AC7102.1 Rev E Final

161Thorn Hill RoadWarrendale, PA 15086-7527

AUDIT CRITERIA

AC7102/1 REV. E

Issued 1995-11

Revised 2013-04

Superseding AC7102/1 Rev. D

BaselineNadcap AUDIT CRITERIA

For BRAZING29-APR-13 Editorial: Para 3.1, 5.3, 5.4, 7.1.4, 9.1, 10.1, 11.2 addition of U-codes

1. SCOPE

1.1 This checklist supplements PRI AC7102 checklist. This checklist shall apply to suppliers who perform brazing in an atmosphere furnace, in a vacuum furnace or in a dip salt bath, and who seek Nadcap accreditation. The requirement for job audits shall be completed for one (1) atmosphere furnace brazing, one (1) vacuum furnace brazing and one (1) dip salt bath brazing, as applicable.If the brazing Supplier performs Induction Brazing or Torch Brazing, then the Auditor shall use PRI AC7110/1 checklist.

2. GENERAL INFORMATION

2.1 This checklist shall be treated as an in-process job audit.

3. VALIDATION NA

3.1 Is the brazing work instruction certified or approved through conforming inspection/test results on representative parts/coupon? (U23)

YES NO

3.2 Does the brazing work instruction conform to the applicable part drawing and specification requirement?

YES NO

3.3 Does the procedure require that customer approval of brazing work instruction is obtained when required?

YES NO NA

3.4 Is there a procedure to re-validate in accordance with the customer requirement? YES NO NA

3.5 Is the re-validation verified and complied with? YES NO NA

4. PERSONNEL

4.1 Training

4.1.1 Are there training procedures that assure personnel performing brazing filler metal application and associated quality and test functions are competent to perform assigned tasks?

YES NO

4.1.2 Does this training comply with customer specifications? YES NO NA

4.1.3 Do records indicate that training is scheduled and attended in accordance with YES NO

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 2008 Performance Review Institute. All rights reserved.t-frm-15 21-May-08

NOTE THIS IS NOT AN OFFICIAL COPY OF THE AC7102/1 CHECKLIST AND IS OFFERED ONLY AS A STARTING POINT FOR THE SUPPLIER TO CREATE A WORKING SELF-AUDIT TOOL. BY ACCEPTING AND USING THIS DOCUMENT, THE SUPPLIER ACCEPTS ALL RESPONSIBILITY TO ASSURE THE INFORMATION ENCLOSED IS THE SAME AS THE OFFICIAL CHECKLIST AND ITS SUBSEQUENT REVISIONS.

PRI AC7102/1 Revision E 2nd DRAFT - 2 -

procedures and documented?

4.2 Evaluation of Personnel

4.2.1 Do procedures require periodic evaluation to ensure that approved personnel maintain proficiency in their assigned brazing filler metal application and related tasks?

YES NO

5. MATERIAL CONTROL NA

5.1 Is there a written procedure for storage and control (including the shelf life of mixed brazing paste, tape, rope, etc.) of brazing filler metal, stop off and brazing aid materials as applicable?

YES NO

5.2 Is there a written procedure that describes the mixing of the brazing pastes or the procurement of the mixed brazing pastes, or it states that the supplier will not mix brazing pastes?

YES NO

5.3 Does the supplier review the raw materials certifications to ensure that the specifications’ requirements are met? (U23)

YES NO

5.4 Is there objective evidence that the raw materials certifications are reviewed? (U23)

YES NO

5.5 Is there a controlled brazing filler metal storage area where the alloys are labeled and segregated, and where the employees’ access is limited?

YES NO

5.6 Are the raw materials containers traceable to a material certification for the applicable lot?

YES NO

6. BRAZE FILLER METAL APPLICATION FACILITY NA

6.1 Does the supplier have a braze filler metal application area so parts can be prepared for brazing in a suitable, clean and lighted environment?

YES NO

6.2 Are the braze filler metals identified with the proper traceable lot number at the individual workstations?

YES NO

7. BRAZING EQUIPMENT

7.1 Vacuum Furnace Brazing NA

7.1.1 Is the gas dew point monitored? YES NO

7.1.2 Is the dew point monitored at the required location? YES NO

7.1.3 Is there a procedure for periodic high temperature bake out of the vacuum brazing chamber when required?

YES NO

7.1.4 Is the vacuum brazing equipment capable to maintain a vacuum level required by the customer? (U23)

YES NO

7.2 Dip Salt Bath Brazing NA

7.2.1 Does the dip brazing salt pot have adequate volume to preclude the parts touching YES NO


the electrodes?

7.2.2 Does the supplier have adequate procedures for conducting the following periodic tests of the salt bath, when required:

YES NO

a. Pyrometry?

b. Dehydration of the bath?

c. pH of the bath?

d. Scum and sludge removal from the bath?

7.2.3 Do the records show that these tests are current and conform to the requirements? YES NO

7.3 Atmosphere Furnace Brazing NA

7.3.1 Is the gas dew point monitored? YES NO

7.3.2 Is the dew point monitored at the required location? YES NO

8. BRAZE FILLER METAL APPLICATION AND ASSEMBLY PLANNING NA

8.1 Does the planning include the removal of all burrs that could inhibit the braze flow? YES NO

8.2 Are the assembly methods defined? YES NO

8.3 Have the resultant dimensional change from the thermal treatment being considered in the planning?

YES NO

8.4 Do procedures state that the tack welding shall be used only when permitted by the engineering drawing or specification?

YES NO

8.5 Are the parts inspected for cleanliness immediately prior to assembly? YES NO

8.6 If the parts do not pass the visual inspection for cleanliness, are they reprocessed through the cleaning operation?

YES NO

8.7 Does the braze filler metal application/assembly work instruction/procedure contain the following, if required:

NA

a. Gap control requirements and what to do if they are not met? YES NO NA

b. Cleaning instructions (including method and product)? YES NO NA

c. Grit blasting instructions (including the limitations and process control plan)? YES NO NA

d. Shimming material type and placement instructions? YES NO NA

e. Fusion or Resistance weld tacking instructions (including the location, sequence, size of the tack welds and tack weld filler metal)?

YES NO NA

f. The training of welders and inspectors to conform to contract requirements? YES NO NA

g. The type of braze filler metal? YES NO NA

h. The form of braze filler metal? YES NO NA


i. The location of filler metal application? YES NO NA

j. The amount of the braze filler metal? YES NO NA

k. The cement requirement (including type, commercial designation, and proportion)?

YES NO NA

l. The stop off requirement (including the location)? YES NO NA

m. Instructions for protection of fixtures and parts from contamination? YES NO NA

9. BRAZE PROCESSING

9.1 Does the braze part sequencing and work instruction contain the following information, if required: (U23)

NA

a. The furnace fixturing (when used) or part orientation in the furnace? YES NO NA

b. The maximum number or maximum weight of parts in the furnace? YES NO NA

c. Precautions to prevent adverse interaction between fixture and furnace materials with the parts at the planned process temperatures?

YES NO NA

d. Brazing atmosphere or dip brazing salt type (including purity and concentration if applicable) (SAFRAN)?

YES NO NA

e. Vacuum limits or atmosphere control throughout the braze cycle? YES NO NA

f. Heat rates and soak times for preheat and brazing? YES NO NA

g. Directions for determining when to start the brazing time and when to complete the brazing time?

YES NO NA

h. Specific equipment certified to run the parts? YES NO NA

i. Test sample preparation, when required? YES NO NA

j. For titanium brazing, provisions made for alpha case testing of coupons? YES NO NA

k. Alpha case testing done to customer requirements? YES NO NA

l. Getter material (deposit of reactive material that is placed inside a vacuum system, to maintain a clean vacuum by absorbing contaminants) (when used): nature, form, quantity, location?

YES NO NA

m. Placement of test samples during the brazing cycle? YES NO NA

n. Temperature and cycle time? YES NO NA

o. Cooling requirements? YES NO NA

p. Directions when to remove parts from the brazing equipment? YES NO NA

q. Cooling gas type, pressure and directions for its introduction? YES NO NA

10. POST-BRAZING CLEANING NA


10.1 Does the post-brazing cleaning work instruction contain the following, if required: (U23)

a. Method and product used for post-cleaning? YES NO

b. Stop off removal? YES NO NA

c. Flux removal? YES NO NA

d. Salt residue removal? YES NO NA

10.2 Does the cleaning method conform to the customers’ requirements? YES NO

11. POST-BRAZING INSPECTION NA

11.1 Does planning address all inspections required by customers’ specifications? YES NO

11.2 Does Supplier perform or insure that the following capabilities exist and can be used as needed for inspection: (U23)

a. Ultrasonic? YES NO NA

b. Visual? YES NO NA

c. Metallography? YES NO NA

d. Radiography? YES NO NA

e. Dye Penetrant? YES NO NA

f. Mechanical testing or functional tests of actual hardware? YES NO NA

g. Leak test? YES NO NA

12. POST-BRAZING TESTS NA

12.1 Are the destructive and/or non-destructive inspection sources approved by the customer when required?

YES NO

12.2 Are records of tests documented? YES NO

12.3 Are the test data and the specimens traceable to the parts which they represent? YES NO

13. BRAZING REWORK NA

13.1 Have the brazing rework conditions been approved by the customer? YES NO

13.2 Where required, are the total rework cycles or the total time tracked and recorded to verify that the maximum time at temperature, or the maximum number of cycles meet the requirements of the engineering drawing or specification?

YES NO NA

13.3 Are the reworked brazed joints inspected in accordance with the original customer requirements?

YES NO


14. JOB AUDIT BRAZING

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 can not 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.

14.1 Job 1 Identity:

a. Purchase order number (when applicable):

b. Customer (and prime, if known):

c. Part number:

d. Part description:

e. Date of job and job number:

(EC) f. Material/alloy

(EC) g. Material specification

(EC) h. Heat treating/Braze specifications:

(EC) i. Braze Filler Metal Specification

(EC) j. Braze Alloy Lot Number

(EC) k. Heat treat and other process and test requirements specified (e.g. fixed process approval):

l. Part size:

m. Number of parts

14.2 Pre-brazing requirements

14.2.1 Prior to brazing, have cleaned parts been protected from contamination? YES NO


14.3 Cleaning NA

14.3.1 Does Supplier have the proper equipment to clean the parts by the approved procedures?

YES NO

14.3.2 Are cleaning/surface preparation methods performed as allowed by the process specification or engineering drawing?

YES NO

14.3.3 Are parts cleaned by the certified or approved brazing procedure? YES NO

14.3.4 If a thermal cleaning process is used for surface preparation, does the time/temperature cycle meet the requirements of the approved work instruction?

YES NO

14.3.5 Does the record indicate that the delay time between cleaning and brazing conforms to the brazing procedure?

YES NO

14.3.6 Are cleaning solutions subject to periodic evaluation by a documented process control plan?

YES NO

14.4 Grit Blasting NA

14.4.1 Are blasted parts cleaned in accordance with the approved procedure? YES NO

14.4.2 Does the delay time between the grit blasting and brazing conform to the brazing procedure?

YES NO

14.4.3 Are parts inspected for residual grit from grit blast operations, if required? YES NO NA

14.4.4 Do grit blasting media comply with customer requirements? YES NO

14.5 Plating NA

14.5.1 Plating by the Brazing Source NA

14.5.1.1 Are plating solutions subject to periodic evaluation by a documented process control plan?

YES NO

14.5.1.2 Does the plating work instruction define the plating thickness and location of the deposited material?

YES NO

14.5.1.3 Are the parts plated in accordance with a work instruction based on the engineering drawing and/or specification requirements?

YES NO

14.5.1.4 Are plating requirements, including all process parameters (surface area, current requirement, etc.), and setup procedure defined in the work instructions?

YES NO

14.5.1.5 If required, is the plating process/facility approved by applicable customer? YES NO NA

14.5.2 Plating by an Outside Supplier NA

14.5.2.1 Has the outside supplier been approved by the customer? YES NO

14.5.2.2 Has the outside plating supplier certified that the parts were plated in accordance with the brazing work instruction, engineering drawing or specification requirement?

YES NO

14.6 Braze Gap Control NA

14.6.1 Is there evidence the braze gap has been verified? YES NO


14.7 Welding NA

14.7.1 Is there evidence that the welding procedures are being followed? YES NO

14.8 Alloying NA

14.8.1 Are the materials specified on the brazing work instruction allowed by the engineering drawing or customer approval?

YES NO

14.8.2 When required, is the manufacturer of the braze filler metal approved by the customer?

YES NO NA

14.8.3 Is the proper brazing filler metal type, form, and amount applied in accordance with the approved brazing work instruction?

YES NO

14.8.4 Is the braze filler metal applied in the locations specified on the braze work instruction?

YES NO

14.8.5 Does the supplier maintain traceability between the lots of brazing filler material and the parts to which they are applied?

YES NO

14.8.6 Is flux used as required (type, amount) by the engineering drawing listed on the brazing work instruction?

YES NO

14.8.7 Is the application of the brazing filler metal performed by authorized personnel? YES NO

14.9 Brazing Aids NA

14.9.1 Is the proper stop off applied in the correct locations in accordance with the approved brazing work instruction?

YES NO

14.9.2 Is the proper aid (shim, feltmetal, etc.) applied in the correct manner as defined in the brazing work instruction?

YES NO

14.10 Dip Brazing Salt NA

14.10.1 Is the specified brazing salt in use? YES NO

14.10.2 Are the operator-controlled variables as specified (such as bath temperature, current, etc.)?

YES NO

14.11 Racking NA

14.11.1 Are customer racking or batching requirements specified? Describe: YES NO(EC) Not to describe

14.11.2 Is the racking or batching specified as requirements on shop paper? YES NO

14.11.3 Verify the racking or batching used. Does it comply? Describe: YES NO(EC) Not to describe

14.12 Thermal Treatment NA


14.12.1 (EC) Brazing Operation – Temperature NA

REQUIREMENT SHOP PAPERREQUIREMENT

SET TEMPERATURE

ACTUAL TEMPERATURES

(EC) (EC) (EC) (EC)Temperature

Check if used

Indicator (EC)

Recorder (EC)

Multipoint (EC)

Load Thermocouples

(EC)

14.12.1.1 Were dip brazed parts preheated for the specified time immediately prior to dipping?

YES NO NA

14.12.1.2 Was the furnace stabilized at or below (including room temperature for vacuum furnace) the set temperature before loading parts?

YES NO

14.12.2 Offsets NA

14.12.2.1 Is the offsetting performed? YES NO

14.12.2.2 Is the offsetting permitted by the customer? YES NO

14.12.2.3 What offset is made? Describe:

14.12.3 Does the furnace instrumentation meet the requirements of the customers’ specification?

YES NO

14.12.4 Is the temperature uniformity specified, or is the furnace number specified on the shop paper?

YES NO

List the specified furnace number(s), or the uniformity:

14.12.5 Does this furnace meet the uniformity requirements? YES NO

14.12.6 (EC) Brazing Operation – Time

REQUIREMENT SHOP PAPER ACTUAL


REQUIREMENT

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 (EC)

14.12.6.1 When fixed process is required by the customer and load thermocouples are not used, was the soak time determined through a validation plan approved by the customer?

YES NO NA

14.12.6.2 What is the basis for determining the start and the end of the soak?

Describe:

14.12.6.3 Does the start and end of soak meet the customers’ requirements? YES NO

14.12.6.4 Does the soak time meet the customers’ requirements? YES NO

14.12.6.5 Does the post brazing cooling method/rate conform to the brazing work instructions?

YES NO

14.12.6.6 Does all thermal treatment meet the specified requirements? YES NO

14.12.7 Load Thermocouples (Batch Furnaces – Does Not Apply to Dip Brazing Pre-Heat)

NA

14.12.7.1 Are the load thermocouple requirements specified by the customer (Info Only)? YES NO

14.12.7.2 Are the load thermocouples specified by the supplier? YES NO

14.12.7.3 Did the type/number/location and attachment of the load thermocouples conform to the requirements?

YES NO

14.12.8 Post Brazing Cleaning NA

14.12.8.1 Are work instructions available at the work station describing how to clean the parts after brazing?

YES NO

14.12.8.2 Are these instructions being used at the work station and followed? YES NO

14.12.8.3 Are the parts (when brazed with flux) checked for flux removal after the post brazing cleaning?

YES NO NA


14.12.8.4 Is the stop off residue removed from the brazed parts? YES NO NA

14.12.8.5 Is Salt residue removed from the dip brazed parts? YES NO NA

14.12.8.6 Does the cleaning method conform to the customers’ requirements? YES NO

14.12.9 Post Brazing Inspection NA

14.12.9.1 Are the parts visually inspected for external coverage in the required areas and surface condition in accordance with the customers’ requirements?

YES NO

14.12.9.2 Are records of tests documented and comply with the customers’ requirements? YES NO

14.12.9.3 If the lot contained reworked parts, were the rework cycles or the maximum time at temperature requirements fulfilled?

YES NO

14.12.10 Operator Control and Job Acceptance

14.12.10.1 Certification and Reports or Test Reports (Independent Heat Treaters) NA

14.12.10.1.1 Does the certificate show compliance to all applicable drawing, specification and PO requirements?

YES NO

14.12.10.1.2 Does the certificate list the revision level of the specification to which the parts were processed?

YES NO

14.12.10.1.3 Do the test reports reflect the actual data? YES NO

14.12.10.1.4 Is the shop paper/traveler verified and accepted by authorized personnel? YES NO

14.12.10.2 Certification and Reports or Test Reports (Manufacturers) NA

14.12.10.2.1 Is the shop paper/traveler verified and accepted by authorized personnel? YES NO

14.12.11 Did this job comply with all the requirements? YES NO

14.13 RECORDS

14.13.1 Are the following records kept for each part or each lot of parts :

a. The name or stamp or quality mark of the brazing operator? YES NO

AC7102.1 Rev E Final

Documents

Transcript of AC7102.1 Rev E Final