Nadcap Supplier Seminar Heat Treatment Presented by Jerry Aston Staff Engineer Heat Treatment

Heat Treat Contacts Jerry Aston - Heat Treat Staff Engineer Phone No. (44) 020 7483 9010 email :- jerry.aston@pri-europe.org.uk Laura Fisher - Heat Treat Staff Engineer Phone No (1) 724 772 1616 ex 8131 email :- fisher@sae.org

Heat Treat Contacts - cont Jenn Walker – Customer Service Representative Phone No. (44) 020 7483 9014 email:- jennifer.walker@pri-europe.org.uk Michele Stefanick - Customer Service Representative Phone No (1) 724 772 1616 ex 8116 email:- stefanck@sae.org

Heat Treat Checklists AC7102 Nadcap Audit Criteria for Heat Treatment The auditor will carryout the audit using checklists (found on e-AuditNet). The checklist are as follows:- AC7102 Nadcap Audit Criteria for Heat Treatment Core document which addresses the Heat treatment controls and pyrometry for heat treatment. This document is the baseline requirement for Heat Treat accreditations. AC7102/1 Nadcap Audit Criteria for brazing Includes supplemental requirements specific to vacuum brazing.

Heat Treat Checklists - cont AC7101/3 Nadcap Audit Criteria for Mechanical Testing Includes supplemental requirements specific to mechanical Testing. AC7101/4 Nadcap Audit Criteria for Metallography and Micro-hardness. Includes supplemental requirements specific to laboratory and Micro-hardness. AC7101/5 Nadcap Audit Criteria for Hardness testing Includes supplemental requirements specific to hardness testing(Vickers, Brinell and Rockwell).

Audit Duration The audit duration depends on the number of different alloy type heat treated and the different types of heat treatment processes carried out. The addition of Tensile testing, Metallography and Hardness testing will increase the length of the audit. Audit duration can be 3 days but more usually last 4-5 days.

Scope of the Audit AC7102 general checklist covers the following topics:- Process planning and control Personnel (training and evaluation) Material handling and protection Test and Inspection Furnace controls and maintenance Job audits

Scope of the audit - cont Furnace control – pyrometry Pyrometry control of furnaces is based on meeting AMS2750 as a minimum, plus your customer specification requirements. As a help the Task Group have written ‘Pyrometry for Dummies’ to guide you through AMS2750. This documents is intended to give the standard interpretation to AMS2750. Pyrometry for dummies is found on e-AuditNet.

Scope of audit - cont AC7102/1 – Brazing This checklist covers the brazing section of the audit. The scope covers Vacuum Brazing Furnace Brazing Hydrogen Furnace Brazing Induction Brazing All other types of brazing covered by the Welding Task Group.

Scope of audit - cont Tensile testing AC7101/3, Metallography AC7101/4, and Hardness Testing AC7101/5. If Nadcap approval is held for these from the MTL Task Group, then these audits are not required by heat treatment. If approval from MTL task group is not held then these approval can by granted by the Heat Treat task group. The approval will be for testing in support of heat treating only. Please note tensile testing is limited to Room Temperature Tensile Testing only.

Job Audits The audit process requires that a minimum of ten job audits are reviewed. During the job audits the auditor is required to see work from a variety of customer’s using all the different processes the supplier has. Job audits are split into short and long job audits

Job audits - cont 2 long job audit are carried out; These are jobs from recent history, and are fully completed jobs ie cover from receipt of the parts to despatch. These are a paperwork review which goes from purchase order, through shop papers, furnace charts, release testing, to the release note.

Job Audits - cont 8 Short job audits are carried out; This is current work going through the furnaces during the audit, and should cover the full scope of approvals and Prime customers. The auditor will want to see load make up, furnace run, and cooling/quenching of the load.

Common Findings Pyrometry Temperature Uniformity Surveys These must meet AMS2750 as a minimum. There must be procedures to cover all requirements If sub contracting the pyrometry, the sub contract suppliers procedures must have been reviewed and accepted. Reporting of the Temperature Uniformity Survey.

Common Findings System Accuracy Tests Correct used of Thermocouple correction factors. Identification of time of test, and recording test on furnace charts. Identifying what action to be taken the temperature deviation is >1C but < 3C. Use of resident probe thermocouple of different thermocouple types. Frequency of SAT testing.

Common Findings Heat treatment parameters Soak time Procedures need to define start of soak, use of load thermocouple. Temperature and Time tolerances This need to be included on shop paper work. It is not acceptable to just give a minimum time, or a single temperature.

Common Findings Over temperature The furnace must be maintained within tolerance during the heat treatment cycle, this included on heat up. Quenching Temperature of quench media at the start and end of the quench. Recording of the transfer time from the furnace to the quench media (especially for Al)

Common Findings Hardness Testing Procedure for carrying out Round Robin testing. Round Robin results need to be analysed by a statistical method to give 95% confidence. Calibration to ASTM standards not ISO, EN, BS etc. Spacing of indents when carrying out the daily test.

Common Findings Operator Training Procedures required to define training for operators. Heat Treat operators competence to be reviewed and the results discussed with the operator with a view to continuous improvement. Contract review If the heat treatment parameters differ from the drawing requirement, customer specification etc, then written customer approval is required. Verbal acceptance from the customer will not be accepted.

Heat Treat Supplier Merit This is a decrease in the audit frequency. Merit is granted by the Heat Treat Task Group to supplier demonstrating their capability in meeting customer and Nadcap requirements. Merit for Heat Treatment can be 12 months, 18 months or 24 months. The requirements for merit can be found in procedure NTGOP001 appendix 3.

Failure Policy - Cont NOP011 – Failure policy Initial: Greater than 40 Total NCRs and/or Greater than 10 Major Findings Reaccreditations: Greater than 15 Total NCRs and/or Greater than 5 Major NCRs. Potential Failure if Supplier has not adequately addressed root cause and corrective action by the third submittal

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