.4, EC Data

1.0 INSTRUCTIONS TO SUPPLIER TO BE AUDITED 1.1 Prior to the Audit 1.1.1 The Supplier shall complete a self-audit to (as applicable):

AC7102 AC7102/1 (If seeking Brazing approval) AC7102/2 (If seeking Aluminum approval) AC7102/3 (If seeking Carburizing approval) AC7102/4 (If seeking Nitriding approval) AC7102/5 (If Hardness testing is used in support of in-house heat

treating) AC7102/6 (If seeking HIP approval) AC7102/7 (If seeking Induction Hardening approval) AC7102/8 (If seeking Heat Treating approval) AC7102/10 (If seeking Localized Heat Treating approval) AC7101/3 (If Tensile testing is used in support of in-house heat

treating) AC7101/4 (If Metallography and Microindentation testing are used

in support of in-house heat treating) AC7102/S (If seeking Primes specific approval)

All non-conformances shall be corrected by the corrective action system, prior to the actual audit. Nonconformance of a technical nature found during the actual audit will, at the Task Groups discretion, require a follow-up audit at the suppliers expense. This self-audit shall be maintained by the Supplier for review by the auditor.

During the self-audit the Supplier shall record each procedure and paragraph number for each checklist question requiring an answer on procedures.

YES NO

PRI AC7102 Revision H - 2 -

Ready availability of all documentation required by the Nadcap auditor will speed up the audit process significantly.

1.1.2 The Supplier shall send the following to the auditor 30 days prior to the scheduled

audit (in English, unless otherwise agreed between auditor and supplier):

List of equipment (atmosphere generation, testing equipment, lab equipment, inspection equipment, plating, coating, cleaning, Pyrometry, and Pyrometry testing, etc.) (U14)

List of purchased services, including name(s) of supplier for calibration, processing, testing, etc., schedule of calibrations, uniformity surveys, system accuracy tests, hardness machines servicing, etc., schedule of periodic tests (tensile, decarburization, etc.)

List of Prime customers and specifications for which heat treater is approved

List of heat treat specifications [military, government, industry (AMS, etc.) and customer] that supplier is working to

Copy of internal general procedures for heat treat processing, Pyrometry and testing/inspection of heat treated product (exemption for ITAR and Export Control documents applies).

Organization chart

YES NO

1.2 During the Audit 1.2.1 The Supplier should provide for an in-briefing for the auditor. Key members of the

Suppliers staff should attend the in-briefing so the audit purpose, methods and assessment process can be discussed.

1.2.2 Working space for the auditor with desks or tables, chairs, telephone, clerical,

typing and reproduction services should be provided as required.

1.2.3 Auditor shall verify the scope of accreditation and modify it in eAuditNet as

required in agreement with the Supplier.

1.2.4 A final debriefing shall be conducted at the completion of the audit. Each

nonconformance report (NCR) shall be reviewed and the Supplier will be given the opportunity to seek clarifications.

NOTE: The Heat Treating Task Group may, upon review, change the auditors

determination of a finding.

1.2.5 The Supplier has 21 calendar days to submit corrective actions and effective

dates for each NCR. The supplier shall respond to each individual NCR using the appropriate form/media (see Public Documents on eAuditNet). Supporting documentation shall be traceable to each individual NCR. The response must address the root cause of the nonconformance from a systems management approach and the actions taken or to be taken to preclude reoccurrence

1.3 Definitions and Interpretations 1.3.1 For definitions and interpretations see Heat Treating Task Group Audit Handbook. 1.3.2 (Info) When noted (as shown) below, the YES/NO column indicates a question

that is asked for information only, with no corresponding requirements. The NO


answers to these questions do not require a nonconformance report or an explanation.

1.4 Additional information for Suppliers 1.4.1 In addition to the commodity checklist noted herein, there may be other pertinent

data such as audit handbooks, attachments and preparatory instructions necessary for the completion of the audit. These can be found and downloaded from eAuditNet under Public Documents.

1.4.2 Questions marked with (U) codes are applicable to all Suppliers. (Uxx)

codes indicate that there are additional related questions in AC7102/S. Those questions concern only the corresponding prime and shall be answered only if the prime is identified as a customer.

2.0 SUPPLIER INFORMATION DIVISION: NATURE OF BUSINESS (U14): IN-HOUSE PRODUCTS ONLY: ACCEPTS OUTSIDE WORK: TOTAL EMPLOYEES: HEAT TREATING PERSONNEL: SQUARE FEET OF HT AREA(S): NO. OF SHIFTS WORKED: ADDITIONAL CONTACTS POSITION EMAIL COMMENTS: 2.1 Cover letter/notes attached.

2.2 Quality System Approval/certificate verified

(AC7004/AS/EN/JISQ 9100)

2.3 Staff Report attached.

Ensure that the scope has been reviewed and signed off in eAudinet with the


Supplier. 2.4 Yes/No Plant Location Changed Yes/No QC Manager Changed Yes/No Equipment Moved Yes/No Common Findings to Previous Audit 3.0 GENERAL QUALITY SYSTEM NA 3.1 Document Control 3.1.1 Are the applicable revisions of the appropriate documents available at the

appropriate workstation? (To make an Audit Handbook clarification/descriptive) YES NO

3.2 Contract Review 3.2.1 Are contracts and incoming purchase orders reviewed to ensure that: YES NO a. The quality and technical requirements, including any unique customer

requirements, are adequately defined and documented?

b. Adequate capability, customer approvals and resources by the processor to

meet the requirements?

c. Any deviations from the proposal/contract are resolved in writing by

authorized personnel/prime/supplier?

d. Adequate definition of the work statement to identify the specific

process(es) to be performed including specification number(s), applicable Type(s), Class(es), Grade(s), etc.?

e. Identification of the prime aerospace customer that has design authority? f. Identification of the aircraft model or hardware that the part numbers

represent where applicable. (e.g. Boeing 777, Airbus A320, etc.)?

g. Does the supplier flow contractual requirements down internally and to sub-

tier suppliers?

3.3 Control of Nonconforming Product 3.3.1 Is the nonconforming material controlled, and the customer notified of each

instance of nonconforming product in accordance with the contractual requirements?

YES NO

3.3.2 When reheat treatment is performed: is it allowed by specification, properly

documented, retested, and in compliance with customer requirements? YES NO

3.4 Corrective Action 3.4.1 Are all corrective actions from the previous Nadcap audit still implemented (check

the last full audit)? YES NO NA

3.5 Internal Audits 3.5.1 Are planned and documented internal quality audits performed on a scheduled YES NO


basis by knowledgeable personnel not directly responsible for the work? 3.5.2 Are all Nadcap elements within the scope of the Suppliers accreditation properly

addressed in the internal audit? YES NO

3.6 Quality Planning These requirements must be checked through all job

audits performed.

3.6.1 Is only the heat treating equipment which meets the requirements of the applicable

specifications for instrumentation and temperature uniformity used for processing? YES NO

3.6.2 Are specified times based on the appropriate thickness of the part or other criteria

in accordance with the applicable specification? YES NO

3.6.3 Are tensile specimens and other test specimens included with production loads

when required? YES NO NA

3.6.4 Are there procedures that address the use and placement of load thermocouples

when required by specification or customer requirements? YES NO NA

3.7 Frozen Planning NA 3.7.1 When customer approved fixed processes are required, is the Supplier working to

the latest revision approved by the Customer and is the evidence of this approval on file?

YES NO

3.8 First Lot Inspection NA 3.8.1 Is engineering first lot inspection and approval documented when required by the

customer? YES NO

3.8.2 Are records maintained for the development of fixturing and racking sketches, for

first article inspection when required by specification or customer requirements? YES NO

3.9 Purchasing 3.9.1 Are all facilities used for subcontracted testing and processing approved by either

the Customer or Prime, as required? YES NO NA

3.9.2

Are consumable goods, such as process atmospheres, quenchants, salts, thermocouples, and materials for test samples, ordered and accepted according to an in-house document or to a specific standard?

YES

NO

3.10 Electronic program control and data acquisition NA 3.10.1 Is there a procedure in place to address software control? YES NO 3.10.2 Is there evidence that software used to control and record Heat Treatment

equipment (programmable controller, electronic charts, etc.), is compliant with approved procedure?

YES NO

3.10.3 Are all software revisions verified by first lot inspection to ensure compliance with

specification requirements? YES NO


4. PERSONNEL 4.1 Training 4.1.1 Are there training procedures that assure personnel performing contract review,

job planning, heat treating and associated quality and test functions are competent to perform assigned tasks?

YES NO

4.1.2 Do records indicate that training is scheduled and attended in accordance with

procedures and documented? YES NO

4.2 Evaluation of Personnel 4.2.1 Do procedures require periodic evaluation to ensure that approved personnel

maintain proficiency in their assigned heat treating and related tasks? YES NO

4.2.2 Do records indicate that the evaluations are performed at documented frequencies

and the results reviewed with employees in a program of continuous improvement of personnel??

YES NO

5. MATERIAL HANDLING AND TRACEABILITY 5.1 Incoming Material to Processing 5.1.1 Are identification, count and quality discrepancies resolved prior to processing of

parts? YES NO

5.1.2 Do procedures ensure that incoming customer documents remain traceable to

those specific jobs throughout processing? YES NO

5.2 General Cleaning NA 5.2.1 Does the internal procedure require that parts be clean prior to loading for

processing in the furnaces? (U18) YES NO

5.2.2 Do records and observations indicate that the procedure is followed? YES NO 5.3 Corrosion Resistant Steels Cleaning NA 5.3.1 Does the internal procedure require that all PH steel parts with any finish machined

surfaces are cleaned prior to heat treatment and handled with clean gloves after cleaning? (U11)

YES NO

5.3.2 Do records and observations indicate that the procedure is followed? YES NO 5.4 Titanium Cleaning and Handling NA 5.4.1 Does the internal procedure for cleaning Titanium surfaces preclude the using of

halogenated substances? YES NO

5.4.2 Does the internal procedure require that parts with any finished surfaces be

handled with clean gloves? YES NO

5.4.3 Are the procedures followed? YES NO 6. INSPECTION


6.1 Process Verification 6.1.1 Is each heat treatment cycle reviewed for job traceability, correct temperature, time

at temperature and all other related parameters? (U11) YES NO

6.1.2 Is this review performed by Quality Assurance, other designated personnel, or self-

inspected by the automated computer control and monitoring system? (See Heat Treating Audit Handbook) (U11, U7)

YES NO

6.1.3 Is the review documented in accordance with the customer requirements? (U11) 6.1.4 Are the acceptance status and any test data recorded on the shop paper only after

the operation for that job has been completed? YES NO

6.2 Sampling Plans NA 6.2.1 Does the supplier have a procedure that details all aspects of sampling inspection

that is in accordance with all customer heat treating specification sampling requirements?

YES NO

6.2.2 Do all supplier heat treating sampling plans contain: a. A method to determine the quantity of product to check in the lot? YES NO b. Specified frequency and method of sampling? YES NO c. When to change to tightened or reduced plans? YES NO 6.2.3 Are sampling plans approved by the customer, when required? YES NO NA 6.2.4 Is there documented training in the use of the sampling plan which includes sample

size and selection, reduced and tightened plans, and when to implement them? YES NO

6.2.5 Does a sampling of jobs where sample inspection is permitted indicate that customer

requirements have been flowed down correctly to the inspector or delegated operator and are met?

YES NO

7. PROCESS CONTROL TESTING 7.1 Does the Supplier have procedures or other documentation in place that addresses

all required Heat Treat process control testing? (See Heat Treating Audit Handbook) YES NO

7.2 Do the procedures or other documentation contain or reference the following

information:

a. All applicable specifications when testing is specified? (See section 3.2) YES NO NA b. All qualification, periodic, and lot/batch acceptance testing as required by

specifications? YES NO

c.

d.

A schedule for the completion of periodic tests? Documentation that tests were performed per the schedule?

YES

YES

NO

NO

7.3 Auditor is to select a minimum of 4 periodic tests (excluding Pyrometry, Hardness,

and Conductivity) consisting of internal or external tests (including requirements, NA


frequency, actual results, compliance, etc.) from the Suppliers Process Control System and evaluate them against the applicable specification requirements, including interval and test method. Two of these verifications may be selected as part of the Job Audits or they may all be selected separately.

7.3.1 Test 1: YES NO 7.3.2 Test 2: YES NO 7.3.3 Test 3: YES NO 7.3.4 Test 4: YES NO 7.4 Hardness and/or Conductivity Testing 7.4.1 For information only, does the supplier perform hardness and/or conductivity testing? YES

(info) NO

If the Supplier performs hardness testing and/or conductivity testing for acceptance of product, Nadcap AC7102/5 checklist shall be executed.

7.5 Metallography/Microhardness 7.5.1 For information only, does the supplier perform metallography and microhardness

testing? (U18) YES (info)

NO

If the Supplier performs metallography/microhardness testing for acceptance of

product or process control of the heat treatment process, Nadcap AC7101/4 checklist shall be executed, unless the supplier is accredited by Nadcap Material Testing Laboratory Task Group to AC7101/4 checklist.

7.6 Mechanical Testing 7.6.1 For information only, does the supplier perform mechanical testing? (U11) YES

(info) NO

If the Supplier performs mechanical testing for acceptance of product or process

control of the heat treatment process, Nadcap AC7101/3 checklist shall be executed, unless accredited by Nadcap Material Testing Laboratory Task Group to AC7101/3 checklist.

7.7 Preparation of Mechanical Test Specimens 7.7.1 For information only, does the supplier prepare the specimens for the mechanical

testing? YES (info)

NO

7.8 Surface Contamination Testing of Alloy Steels NA 7.8.1 Do the internal testing procedures conform to the specifications? YES NO 7.8.2 Do the internal testing procedures cover the following: a. Partial decarburization of steels? YES NO


b. Total decarburization of steels? YES NO c. Carburization of steels? d. IGO/IGA (Inter Granular Oxidation/Inter Granular Attack) test? YES NO 7.8.3 Are the test records current and complete? YES NO 7.8.4 Is there a system in place to ensure that decarburization tests are performed at the

proper frequency, whether it is periodic or with the load? (U11) YES NO

7.9 Titanium Testing NA 7.9.1 Is there a system in place to control the test coupons and their use when required? YES NO 7.9.2 Does the internal documentation support that the test coupons are used in

accordance with the procedures/specifications? YES NO

7.9.3 Is there a system in place and adequate procedures for the control of hydrogen pick

up that meets the method and frequency specified by the customers requirements? YES NO

8. REFRIGERATION AND SUB-ZERO TREATMENTS OF STEELS NA 8.1 Do procedures cover sub-ambient/sub-zero cooling according to the customer

requirements, or in absence of customer requirements, does the supplier have a default procedure?

YES NO

8.2 Do procedures and job planning specify time/temperature limits for sub-ambient/sub-

zero treatments? YES NO

8.3 Do records indicate that the procedures are followed? YES NO 9. FURNACE CONTROL AND MAINTENANCE 9.1 Furnace Document Control 9.1.1 Operating Instructions 9.1.1.1 Are the current operating manuals or instructions available to furnace operators,

maintenance personnel and other personnel requiring the information? YES NO

9.1.2 Heating and Cooling Parameters (U10) 9.1.2.1 Does the internal procedure specify the method for determining heat-up rate, start of

soaking time, end of soaking time and cooling rate? (U10) YES NO

9.1.2.2 Do records on the furnace chart or furnace log indicate compliance to the above

procedure and customer requirements? YES NO

9.2 Maintenance 9.2.1 Are all components of each furnace that can affect the functionality inspected and

maintained in accordance with a documented preventative maintenance schedule? (U3)

YES NO


9.2.2 Do records indicate that the inspection and maintenance have been performed in accordance with the schedule?

YES NO

9.3 Control of the Heating Environment NA 9.3.1 Does the internal procedure specify how atmospheres are to be controlled and

monitored to ensure conformance to the requirements? YES NO

9.3.2 Do records indicate that the procedure is followed? YES NO 9.4 Metering NA 9.4.1 Are the flow meters operational and appropriate for the gas and flow rates used? YES NO 9.4.2 Do the inspection and maintenance schedule include periodic checks of flow meters

to ensure that they are functioning? YES NO

9.4.3 Does the internal procedure address the safety shut-off valves and the emergency

gas purges? YES NO

9.5 Purging NA 9.5.1 When the atmosphere is changed, is the furnace purged in accordance with an

internal procedure that assures elimination of the effects of previous atmosphere? YES NO

9.5.2 Does the internal procedure for purging Ammonia bearing atmospheres used for

nitriding include an Ammonia cut-off and purge in accordance with specification requirements?

YES NO

9.5.3 Do records indicate that the procedure is followed? YES NO 9.6 Neutral Salt baths for Steel NA 9.6.1 Is each salt bath tested periodically in accordance with the applicable heat treatment

specifications? YES NO

9.6.2 Do the salt bath test results demonstrate conformance to carburization,

decarburization, nitriding, and intergranular attack requirements? YES NO

9.6.3 Is there an internal procedure for these tests? YES NO 9.6.4 Do records indicate that the procedure is followed? YES NO 9.7 Carbon Controls for Steels NA 9.7.1 Do the internal procedures specify a system of maintenance and calibration of carbon

control indicators? YES NO

9.7.2 Do records indicate that the maintenance and calibrations are performed as required

by the procedures and applicable specifications? YES NO

9.7.3 Is the accuracy of the carbon control system confirmed by the results of tests

required by the heat treatment specifications? YES NO

9.8 Snap Temper NA 9.8.1 Are there procedures that address snap tempering within the time limits required by

the customers specifications? (U11) YES NO


9.9 Quench System NA 9.9.1 Are the quench mechanisms operational and capable of meeting maximum quench

delay provisions of the specifications? YES NO

YES NO 9.10 Quenchant Maintenance NA 9.10.1 Does the internal procedure specify that quenchant temperatures are to be controlled

and documented? YES NO

9.10.2 Is all temperature recording and controlling equipment calibrated? YES NO 9.10.3 Do quenchant agitation and/or agitation of the product during quenching conform to

the applicable specifications? YES NO

9.11 Polymer Quenchants (Except Aluminum see AC7102/2) NA 9.11.1 Is there a system in place that ensures polymer quenching is only used when

permitted by the particular specification for the alloy and metal thickness? YES NO

9.11.2 Do procedures define the polymer concentration in accordance with the

requirements? YES NO

9.11.3 Do the records indicate compliance? YES NO 9.11.4 Do procedures specify the frequency and methods for determining the polymer

concentration in accordance with the requirements? YES NO

9.12 Quench Effectiveness NA 9.12.1 Do procedures specify the frequency and methods for the testing of oil quenchants

in accordance with all customer requirements? (See Section 7)

YES NO

9.12.2

Do the records indicate that quenchant effectiveness is consistent and meets the specifications requirements?

YES

NO

9.13 Press Quench NA 9.13.1 Are the expander pressure, the cylinder pressure, and the number and force of hold

down springs, and applicable tolerances documented on or traceable to the traveler for each job?

YES NO

9.14 Racks, Fixtures and Baskets NA 9.14.1 Do internal procedures require that, when a part requires a specially designed

fixturing or racking method, that the specific fixturing or racking is used? YES NO

9.14.2 Are there internal procedures, racking sketches, or other means to ensure that

spacing between the parts is adequate for circulation of the heating medium and coolant/quenchant as required by the specifications?

YES NO

9.14.3 Do records indicate that the procedures are followed? YES NO 9.14.4 Does the internal procedure require that the racks/fixtures/baskets are examined for

integrity, and repaired or scrapped as necessary? YES NO


9.14.5 Do records indicate that the procedure is followed? YES NO 9.15 Fasteners NA 9.15.1 Is there a system in place to ensure that the fasteners are only processed in qualified

containers to approved procedures and customer requirements, or, when qualified, in a continuous furnace?

YES NO

9.16 Plating NA

Note: For purposes of this section, plating is limited to the plating operations utilized for temporary masking or other operations for successful heat treatment or brazing. This is not intended to replace plating for finishing purposes as controlled by Chemical Processing Task Group. If the supplier has a current Nadcap Chemical Processing accreditation that includes both plating and stripping, questions 9.16.1 through 9.16.7.2 are YES unless otherwise noted as part of the finding during this Special Process audit.

9.16.1

Does a general or part-specific documented procedure define the following:

9.16.1.1 In-process cleaning methods, water break free check? YES NO 9.16.1.2 Etching? YES NO NA 9.16.1.3 Strike/Activation, including temperature, time, current (as applicable)? YES NO 9.16.1.4 Post-process cleaning methods? YES NO 9.16.1.5 The specified plate thickness and method(s) of its measurement? YES NO 9.16.1.6

Any required treatment for preventing hydrogen embrittlement?

YES

NO

9.16.2

Fixturing, racking, masking

NA 9.16.2.1 9.16.2.2

Are the fixtures, racks and masking materials defined and identified? Do fixtures and masking prevent the entrapment of air or process solutions, and protect parts from corrosion and unwanted coverage?

YES

YES

NO

NO

9.16.2.3 Does the fixturing and racking facilitate solution neutralization and removal during

rinsing, and minimize solution and rinse water drag-out and cross contamination of process tanks?

YES NO

9.16.2.4 Do the fixturing, racking, electric circuit design and lifting equipment preclude

mechanical damage or electrical arcing? YES NO

9.16.3 Processing tanks NA 9.16.3.1 Are processing tanks identifiable for their contents and specified temperature

ranges? YES NO

9.16.3.2 Are the tanks with specified temperature ranges operating within those ranges at the

time of processing? YES NO

9.16.3.3 Are tanks of sufficient volume and dimensions to contain hardware during processing

and assure sufficient coverage of parts? YES NO

9.16.3.4 Are tanks that require uniform temperature and solution concentration agitated? YES NO


9.16.3.5 Are tanks for electrolytic coatings equipped and configured to promote the required

uniform deposition rate? YES NO

9.16.4 Are anodes controlled and specific to each process solution to avoid cross

contamination? YES NO

9.16.5 Are equipment and solutions in compliance with applicable customer requirements? YES NO 9.16.6 Do the records show that the specified thickness of plate is achieved? YES NO 9.16.7 Stripping NA 9.16.7.1 Are the methods and materials for removal of plating as specified or approved by the

customer? YES NO

9.16.7.2 Do stripping procedures include an inspection of the stripped component following

the strip operation? YES NO

10. PYROMETRY TESTING

The auditor shall execute Nadcap AC7102/8 checklist as part of this audit.

11. VACUUM FURNACES NA 11.1 Procedures 11.1.1 Does the internal procedure or other documentation specify cleaning of parts, tooling

and baskets by methods and with materials that ensure freedom from contamination during vacuum heat treating?

YES NO

11.1.2 Does the internal procedure, photographic evidence, or other documentation specify

placement of load thermocouples, racking of parts, and furnace loading? (U10) YES NO

11.2 Tests and Records 11.2.1 Does the internal procedure control the following: a. Leak-up rate test? (U10 & U7) YES NO b. Calibration of vacuum instruments, controllers, recorders, thermocouples,

master gauges, dew point and other gas contaminant measuring instruments? (U10 & U7)

YES NO

c. Quench gas purity and/or dew point (i.e. does the gas certification meet

specification requirements)? YES NO

d. Furnace burn-out? YES NO e. For partial pressure atmosphere, does the dew point of the gas is periodically

checked as the gas enters the furnace? YES NO NA

11.2.2 Does the calibration interval of the vacuum systems sensor, control panel and

recorder meet the frequency of the customer specification? YES NO

11.2.3 Are calibration acceptance criteria defined in the internal procedure? Yes NO


11.2.4 Do records indicate that the tests and calibrations are performed as required by the internal procedure and all applicable specifications?

YES NO

11.2.5 Is the vacuum level in the heating and cooling chambers recorded during all thermal

cycles requiring vacuum? (U10) YES NO

12. COMPLIANCE AUDITS OF COMPLETED HEAT TREATING JOBS 12. to 13. The Auditor shall execute two (2) completed long job audits (including final testing). When the YES/NO is followed by (Info), the info notation indicates a question that is asked for

information only, with no corresponding requirement. A NO answers to these questions do not require a nonconformance report or an explanation.

14. COMPLIANCE AUDITS OF ABBREVIATED IN-PROCESS HEAT TREATING JOBS 14. to 21. The Auditor shall execute eight (8) abbreviated in-process job audits for a single lot of in-process

parts, except when the in-process Heat Treating jobs are replaced by an equal amount of in-process Brazing jobs (part of the checklist AC7102/1 performed in conjunction with AC7102 checklist). When eight (8) abbreviated in-process jobs cannot be witnessed, completed jobs may substitute the in-process jobs, but not for more than four (4).

When the YES/NO is followed by (Info), the info notation indicates a question that is asked for

information only, with no corresponding requirement. A NO answers to these questions do not require a nonconformance report or an explanation.


12. COMPLIANCE AUDIT OF COMPLETED HEAT TREATING JOB NA The Supplier needs to clearly identify the Export Control status of all parts being used in the

audit. Technical information on parts which have been designated Export Controlled License Required (EC-LR) cannot be input into eAuditNet.

Throughout the Compliance section of the audit specific questions/data entry points are marked

with an (EC). These are questions which have been designated by the Task Group as those which cannot be answered in eAuditNet IF the part is (EC-LR). Do not enter technical data, add the comment EC Technical Data Restricted. If Auditors have any questions about this, they should contact the Staff Engineer for directions.

12.1 Job #1 Identity: (Info) a. Purchase order number (for Independent Heat Treaters only): b. Customer (and prime, if known): c. Job number, Part number: d. Part description: e. Part size: f. Maximum part thickness: g. Number of parts: (EC) h. Material alloy, Material specification (if available): (EC) i. Heat Treating specification: (EC) j. Heat treat and other process and test requirements specified by customer

specification (i.e. fixed process approval):

(EC) k. Pre-heat treatment requirements (cleaning, plating, etc.) - See sections 5

and 9

12.1.1 Does the job planning contain all of the applicable items described below? YES NO a. Part number and/or adequate description of the material. b. Identification of quantity, material type, condition, form, and test samples as

applicable.


authorized personnel/prime/supplier.



process(es) to be performed including specification number(s), applicable Type(s), Class(es), Grade(s), etc.

e. Any changes, additions, and deletions are made by authorized personnel. f. Place to record inspection status. g. Place to record test requirements and results. h. Place to record identification of person(s) doing the work. i. Place to record date operation performed.

12.2 Racking NA 12.2.1 Are customer racking or batching requirements specified? YES NO (EC) Describe: (EC) Do not describe but answer YES or NO 12.2.2 Is racking or batching specified as requirement on the shop paper? YES NO (EC) Describe: (EC) Do not describe but answer YES or NO 12.2.3 Is the racking or batching used in accordance to requirements? YES NO (EC) Describe: (EC) Do not describe but answer YES or NO 12.2.4 Did racking ensure that air is not entrapped detrimentally during the quench? YES NO NA 12.3 Thermal Treatment Step One NA 12.3.1 Step One: Furnace used: Date part(s) processed: 12.3.2 (EC) Step One Temperature

REQUIREMENT SHOP PAPER

REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES

Temperature (EC) (EC) (EC) Check if used

Control (EC)

Recorder (EC)

High/Low - Type A or C Instrumentation

(EC)


Load Thermocouples

(EC)

12.3.3 (EC) Step One Time REQUIREMENT SHOP PAPER

REQUIREMENT ACTUAL

Atmosphere (EC) (EC) (EC)

Time and Tolerance

(EC) (EC) (EC)

Time loaded into furnace

Time start of soak (EC)

Time end of soak (EC)

Media for Cooling (EC)

Cooling Rate (Excluding Quench)

(EC)

12.3.4 (EC) Step One Quench

NA

REQUIREMENT SHOP PAPER REQUIREMENT

ACTUAL

Quench delay (EC) (EC) (EC)

Quench media % (EC) (EC) (EC)

Quenchant Temperature Start

(EC)

Quenchant Temperature End

(EC)

Quenchant Temperature Rise

(EC)

Quench gauge calibration

Delay to the next operation

(EC)

12.3.5 Was the furnace stabilized at or below set temperature (including the room

temperature for vacuum furnaces) before loading the parts? YES NO

(EC) Describe: (EC) Do not describe but answer YES or NO. 12.3.6 What is the basis for determining the start and the end of the soak? Describe:


12.3.7 Does the method for determining the start and the end of soak meet the customer


12.4 Offsets NA 12.4.1 Is offsetting performed? YES NO 12.4.2 Is offsetting permitted by the customer? YES NO 12.4.3 What offset is made? Describe: 12.5 Step One Summary NA 12.5.1 Is the uniformity requirement or furnace number specified on shop paper? YES NO (List below): 12.5.2 Does the furnace meet the uniformity requirement? YES NO 12.5.3 Does the furnace possess the control and recording instrumentation required by

the governing specification for this heat treatment? YES NO

12.5.4 Did cooling/quenching meet the requirements? YES NO 12.5.5 Does all thermal treatment meet the specified requirements? YES NO 12.5.6 Is there evidence that heat treatment cycles are reviewed for job traceability,

correct temperature and time at temperature? YES NO

12.5.7 Was this review performed by QA or other designated personnel and the review

documented in accordance with the customer requirements? (U11) YES NO

12.6 Thermal Treatment Step Two Temper NA 12.6.1 Step Two Temper: Furnace used: Date part(s) processed: 12.6.2 (EC)

What is the basis for determining the tempering temperature for alloy steels?

a. Specified in the shop paper b. As quenched hardness c. Other (Describe)

12.6.3 (EC) Step Two Temper Temperature



SET TEMPERATURE

ACTUAL TEMPERATURES

Temperature

(EC) (EC) (EC)

Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)

12.6.4 (EC) Step Two Temper Time


ACTUAL


Time and Tolerance

(EC) (EC) (EC)





Cooling Condition (EC)

12.7 Thermal Treatment Step Two Age/PPT/Second Temper NA 12.7.1 Step Two Age/PPT/Second Temper: Furnace used: Date part(s) processed:

12.7.2 (EC) Step Two Age/PPT/Second Temper Temperature


REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES Temperature (EC) (EC) (EC)


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)

12.7.3 (EC) Step Two Age/PPT/Second Temper Time


ACTUAL


Time and Tolerance (EC) (EC) (EC)






12.8 Step Two Summary NA 12.8.1 Is the uniformity or furnace number specified on shop paper? YES NO (List below): 12.8.2 Does the furnace meet the uniformity requirement? YES NO 12.8.3 Does the furnace possess the control and recording instrumentation required by the

governing specification for this heat treatment? YES NO

12.8.4 Did cooling/quenching meet the requirements? YES NO


12.8.5 Does all thermal treatment meet the specified requirements? YES NO 12.8.6 Is there evidence that the heat treatment cycles are reviewed for job traceability,




12.9 Cold Temperature Treatments NA (EC) Treatment specified: (EC) Treatment on the shop paper: (EC) Treatment performed and documented: (EC) YES or NO answer only 12.9.1 Do these treatments meet the customer requirements? YES NO

12.10 Load Thermocouples NA 12.10.1 Are the load thermocouples required for this job either by the customer or internal

procedure? YES NO

(EC) What requirements/documentation is specified? (EC) How many load thermocouples are used? What kind (expendable/non-expendable) and type? How are the usage cycles or time intervals controlled? (EC) Location of the load thermocouples: Method of attachment or method to simulate the maximum part thickness: 12.10.2 Did the usage and placement of load thermocouples conform to requirements? YES NO 12.11 Straighten/Stress Relieve NA 12.11.1 Was the straightening/stress relieving done? YES NO


Treatment specified (EC)

Treatment on the shop paper (EC)

Treatment performed (EC)

12.11.2 Do these treatments meet the customer requirement?

YES NO

Note: Straightening time and temperature allowances for straightening may be in subordinate specifications rather than in the basic heat treating specification. 12.12 (EC) Hardness Testing NA


ACTUAL

Hardness/Tensile range

(EC) (EC) (EC)

Hardness converted from Tensile

(EC) (EC) (EC)

Sample/Parts tested

(EC) (EC) *Only record if a part or sample was tested

Test frequency (EC) (EC)

Converted hardness recorded

(EC) (EC) (EC)

12.12.1 Does the hardness obtained conform to specification? YES NO 12.12.2 Is the operator currently qualified/certified to perform Hardness Testing? YES NO 12.13 (EC) Conductivity Testing NA


ACTUAL

Conductivity range (EC) (EC) (EC)

Test method (EC) (EC) (EC)

Sample/Parts tested

*record if sample or part tested 12.13.1 Does the conductivity obtained conform to specification? YES NO 12.13.2 Is the operator currently qualified/certified to perform Conductivity Testing? YES NO

12.14 Additional Periodic and Lot testing required: (Charpy impact, Tensile test, Fracture toughness, Metallographic and/or Microhardness tests, etc.)

NA


(EC) Additional lot or periodic testing required by the specification:

(EC) Shop paper requirement for additional testing:

(EC) Actual additional testing results: 12.14.1 Are these tests properly documented in the Suppliers Process Control System? YES NO 12.14.2 Do the tests meet the customer requirement? YES NO 12.15 Operator Control and Job Acceptance 12.15.1 Independent Heat Treaters NA 12.15.1.1 Does the certificate show compliance to all applicable drawing, specification and

PO requirements including documentation of any exceptions (e.g. pre- and post-cleaning, straightening, testing, etc.)?

YES NO

12.15.1.2 Does the certificate list the revision level of the specification to which the parts

were processed? YES NO

12.15.1.3 Do the test reports reflect the actual data? YES NO 12.15.1.4 Is the shop paper verified and accepted by authorized personnel? YES NO 12.15.2 Manufacturers/Captive Heat Treaters NA 12.15.2.1 Is the shop paper verified and accepted by authorized personnel? YES NO 12.16 Did this job comply with all other requirements? YES NO


13. COMPLIANCE AUDIT OF COMPLETED HEAT TREATING JOB NA The Supplier needs to clearly identify the Export Control status of all parts being used in the






(EC) k. Pre-heat treatment requirements (cleaning, plating, etc.) - See sections 5

and 9


applicable.






e. Any changes, additions, and deletions are made by authorized personnel. f. Place to record inspection status. g. Place to record test requirements and results. h. Place to record identification of person(s) doing the work. i. Place to record date operation performed.

13.2 Racking NA 13.2.1 Are customer racking or batching requirements specified? YES NO (EC) Describe: (EC) Do not describe but answer YES or NO 13.2.2 Is racking or batching specified as requirement on the shop paper? YES NO (EC) Describe: (EC) Do not describe but answer YES or NO 13.2.3 Is the racking or batching used in accordance to requirements? YES NO (EC) Describe: (EC) Do not describe but answer YES or NO 13.2.4 Did racking ensure that air is not entrapped detrimentally during the quench? YES NO NA 13.3 Thermal Treatment Step One NA 13.3.1 Step One: Furnace Used: Date part(s) processed: 13.3.2 (EC) Step One Temperature


REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES

Temperature (EC) (EC) (EC)

Check if used

Control (EC)

Recorder (EC)


(EC)


Load Thermocouples

(EC)

13.3.3 (EC) Step One Time


ACTUAL


Time and Tolerance

(EC) (EC) (EC)






(EC)

13.3.4 (EC) Step One Quench NA


ACTUAL

Quench delay (EC) (EC) (EC)

Quench media % (EC) (EC) (EC)

Quenchant Temperature Start

(EC)

Quenchant Temperature End

(EC)

Quenchant Temperature Rise

(EC)

Quench gauge calibration

Delay to the next operation

(EC)

13.3.5 Was the furnace stabilized at or below set temperature (including the room

temperature for vacuum furnaces) before loading the parts? YES NO

(EC) Describe: (EC) Do not describe but answer YES or NO. 13.3.6 What is the basis for determining the start and the end of the soak? Describe:


13.3.7 Does the method for determining the start and the end of soak meet the customer


13.4 Offsets NA 13.4.1 Is offsetting performed? YES NO 13.4.2 Is offsetting permitted by the customer? YES NO 13.4.3 What offset is made? Describe: 13.5 Step One Summary NA 13.5.1 Is the uniformity or furnace number specified on shop paper? YES NO (List below): 13.5.2 Does the furnace meet the uniformity requirement? YES NO 13.5.3 Does the furnace possess the control and recording instrumentation required by


13.5.4 Did cooling/quenching meet the requirements? YES NO 13.5.5 Does all thermal treatment meet the specified requirements? YES NO 13.5.6 Is there evidence that heat treatment cycles are reviewed for job traceability,




13.6 Thermal Treatment Step Two Temper NA 13.6.1 Step Two Temper: Furnace Used: Date part(s) processed: 13.6.2 (EC)

What is the basis for determining the tempering temperature for alloy steels?

a. Specified in the shop paper b. As quenched hardness c. Other (Describe)

13.6.3 (EC) Step Two Temper Temperature



REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)

13.6.4 (EC) Step Two Temper Time


ACTUAL








13.7 Thermal Treatment Step Two Age/PPT/Second Temper NA 13.7.1 Step Two Age/PPT/Second Temper: Furnace Used: Date part(s) processed:

13.7.2 (EC) Step Two Age/PPT/Second Temper Temperature


REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES



Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)

13.7.3 (EC) Step Two Age/PPT/Second Temper Time


ACTUAL








13.8 Step Two Summary NA 13.8.1 Is the uniformity or furnace number specified on shop paper? YES NO (List below): 13.8.2 Does the furnace meet the uniformity requirement? YES NO 13.8.3 Does the furnace possess the control and recording instrumentation required by


13.8.4 Did cooling/quenching meet the requirements? YES NO 13.8.5 Does all thermal treatment meet the specified requirements? YES NO 13.8.6 Is there evidence that the heat treatment cycles are reviewed for job traceability,




13.9 Cold Temperature Treatments NA


(EC) Treatment specified: (EC) Treatment on the shop paper: (EC) Treatment performed and documented: (EC) YES or NO answer only 13.9.1 Do these treatments meet the customer requirements? YES NO

13.10 Load Thermocouples NA 13.10.1 Are the load thermocouples require for this job either by the customer or internal

procedure? YES NO

(EC) What requirements/documentation is specified? (EC) How many load thermocouples are used? What kind (expendable/non-expendable) and type? How are the usage cycles or time intervals controlled? (EC) Location of the load thermocouples: Method of attachment or method to simulate the maximum part thickness: 13.10.2 Did the usage and placement of load thermocouples conform to requirements? YES NO 13.11 Straighten/Stress Relieve NA 13.11.1 Was the straightening/stress relieving done? YES NO

Treatment specified

(EC) Treatment on the shop paper

(EC) Treatment performed

(EC)

13.11.2 Do these treatments meet the customer requirement? YES NO

Note: Straightening time and temperature allowances for straightening may be in subordinate specifications rather than in the basic heat treating specification.

13.12 (EC) Hardness Testing NA


ACTUAL


Hardness/Tensile range

(EC) (EC) (EC)

Hardness converted from Tensile

(EC) (EC) (EC)

Sample/Parts tested

(EC) (EC)

*only record if a part or sample was tested Test frequency

(EC) (EC)

Converted hardness recorded

(EC) (EC) (EC)

13.12.1 Does the hardness obtained conform to specification? YES NO 13.12.2 Is the operator currently qualified/certified to perform Hardness Testing? YES NO 13.13 (EC) Conductivity Testing NA


REQUIREMENT ACTUAL

Conductivity range (EC) (EC) (EC)

Test method (EC) (EC) (EC)

Sample/Parts tested

*record if sample or part tested

13.13.1 Does the conductivity obtained conform to specification? YES NO 13.13.2 Is the operator currently qualified/certified to perform Conductivity Testing? YES NO 13.14 Additional Periodic or Lot testing required: (Charpy impact, Tensile test,

Fracture toughness, Metallographic and/or microhardness tests, etc.) NA

(EC) Additional lot or periodic testing required by the specification: (EC) Shop paper requirement for additional testing: (EC) Actual additional testing results: 13.14.1 Are these tests properly documented in the Suppliers Process Control System? YES NO 13.14.2 Do the tests meet the customer requirement? YES NO 13.15 Operator Control and Job Acceptance 13.15.1 Independent Heat Treaters NA 13.15.1.1 Does the certificate show compliance to all applicable drawing, specification and YES NO


PO requirements including documentation of any exceptions (e.g. pre- and post-cleaning, straightening, testing, etc.)?

13.15.1.2 Does the certificate list the revision level of the specification to which the parts

were processed? YES NO

13.15.1.3 Do the test reports reflect the actual data? YES NO 13.15.1.4 Is the shop paper verified and accepted by authorized personnel? YES NO 13.15.2 Manufacturers/Captive Heat Treaters NA 13.15.2.1 Is the shop paper verified and accepted by authorized personnel? YES NO 13.16 Did this job comply with all other requirements? YES NO


14. COMPLIANCE AUDIT OF ABBREVIATED IN-PROCESS HEAT TREATING JOB NA The Supplier needs to clearly identify the Export Control status of all parts being used in the





specification (e.g. fixed process approval) - See sections 3.2, 3.7 and 7:

(EC) k. Pre-heat treatment requirements (cleaning, racking, normalizing, plating,

stress relieving, etc.):

(EC) l. Pre-heat treatment requirements on the shop paper - See sections 5 and 9: (EC) m. Pre-heat treatment actually performed - See sections 5 and 9: 14.1.1 Does the job planning contain all of the applicable items described below? YES NO a. Part number and/or adequate description of the material.


b. Identification of quantity, material type, condition, form, and test samples as applicable.





e. Any changes, additions, and deletions are made by authorized personnel. f. Place to record inspection status. g. Place to record test requirements and results. h. Place to record identification of person(s) doing the work.

14.2 Thermal Treatment Step One NA 14.2.1 Step One: Furnace used: Date part(s) processed: 14.2.2 Does the furnace possess the control and recording instrumentation required by


14.2.3 (EC) Step One Temperature


REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL









(EC)

14.3 Thermal Treatment Step Two NA 14.3.1 Thermal Treatment Step Two Temper NA 14.3.1.1 Step Two Temper: Furnace used: Date part(s) processed: 14.3.1.2 Does the furnace possess the control and recording instrumentation required by


14.3.1.3 (EC) Step Two Temper Temperature


SET TEMPERATURE

ACTUAL TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)

14.3.1.4 (EC) Step Two Temper Time


REQUIREMENT ACTUAL









14.3.2 Thermal Treatment Step Two Age/PPT/Second Temper NA 14.3.2.1 Step Two Age/PPT/Second Temper: Furnace used: Date part(s) processed: 14.3.2.2 Does the furnace possess the control and recording instrumentation required by


14.3.2.3 (EC) Step Two Age/PPT/Second Temper Temperature


REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)

14.3.2.4 (EC) Step Two Age/PPT/Second Temper Time


REQUIREMENT ACTUAL









14.4 Testing for the abbreviated Job #1 NA 14.4.1 Testing requirements by Specification, P/O or Drawing (EC) 14.4.2 Shop paper testing requirements: (EC) 14.4.3 Actual testing performed: (EC) 14.5 Job Acceptance 14.5.1 Is the operation signed off or data recorded only after completion? YES NO 14.5.2 Did the treatment of hardware conform to customers specified requirements? YES NO










(EC) l. Pre-heat treatment requirements on the shop paper: (EC) m. Pre-heat treatment actually performed:

15.1.1 Does the job planning contain all of the applicable items described below? YES NO a. Part number and/or adequate description of the material.


b. Identification of quantity, material type, condition, form, and test samples as applicable.

c. Any deviations from the proposal/contract are resolved in writing by authorized

personnel/prime/supplier.

d. Adequate definition of the work statement to identify the specific process(es) to

be performed including specification number(s), applicable Type(s), Class(es), Grade(s), etc.


15.2 Thermal Treatment Step One NA 15.2.1 Step One Information: Furnace used: Date part(s) processed: 15.2.2 Does the furnace possess the control and recording instrumentation required by




REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL









(EC)





REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL



Time loaded into


furnace









REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL









15.4 Testing for the abbreviated Job #2 NA 15.4.1 Testing requirements by Specification, P/O or Drawing: (EC) 15.4.2 Shop paper testing requirements: (EC) 15.4.3 Actual testing performed: (EC) 15.5 Job Acceptance 15.5.1 Is the operation signed off or data recorded only after completion? YES NO 15.5.2 Did the treatment of hardware conform to customers specified requirements? YES NO


applicable. c. Any deviations from the proposal/contract are resolved in writing by authorized









REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL









(EC)





REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL













REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL

















17.1.1 Does the job planning contain all of the applicable items described below? YES NO a. Part number and/or adequate description of the material.


b. Identification of quantity, material type, condition, form, and test samples as

applicable.

c. Any deviations from the proposal/contract are resolved in writing by authorized









REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL









(EC)





REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL













REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL
















(EC) l. Pre-heat treatment requirements on the shop paper: (EC) m. Pre-heat treatment actually performed: 18.1.1 Does the job planning contain all of the applicable items described below? YES NO a. Part number and/or adequate description of the material.


b. Identification of quantity, material type, condition, form, and test samples as

applicable.










REQUIREMENT SET

TEMPERATURE ACTUAL

TEMPERATURES


Check if used

Control (EC)

Recorder (EC)


(EC)

Load Thermocouples

(EC)



REQUIREMENT ACTUAL









(EC)



18.3.1.3 (EC) Step Two Temper Temper

AC7102 Rev H Heat Treat

Documents

actual audit

followup audit

scheduled audit

audit process

audit criteria ac7102

approval ac710210

approval ac71013

testing equipment