Nadcap Supplier Seminar Heat Treatment

1
Nadcap Supplier Seminar Heat Treatment

• Presented by Jerry Aston
• Staff Engineer Heat Treatment

2
Heat Treat Contacts

• Jerry Aston - Heat Treat Staff Engineer
• Phone No. (44) 020 7483 9010
• email - jerry.aston_at_pri-europe.org.uk
• Laura Fisher - Heat Treat Staff Engineer
• Phone No (1) 724 772 1616 ex 8131
• email - fisher_at_sae.org

3
Heat Treat Contacts - cont

• Jenn Walker Customer Service Representative
• Phone No. (44) 020 7483 9014
• email- jennifer.walker_at_pri-europe.org.uk
• Michele Stefanick - Customer Service
  Representative
• Phone No (1) 724 772 1616 ex 8116
• email- stefanck_at_sae.org

4
Heat Treat Checklists

• 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.

5
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).

6
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.

7
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

8
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.

9
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.

10
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.

11
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 customers using all
  the different processes the supplier has.
• Job audits are split into short and long job
  audits

12
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.

13
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.

14
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.

15
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 gt1C but lt 3C.
• Use of resident probe thermocouple of different
  thermocouple types.
• Frequency of SAT testing.

16
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.

17
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)

18
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.

19
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.

20
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.

21
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

22
?