Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
Special Process: Heat Treat System Assessment
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Section 1 - Management Responsibility & Quality Planning
To ensure readily available expertise, there shall be
a dedicated and qualified heat treat person on site.This individual shall be a full-time employee and theposition shall be reflected in the organization chart.
Is there a dedicated andA job description shall exist identifying the
qualifications for the position including metallurgicalqualified heat treat
and heat treat knowledge. The qualifications shallperson on-site?
include a minimum of 5 years experience in heattreat operations or a combination of a minimum of 5years of formal metallurgical education and heattreat experience.
The organization shall incorporate a documentedadvance quality planning procedure. A feasibilitystudy shall be performed and internally approved foreach part. Similar parts can be grouped into partfamilies for this effort as defined by the organization.After the part approval process is approved by thecustomer, no process changes are allowed unlessapproved by the customer. The heat treater shallcontact the customer when clarification of processchanges is required. This clarification of processeschange shall be documented.
1.1
1.2
Does the heat treaterperform advancedquality planning?
1.3
The organization shall incorporate the use of adocumented Failure Mode and Effects Analysis(FMEA) procedure and ensure the FMEA's areupdated to reflect current part quality status. TheFMEA shall be written for each part or part family orthey may be process-specific and written for each
Are heat treat FMEA's
process. In any case, they shall address all process
up to date and reflecting
steps from part receipt to part shipment and all key
current processing?
heat treat process parameters as defined by theorganization. A cross-functional team shall be usedin the development of the FMEA. All special
characteristics, as defined by the organization andits customers, shall be identified, defined, andaddressed in the FMEA.
CQI-9
Special Process: Heat Treat System Assessment
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1.4
The organization shall incorporate the use of a
documented Control Plan procedure and ensure theControl Plans are updated to reflect currentcontrols.
The Control Plans shall be written for each part orpart family or they may be process-specific andwritten for each process. In any case, they shalladdress all process steps from part receipt to partshipment and identify all equipment used and all keyheat treat process parameters as defined by the
Are heat treat processorganization.
control plans up to dateA cross-functional team, including a productionand reflecting currentoperator, shall be used in the development ofprocessing?Control Plans, which shall be consistent with all
associated documentation such as work
instructions, shop travelers, and FMEA's. All specialcharacteristics, as defined by the organization andits customers, shall be identified, defined, andaddressed in the Control Plans.
Sample sizes and frequencies for evaluation ofprocess and product characteristics shall also beaddressed consistent with the minimum
requirements listed in the Process Tables, Sections3.0 and 4.0.
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
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To ensure all customer requirements are both
understood and satisfied, the organization shallhave all related heat treat and customer referencedstandards and specifications available for use and amethod to ensure that they are current. Suchstandards and specifications include, but are notlimited to, those relevant documents published bySAE, AIAG, ASTM, General Motors, Ford, andDaimlerChrysler.
Objective Evidence
1.5
Are all heat treat relatedand referenced
specifications currentand available? Forexample: SAE, AIAG,ASTM, General Motors,Ford, and
DaimlerChrysler.
The organization shall have a process to ensure thetimely review, distribution, and implementation of allcustomer and industry engineering standards /specifications and changes based on customer-required schedule. Timely review should be as soonas possible and shall not exceed two workingweeks. The organization shall document this
process of review and implementation, and it shalladdress how customer and industry documents areobtained, how they are maintained within the
organization, how the current status is established,and how the relevant information is cascaded to theshop floor within the two-week period. The
organization shall identify who is responsible forperforming these tasks.
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Special Process: Heat Treat System Assessment
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1.6
The heat treater shall have written process
specifications for all active processes and identify allsteps of the process including relevant operatingparameters. Examples of operating parametersinclude process temperatures, cycle times, loadrates, atmosphere or gas flow settings, belt speeds,
Is there a written
quench agitation speeds, etc. Such parameters
process specification for
shall not only be defined, they shall have operating
all active processes?
tolerances as defined by the organization in order tomaintain process control. All active processesshould have a written process specification.
These process specifications may take the form ofwork instructions, job card, computer-based recipes,or other similar documents.
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Special Process: Heat Treat System Assessment
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To demonstrate each process is capable of yielding
acceptable product the organization shall performproduct capability study for the initial validation ofeach process, after relocation of any processequipment, & after a major rebuild of any
equipment. The organization shall define what
constitutes a major rebuild. Initial product capabilitystudies shall be conducted for all heat treat
processes per furnace line defined in scope of work& in accordance with customer requirements.A furnace line may include a combination of
equipment that is integrated in the performance of aheat treatment process, e.g. hardening, quenching,and tempering. Capability study techniques shall beappropriate for the heat treat product
characteristics, e.g. tensile strength, case depth,hardness. Any specific customer requirements shallbe met, in the absence of customer requirements,the organization shall establish acceptable rangesfor measures of capability. An action plan shall existto address the steps to followed in case capabilityindices fall outside customer requirements orestablished ranges.
Objective Evidence
1.7
Has a valid productcapability study beenperformed initially andafter process equipmenthas been relocated, orhad a major rebuild?
1.8
The analysis of products and processes over timecan yield vital information for defect preventionefforts. The organization shall have a system to
Does the heat treater
collect, analyze, and react to product or process
collect and analyze data
data over time.
over time, and react to
Methods of analysis shall include ongoing trend or
this data?
historical data analysis of product or process
parameters. The organization shall determine whichparameters to include in such analysis.
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Special Process: Heat Treat System Assessment
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1.9
Management shall review the furnace monitoring
systems at intervals not to exceed 24 hours. Theheat treat monitoring system includes but is notlimited to temperature strip charts, atmosphere strip
Is management
charts, computer data logs, furnace and operator
reviewing the heat treat
logs, etc.
monitoring system every
The management review shall include efforts to
24 hours?
detect out-of-control conditions or alarm conditions.The process of reviewing the furnace data shall bedocumented and this requirement also applies tocomputerized data.Are internal
assessments beingThe organization shall conduct internal
completed on an annualassessments on an annual basis, at a minimum,basis, at a minimum,using the AIAG HTSA.using AIAG HTSA?
The quality management system shall include adocumented process for reprocessing that shallinclude authorization from a designated individual.The reprocessing procedure shall describe productcharacteristics for which reprocessing is allowed aswell as those characteristics for which reprocessingis not permissible.
Any reprocessing activity shall require a newprocessing control sheet issued by qualified
technical personnel denoting the necessary heattreat modifications. Records shall clearly indicatewhen and how any material has been reprocessed.The Quality Manager or a designee shall authorizethe release of reprocessed product.
The quality management system shall include a
process for documenting, reviewing, and addressingcustomer concerns and any other concerns internalto the organization. A disciplined problem-solvingapproach shall be used.
1.10
1.11
Is there a system inplace to authorizereprocessing and is itdocumented?
1.12
Does the QualityDepartment review,address, and documentcustomer and internalconcerns?
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The heat treater shall define a process for continual
improvement for each heat treat process identifiedin the scope of the HTSA. The process shall bedesigned to bring about continual improvement inquality and productivity. Identified actions shall beprioritized and shall include timing (estimatedcompletion dates). The organization shall showevidence of program effectiveness.
Objective Evidence
1.13
Is there a continualimprovement planapplicable to eachprocess defined in thescope of theassessment?
1.14
Does the Quality
The Quality Manager is responsible for authorizingManager or designee
authorize the dispositionand documenting appropriate personnel toof material fromdisposition quarantine material.quarantine status?
There shall be procedures or work instructionsavailable to heat treat personnel covering the heat
Are there procedures ortreating process. These procedures or workwork instructionsinstructions shall include methods of addressingavailable to heat treatpotential emergencies (such as power failure),personnel that defineequipment start-up, equipment shut-down, productthe heat treatingsegregation (See 2.8), product inspection, andprocess?general operating procedures. These procedures or
work instructions shall be accessible to shop floorpersonnel.
The organization shall provide employee training forall heat treating operations. All employees,includingbackup and temporary employees, shall be trained.Documented evidence shall be maintained showingthe employees trained and the evidence shallinclude an assessment of the effectiveness of thetraining. Management shall define the qualificationrequirements for each function, and ongoing orfollow-up training shall also be addressed.
1.15
1.16
Is managementproviding employeetraining for heattreating?
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Special Process: Heat Treat System Assessment
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1.17
The organization shall maintain a responsibility
Is there a responsibilitymatrix identifying all key management and
matrix to ensure that allsupervisory functions and the qualified personnelkey management andwho may perform such functions. It shall identifysupervisory functionsboth primary and secondary (backup) personnel forare performed bythe key functions (as defined by the rganization).qualified personnel?This matrix shall be readily available to
management at all times.
1.18
The organization shall have a documented
preventive maintenance program for key processequipment (as identified by the organization). Theprogram shall be a closed-loop process that tracksmaintenance efforts from request to completion toassessment of effectiveness. Equipment operatorsshall have the opportunity to report problems, and
Is there a preventive
problems shall also be handled in a closed-loop
maintenance program?
manner.
Is maintenance data
Company data, e.g., downtime, quality rejects, first-being utilized to form a
time-through capability, recurring maintenance work
predictive maintenance
orders, and operator-reported problems, shall be
program?
used to improve the preventive maintenanceprogram. Furnaces and generators shall be
scheduled for burn-out at frequencies determinedby the organization (see Section 1 of the ProcessTables).
Maintenance data shall be collected and analyzedas part of a predictive maintenance program.Has the Heat Treaterdeveloped a criticalspare part list and arethe parts available tominimize productiondisruptions?
1.19
The heat treater shall develop and maintain acritical spare parts list and shall ensure theavailability of such parts to minimize productiondisruptions.
CQI-9
Special Process: Heat Treat System Assessment
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Section 2 - Floor and Material Handling Responsibility
It is critical that all customer requirements and lot
identification be adequately transferred to internalheat treat documents. The facility shall ensure thatthe data entered in the receiving system match theinformation on the customer's shipping documents.
Does the facility ensure
Documented processes and evidence of
that the data entered in
compliance shall exist, e.g., shop travelers, work
the receiving system
orders, etc. Sometimes the material received does
matches the information
not precisely correspond to customer shipping
on the customer's
documents. The facility shall have a detailed
shipping documents?
process in place to resolve receiving discrepancies.The requirements stated above also apply to
captive heat treat departments. This process refersto receiving and shipping the parts in and out of theheat treat department.
Procedures for part and container identification helpto avoid incorrect processing or mixing of lots.Appropriate location and staging within the facilityalso help to ensure that orders are not shipped untilall required operations are performed. Customerproduct shall be clearly identified and staged
throughout the heat treat process. Non-treated, in-process, and finished product shall be properlysegregated and identified. All material shall bestaged in a dedicated and clearly defined area.Out-going lot(s) shall be traceable to the incominglot(s).
The discipline of precisely identifying lots and linkingall pertinent information to them enhances the abilityto do root cause analysis and continualimprovement.
2.1x
2.2
Is product clearlyidentified and stagedthroughout the heattreat process?
2.3
Is lot traceability andintegrity maintainedthroughout allprocesses?
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Special Process: Heat Treat System Assessment
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2.4
The control of suspect or non-conforming product is
necessary to prevent inadvertent shipment orcontamination of other lots. Procedures shall be
Are procedures
adequate to prevent movement of non-conforming
adequate to prevent
product into the production system. Procedures
movement of non-shall exist addressing proper disposition, product
conforming product into
identification, and tracking of material flow in and
the production system?
out of the hold area. A non-conforming hold areashall be clearly designated to maintain segregationof such material.Heat-treating furnaces and other processing
equipment contain areas that have a risk of trapping
Is there a system toor holding parts. Such trapping of parts can lead toidentify trap points in thedamage, improperly processed parts or lotentire heat treat processmixing/contamination. A system shall exist to
to reduce risk of mixedidentify trap points in the entire heat treat process toparts (inappropriate,reduce risk of mixed parts (inappropriate, non-heatnon-heat treated, ortreated, or improperly heat treated parts). The heatimproperly heat treatedtreater shall have documented procedures toparts)?identify and monitor trap points for each
process/equipment. Monitoring of potential trappoints shall occur for every part changeover.Containers handling customer product shall be freeof inappropriate material. After emptying and beforere-using containers, containers shall be inspected to
Are containers free ofensure that all parts and inappropriate material haveinappropriate material?been removed. The source of inappropriate material
shall be identified and addressed. This is to ensurethat no nonconforming heat treated parts or
inappropriate material contaminate the finished lot.
Furnace loading parameters shall be specified,
documented, and controlled. Examples include feedrate, belt speed, number of parts per fixture, andload weight. Refer to Process Tables, Section 3.0,for frequency of checks.
2.5
2.6
2.7
Is furnace loading
specified, documentedand controlled?
CQI-9
Special Process: Heat Treat System Assessment
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2.8
Unplanned or emergency downtime greatly raises
the risk of improper processing. Operators shall betrained in material handling, containment action,
Are operators trained in
and product segregation in the event of an
material handling,
equipment emergency including power failure.
containment action and
Training shall be documented. Work instructions
product segregation in
specifically addressing potential types of equipment
the event of an
emergencies and failures shall be accessible to and
equipment emergency
understood by equipment operators. These
including power failure?
instructions shall address containment actions
related to all elements of the heat-treating process,e.g., loading, austenitizing, quenching, tempering.Handling, storage, and packaging shall be adequateto preserve product quality. The heat treater’sfurnace loading system, in-process handling, and
Is the handling, storageshipping process shall be assessed for risk of partand packagingdamage or other quality concerns. Some equipmentadequate to preserveincludes conveyors and other moving componentsproduct quality?that may not be able to handle all part
configurations. Other practices such as stacking ofoverloaded containers can also increase the risk ofpart damage.
2.9
2.10
Plant cleanliness, housekeeping, environmental,and working conditions shall be conducive to
Are plant cleanliness,
controlling and improving quality. The heat treater
housekeeping,
should evaluate such conditions and their effect on
environmental, and
quality. A housekeeping policy shall be clearly
working conditions
defined and executed. The facility shall be reviewed
conducive to control and
for conditions that are detrimental to quality
improved quality?
processing such as loose parts on floor, oil aroundquench tanks, inadequate plant lighting, smoke, etc.
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2.11
Many heat-treated parts are subjected to surface
finish or appearance operations such as plating orcoating after heat treatment. Parts shall be freefrom contaminants that are detrimental to
subsequent processes or the product. Pre-wash (ifapplicable) and post-wash parameters shall bemonitored and documented. Oils and other
Are parts free from
contaminants or residues can be difficult to remove
contaminants that would
once subjected to the heat treatment process.
be detrimental to the
Review the chemical supplier’s recommendation for
heat treatment of the
cleaning the system. Parts shall be free of rust,
product?
burrs, chips, detrimental amounts of drawingcompound, cutting fluids, rust preventing oils,lubricants, etc., prior to heat treat.
Note: Refer to the appropriate heat treater'srequirements and specifications to determine
acceptability. Refer to Process Table, Section 5.0,for frequency of checking washer solutions.The quenching system shall be monitored,documented, and controlled. The temperature,
agitation, level, concentration (if applicable), time inthe quenchant, and additions shall be controlled tothe heat treater's specifications. Refer to ProcessTables, Sections 3.0 and 5.0, for frequency of
Is the quenching system
checks. Computer-monitoring equipment, with
monitored, documented,
alarms and alarm logs, satisfy the verification
and controlled?
requirement. Quench delay tolerance and alarm isrequired for furnaces with integral quench tanks.Temper delay time shall be specified by the heattreater for parts that are quenched and tempered,e.g., carburizing, carbonitriding, neutral hardening,solution treating and aging.
2.12
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2.13
Parts are often dipped in or sprayed with rust
preventive solutions immediately after the heat
Is soluble oil or othertreating process. Soluble oil solutions or other rustrust preventivepreventive solutions shall be monitored andmonitored andcontrolled, if applicable. The heat treater shall havecontrolled if applicable?and maintain documented tolerances for the
solutions. Refer to Process Tables, Section 5.0, forfrequency of checks.
Process control parameters shall be monitored perfrequencies specified in Process Tables. Refer toProcess Tables, Section 3.0. Computer monitoringequipment with alarms and alarm logs satisfy theverification requirement. A designated floor personshall verify the process parameters, e.g., byinitialing a strip chart or data log. Managementreview is required per Question 1.9.
2.14
Are process controlparameters monitoredper frequencies
specified in ProcessTables?
2.15
Are In-Process / FinalTest Frequencies
performed as specifiedin Process Tables?
In-Process / Final Test Frequencies shall be
performed as specified in Process Tables. Refer toProcess Tables, Section 4.0.
Product test equipment shall be verified. Test
equipment shall be verified/calibrated per applicablecustomer-specific standard or per an applicableconsensus standard such as those published byASTM, DIN, EN, ISO, JIS, NIST, SAE etc.
Verification/calibration results shall be internallyreviewed, approved, and documented. Refer toProcess Tables, Section 1.0, for frequency ofchecks.
2.16
Is product test
equipment verified?
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Section 3 - Equipment
The heat-treat furnaces, generators, and quench
Do furnaces,systems shall have proper process controls andgenerators, and quenchrelated equipment. Examples include temperature,systems have propercarbon potential/dew point, gas flow, quenchprocess controlmonitoring systems including agitation, temperatureequipment?control and quenching oil analysis, etc. as listed in
the applicable Process Tables, Section 1.0.The calibration and certification of the process
Are process equipment
equipment shall be checked at regular specified
calibrations and/or
intervals. Refer to the applicable Process Tables,
verification certified,
Sections 1.0 and 2.0, for equipment calibration or
posted, and current?
certification time tables.Are thermocouples &protection tubes
checked or replaced perProcess Tables?
The thermocouples and protection tubes shall bechecked or replaced in compliance to a preventivemaintenance schedule. Refer to the applicableProcess Tables, Section 2.0.
3.1
3.2
3.3
3.4
Temperature uniformity surveys shall be conductedper the requirements in the applicable Process
Are temperatureTables, Section 2.0. The frequency reductionsuniformity surveysallowed in AMS 2750D are not allowed under thisperformed perdocument. Certain furnace designs, e.g., rotaryrequirements in Processretorts preclude direct temperature profiles.Tables?Alternate test methods per AMS 2750D 3.5.15 are
acceptable for furnaces where temperatureuniformity studies are not possible.Is the variation of thefurnace controlled
thermocouple from setpoint within therequirements in theProcess Table?
The variation between the furnace-control
thermocouple and the set point temperature shall bewithin the limits defined in the applicable ProcessTables, Section 2.0. This does not apply to the firstzone of a multi-zone continuous furnace.
3.5
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Special Process: Heat Treat System Assessment
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Are the process &
equipment alarm checksbeing tested quarterly orafter any repair orrebuild?
Requirements and Guidance
The heat treater shall have a list of heat treat
process and equipment alarms. These alarms shallbe independently tested quarterly at a minimum,and after any repair or rebuild. These checks shallbe documented.
Objective Evidence
3.6
3.7
Generator and furnace atmosphere carbon
potential/dew point shall be continuously monitored,automatically controlled, and documented. This
requirement is specific to Process Table 1, Sections1.0 and 3.0, for carburizing, carbontiriding, andneutral hardening. Continuous monitoring and
automatic control of the carbon potential/dew pointis required for all generators and atmospherefurnaces except rotary retort and shaker furnacesthat preclude in situ control and monitoring. Forrotary retort and shaker furnaces, the methoddescribed in AMS 2750D 3.5.15.2 \"Property
Surveys\" shall be used to ensure adequate controlof the furnace atmosphere. If generators are not
Are generators andused, the flow rates of the supplied atmospherefurnace atmospheresgases shall be monitored and controlled. Thecontinuously monitored,assessor shall verify the effectiveness of theautomatically controlled,atmosphere control system per customerand documented?requirements, the heat treater’s control plan, and
internal procedures.
The atmosphere control system shall maintain theatmosphere dew point/carbon potential set pointwithin the parameters specified in the control plan orinternal procedures. The heat treater shall have aback-up method of checking the carbon
potential/dew point. Examples are dew point,
electrical wire resistance, gas analysis, shim stock,carbon bar, etc. The automatic and continuousatmosphere control system shall consist of sensorssuch as oxygen probes or on-line infraed (IR) gasanalysis. See Process Table A, Section 3.0 forverification frequencies.
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3.8
When the back-up
verification check of theatmosphere does notagree or correlate withinpre-established limitswith the primary controlmethod (carbonpotential/dew pointreading), is correlationof the carbon-bearingatmosphere to the
primary control methodre-established?
This issue is specific to Process Table A,
carburizing, carbonitriding, and neutral hardening.When the back-up verification check of the
atmosphere does not agree or correlate within pre-established limits with the primary control method(carbon potential/dew point reading), the heattreater shall resolve the out-of-limit discrepancy.The back-up atmosphere monitoring system readingand the automatically controlled atmosphere dewpoint/carbon potential reading shall be maintainedwithin the correlation limits specified in the controlplan or internal procedures. These range tolerancesvary with the specific heat treat process and theequipment used.
The heat treater shall make appropriate technicaladjustments and corrections and then re-establish/demonstrate the correlation of the actual
atmosphere carbon potential/dew point reading tothe primary control and back-up atmospherereading. The range tolerances for correlationbetween the two readings shall be in the controlplan or internal procedures. The back-up carbonpotential/dew point reading shall be established usin• Carbon bar or slug• Shim stock• 3-gas analyzer• Dew point
• Hot wire resistance
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All ammonia lines to furnaces shall be equippedwith quick disconnects or a three-valve fail-safe ventsystem. Normal valves may allow ammonia to leakthrough even when they are closed. This can beundesirable and detrimental in heat treat processesnot specifying/requiring ammonia.
• A quick disconnect shall be present in any
ammonia line going to a furnace. This line shall bedisconnected after carbonitriding (or any otherprocess using ammonia) before another heattreating operation not specifying/using ammoniabegins.
• An alternative three-valve ammonia \"fail-safe\" ventsystem is permitted. See the definition “Three ValveFail-Safe Vent” and diagram in the glossary.
• Documentation shall show when ammonia linesare disconnected for non-ammonia bearingatmosphere processes.
Objective Evidence
3.9
Are all ammonia linesequipped with quickdisconnects or a threevalve fail safe ventsystem?
3.10
This is applicable to fasteners and small metalparts. The heat treater shall perform a minimum 3hours oxidizing burn-out prior to processing product
For fasteners and small
not requiring ammonia as an addition. Ammonia
metal parts, is a
pick-up can be undesirable in parts and heat treat
minimum of 3 hours
processes not specifying/requiring ammonia as an
allocated for an
addition. Log book, data logger, or other records
oxidizing burn-out prior
shall document the actual oxidizing burn-out time
to processing product
and that sufficient time has been allocated to
not requiring ammonia?
remove ammonia from the furnace prior toprocessing parts in heat treat processes notspecifying ammonia.All atmosphere furnaces and generators (outputtrim/adjustment gas) shall have flow scopes or flow
Do all atmosphere
meters for all gases. Flow scopes and meters shall
furnaces and generators
be periodically serviced per the heat treater's
have flow scopes or flow
preventive maintenance program. Cleaning and
meters for all gases?
proper re-assembly procedures shall bedocumented.
3.11
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Infrared temperature pyrometers are required at the
exit end of continuous belt furnaces running
threaded fasteners to monitor for under temperatureparts. The temperature alarm shall be within 28C(50F) of the furnace set point temperature. Resultsshall be strip charted or continuously data logged.Infrared (IR) units shall be calibrated annually at aminimum and certified. All sight glasses shall becleaned per the preventive maintenance schedule.Applicable to ferritic-nitrocarburizing, austempering,and neutral hardening in salt. The heat treater shallcheck the salt chemistry in the austenitizing saltbath, or part decarburization, daily. Refer to theapplicable Process Tables, Section 3.0, forfrequency of checks.
The heat treater shall periodically have the
quenching medium analyzed for specific quenchingcharacteristics, e.g., cooling curve, water content,salt concentration, as specified in the applicableProcess Tables, Section 5.0.
• The quench media characteristic tolerances shallbe specified by the quench medium supplier or theheat treater.
• Analysis shall be reviewed for conformance by theheat treater. This review shall be documented.
Objective Evidence
3.12
For threaded fasteners,are all continuous beltfurnaces equipped withsight glass inspectionports and infrared
pyrometers at dischargeend of the hardeningfurnace?
3.13
Is salt chemistry in theaustenitizing salt bathmonitored?
3.14
Is the quenchingmedium analyzed?
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For Induction Heating
3.15
Is the positioning of
each part beingcontrolled?
A method to detect proper part position, such as theuse of proximity switches, optical sensors,
mechanical probes, etc., is required for each part.The heat treater shall control the energy or powerfor each part.
• A signature monitor for each machine is preferred.A signature monitor gives the energy unit (voltage,kilowatt, etc.) vs. time or distance (for scanningsystems).
• An energy monitor or equivalent is acceptable ifapproved by the design authority.
3.16
Does the heat treatercontrol the energy orpower for each part?
3.17
The heat treater shall have a coil managementsystem. Coil refers to the heating coil and the
Does the supplier have
quench plenum.
a coil management
• Spare coils for each part shall be available onsite.
system? Coil refers to
• Coils shall conform to the approved original
the heating coil and the
design.
quench plenum.
• Engineering change approval from the customer isrequired whenever the coil design is changed.
The quench system shall be an automatic
operation. No manual quenching is allowed unlessspecifically approved by the authorized customerrepresentative. Quenching shall be automaticallyinitiated and controlled
3.18
Is quench systemautomatic?
3.19
Does each lot of partsThe heat treater shall perform first piece set-up forhave first piece set-up?each lot of parts
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
Section 4 - Job Audit
Job Identity:Customer:
Shop Order Number:
Part Number:Part Description:
Material:
Heat Treat Requirements:
Job (Shop) Order orReference Documentation
Requirement
Question #Job Audit Question
Related HTSAQuestion #
1.21.31.41.171.151.62.12.22.32.42.11.62.72.9
Customer or Internal
RequirementActual Condition(Objective Evidence)Pass / Fail /
N/A
4.1
Are contract review, advance qualityplanning, FMEA, control plans, etc.,performed by qualified individuals?Does the heat treat facility have thecustomer specifications for the part?Is a shop traveler created to meetcustomer requirements?
Is material identification (part
numbers, lot numbers, heat numbers,contract numbers, etc.) maintainedthroughout the heat treat process?Is there documented evidence ofReceiving Inspection?Are the Loading / Rackingrequirements identified?
N/A
4.24.34.4
N/A
4.54.6
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
Section 4 - Job Audit
Job Identity:Customer:
Shop Order Number:
Part Number:Part Description:
Material:
Heat Treat Requirements:
Job (Shop) Order orReference Documentation
Requirement
Question #Job Audit Question
Related HTSAQuestion #
1.51.62.12.142.15
Customer or Internal
RequirementActual Condition(Objective Evidence)Pass / Fail /
N/A
4.7
Is the proper recipe or processspecification (cycle times,
temperature, atmosphere, etc.) used?Refer to Process Tables, Section 3.0,for specific parameters. List
parameters that were verified in thisaudit in the spaces provided below.What are the product inspectionrequirements?Requirement: (1)Test Method:
Test frequency or quantity:Selection of samples:SpecificationRequirement: (2)Test Method:
Test frequency or quantity:Selection of samples:SpecificationRequirement: (3)Test Method:
Test frequency or quantity:Selection of samples:
4.84.8.1
2.15
4.8.2
4.8.3
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
Section 4 - Job Audit
Job Identity:Customer:
Shop Order Number:
Part Number:Part Description:
Material:
Heat Treat Requirements:
Job (Shop) Order orReference Documentation
Requirement
Question #Job Audit Question
Related HTSAQuestion #Customer or Internal
RequirementActual Condition(Objective Evidence)Pass / Fail /
N/A
Specification
4.8.4Requirement: (4)
Test Method:
Test frequency or quantity:Selection of samples:Specification
Operator or Inspector Responsibilities
4.9Were appropriate process steps
signed off?
4.10
4.11
4.12
Were all inspection steps, asdocumented in control plan,performed?
Were steps/operations performed thatwere not documented in the controlplan?
If additional steps were performed,were they authorized?
1.42.22.32.141.21.41.21.41.61.21.41.61.111.171.11
4.13
Does the governing specificationallow reprocessing or rework?
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
Section 4 - Job Audit
Job Identity:Customer:
Shop Order Number:
Part Number:Part Description:
Material:
Heat Treat Requirements:
Job (Shop) Order orReference Documentation
Requirement
Question #Job Audit Question
Related HTSAQuestion #
2.142.151.172.62.11
Customer or Internal
RequirementActual Condition(Objective Evidence)Pass / Fail /
N/A
If the order was certified, did thecertification accurately reflect theprocess performed?
4.15Was the certification signed by an
authorized individual?
4.16Are the parts and containers free of
inappropriate objects orcontamination?
Packaging Requirements
4.17Are packaging requirements
identified?
4.18Are parts packaged to minimize
mixed parts (for example, partspacked over height of container)?Shipping Requirements
4.19Were the parts properly identified?
4.20
Were the containers properly
labeled?
4.14
2.92.9
2.32.92.32.9
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening /
Austempering / Martempering / Tempering / Precipitation Hardening - Aging
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).-----indicate \"not applicable\".
Item#
1.0A1.1A1.2
RelatedHTSAQuestion #
Category/Process Steps
PROCESS AND TEST EQUIPMENTREQUIREMENTS
All furnaces, generators and quench systemsshall have temperature indicating instruments.Continuous strip charts and/or data loggers arerequired for temperature and carbon monitoringunit, e.g., dew point, oxygen probe, IR gasanalyzer,etc.
A program for furnace and generator burnout isrequired (applies to carbon bearingatmospheres).
Furnace weigh scales shall be verified quarterlyand calibrated annually at a minimum.
Dew pointers, 3-gas analyzers, spectrometers,and carbon IR combustion analyzers (shim stockanalysis), used to verify carbon potential infurnaces, shall be calibrated annually at aminimum.
Verification of calibration of spectrometers, andcarbon IR combustion analyzers, shall bechecked daily or prior to use.
Verification of calibraion of 3-gas analzers withzero gas and span gas shall be performed weeklyat a minimum.
Oxygen probe controllers shall be calibratedquarterly at a minimum.
All hardness test equipment (for each scale used)shall be calibrated semi-annually minimum, andverified daily minimum per the applicable ASTMstandard.
Files shall be verified daily (or prior to use) withprovers per SAE J8.
Refractometers (typically used to check polymerquenchants and washer solutions) shall be
verified daily (with distilled water) and calibratedannually (per manfacturer's requirements) at aminimum.PYROMETRY
Thermocouples and calibration of thermocouplesshall conform to AMS 2750D.
Instrument Calibration per AMS 2750D shall bequarterly at a minimum.
Frequency reductions per AMS 2750D are notallowed.
BatchFurnaceContinuousFurnace *
Generators
3.13.73.13.7
YesYes
YesYes
YesYes
A1.31.18YesYesYes
A1.4A1.5
3.23.2
Yes -----
Yes -----
----- -----
A1.63.2 ----- ----- -----
A1.73.2 ----- ----- -----
A1.8A1.9
3.22.16
Yes -----
Yes -----
Yes -----
A1.10A1.11
2.163.2
----- -----
----- -----
----- -----
2.0A2.1A2.2
3.23.33.23.3
YesYes
YesYes
YesYes
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening /
Austempering / Martempering / Tempering / Precipitation Hardening - Aging
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).-----indicate \"not applicable\".
Item#
A2.3
RelatedHTSAQuestion #
3.23.3
Category/Process Steps
CQI-9 requires a comparative check of the controltemperature sensor(CTS) in the Qualified WorkZone to a (1) calibrated test temperature sensor(CTTS) or, (2) resident thermocouple(R-T/C).(1) The CTS shall be within an operating
temperature range of +/- 5C(or +/- 10F) of theCTTS. This check shall be performed monthly.(2) Within the operating temperature range thedifference between the CTS and R-T/C readingsshall be no more than +/- 1C(or +/-2F) asdetermined at the time of the most recent
temperature uniformity survey. This check shallbe performed weekly.
Any actions to correct a failing reading or validatea test result shall be documented. Additionally,Type K and N thermocouples shall be checkedmonthly for equipment operating at or above760C(1400F) and changed annually at a
minimum. Type K and N thermocouples shall bechecked quarterly for equipment operating below760C(1400F) and changed every two years at aminimum.
Type R and S thermocouples shall be checkedmonthly for equipment operating at or above760C(1400F) and changed every two years at aminimum. Protection Tubes shall be visuallychecked at the same frequency asthermocouples.
BatchFurnace
Yes
ContinuousFurnace *
Yes
Generators
Yes
A2.43.4
Temperature Uniformity Survey (TUS): refer toAMS 2750D for procedures. TUS frequency shallbe annual and after major rebuild.
Temperature uniformity tolerance for hardeningfurnaces shall be +/- 14 C (25 F). Temperatureuniformity tolerance for tempering furnaces shallbe +/- 11 C (20 F).
Minimum and maximum temperature ranges shallbe tested per AMS 2750D. Exception: If theoperating range of the Qualified Work Zone isequal to or less than 85C(153F) then only onetemperature is required to be tested. The
temperature shall be within the operating range ofthe Qualified Work Zone.
Frequency reductions per AMS 2570D are notallowed.
Yes
Yes - In Qualified Work
Zone
-----
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening /
Austempering / Martempering / Tempering / Precipitation Hardening - Aging
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).-----indicate \"not applicable\".
Item#
A2.5
RelatedHTSAQuestion #
3.5
Category/Process Steps
Recorded temperature(s) for austenitizing
processes shall be controlled within +/- 9C (15F)of the set point as evidenced by continuous
recording pyrometers.Furnace temperature shallbe controlled with soak times starting at the lowertolerance limit (as defined above).
Recorded temperature(s) for tempering andprecipitation hardening processes shall be
controlled within +/- 6C (10F) of the set point asevidenced by continuous recording pyrometers.Furnace temperature shall be controlled with soaktimes starting at the lower tolerance limit (asdefined above).
Infrared pyrometers shall be calibrated to a blackbody furnace annually.
PROCESS MONITOR FREQUENCIESMonitor primary temperature controlinstrument(s).
BatchFurnace
Yes
ContinuousFurnace *
Yes - In Qualified Work
Zone
Generators
-----
A2.63.5Yes
Yes - In Qualified Work
Zone
-----
A2.73.0A3.1
3.2 -----
1.42.14
Each batch or
continuous recordingwith sign-off every 2hours. Alarm systemssatisfy the sign-offrequirement
-----
Each lot or continuousrecording with sign-offevery 2 hours. Alarmsystems satisfy thesignoff requirement
-----
Each Shift
A3.2
1.42.143.71.42.143.7
Monitor generator atmospheresContinuous
A3.3
A3.4
1.42.143.71.42.143.131.42.12
Monitor primary furnace atmosphere control(s)**.Continuous recording
with sign-off every 2hours. Alarm systemssatisfy the sign-offrequirement
Verify primary atmosphere control method byDailybackup method**.
For austentizing salt baths: Salt chemistry(solubleoxides) or decarburization on the parts shall bechecked daily
Quench Media Process Parameters--Temperature
Daily
Continuous recordingwith sign-off every 2hours. Alarm systemssatisfy the sign-offrequirement
Daily
-----
Daily
A3.5Daily -----
A3.6
--Quench Level--Agitation
Each batch or
continuous recordingwith sign-off every 2hours. Alarm systemssatisfy the sign-offrequirementDaily--Daily visual check isrequired
--Monitor each load inthe absence of analarm system.
Each lot or continuousrecording with sign-offevery 2 hours. Alarmsystems satisfy thesignoff requirement
Daily
--Daily visual check isrequired
--Monitor every 2 hrs inthe absence of analarm system
-----
----- -----
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening /
Austempering / Martempering / Tempering / Precipitation Hardening - Aging
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).-----indicate \"not applicable\".
Item#
A3.7
RelatedHTSAQuestion #
1.42.141.42.71.42.12
Category/Process Steps
Monitor time in furnace, cycle time or belt speed
BatchFurnace
Each batch
ContinuousFurnace *
Twice/shift & after anychange in the beltspeed
Twice/shift & after anychange in loading rateEach basket for pusher-type continuousfurnaces. Notapplicable for beltfurnaces.
Generators
-----
A3.8A3.9
Monitor load size or fixturing or loading rate asapplicable.
Quench Delay Time -Alarm system shall be based on the time that theload exits the furnace to the time the load is at thebottom of the quench tank.
Each batchEach batch
----- -----
4.0A4.1A4.2A4.3A4.45.0A5.1
2.123.141.42.151.42.151.42.151.42.15
IN-PROCESS/FINAL TEST FREQUENCIESMicrostructureSurface hardness
Core hardness (when specified)Case depth (when specified)
QUENCHANT AND SOLUTION TESTFREQUENCIES
Polymer Quench Media- Concentration
- Quenchability Check; e.g., cooling curve,viscosity, or titration
DailyEvery six months
DailyEvery six months
----- -----Daily per furnaceEach batchEach batch Each batch
Daily per furnaceEvery 2 hours minimum
Every 4 hoursEvery 4 hours
----- ----- ----- -----
A5.2A5.3A5.4
2.123.142.123.142.123.142.123.14
Water Quench Media- Suspended solidsSalt Quench Media- Analysis & ContaminantsBrine or Caustic Quench Media- Concentration and/or Specific Gravity- Suspended solidsOil Quench Media
- Water content, suspended solids,viscosity, cooling curve, total acid,and flash point.
Rust Preventive - Soluble Oil- Concentration
2x / weekDailyEach shift
2x / weekDaily Each shift
----- ----- -----Washers
- Concentration of cleaner
- Temperature of solution (required if temperatureis specified to be above ambient temperature).
Quarterly
Quarterly
-----DailyEvery six months
DailyEvery six months
----- -----Every six months
Every six months
-----Every six months
Every six months
-----
A5.5
A5.6A5.7
2.132.11
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.-----indicate \"not applicable\".
RelatedHTSAQuestion #
Item#
1.0B1.1
Category/Process Steps
PROCESS AND TEST EQUIPMENTREQUIREMENTS
All furnaces, generators and quench
systems shall have temperature indicatinginstruments.
Continuous strip charts and/or data
loggers are required for temperature andcarbon monitoring unit, e.g., dew point,oxygen probe, IR gas analyzer,etc.A program for furnace and generator
burnout is required. Not required for retortgas nitriding.
For austentizing salt baths: Saltchemistry(soluble oxides) or
decarburization on the parts shall bechecked daily.
Furnace weigh scales shall be verifiedquarterly and calibrated annually at aminimum.
Dew pointers and gas analyzers, used toverify proper atmosphere in furnaces,
shall be calibrated annually at a minimum.All hardness test equipment (for eachscale used) shall be calibrated semi-annually minimum, and verified dailyminimum per the applicable ASTMstandard.
Files shall be verified daily (or prior touse) with provers per SAE J8.Refractometers (typically used to checkpolymer quenchants and washersolutions) shall be verified daily (withdistilled water) and calibrated annually(per manfacturer's requirements) at aminimum.PYROMETRY
Thermocouples and calibration ofthermocouples shall conform to AMS2750D.
Instrument Calibration per AMS 2750Dshall be quarterly at a minimum.
Frequency reductions per AMS 2750Dare not allowed.
BatchFurnaceContinuousFurnace *
GeneratorsSalt Bath
3.13.73.13.7
YesYesYesYes
B1.2YesYesYes
Yes - Fortemperature only
B1.31.18YesYes ----- -----
B1.4
3.123.13
----- ----- ----- -----
B1.53.2YesYes ----- -----
B1.63.2 ----- ----- ----- -----
B1.72.16 ----- ----- ----- -----
B1.8B1.9
2.163.2
----- -----
----- -----
----- -----
----- -----
2.0B2.1
3.23.33.23.3
YesYesYesYes
B2.2YesYesYesYes
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.-----indicate \"not applicable\".
RelatedHTSAQuestion #
3.23.3
Item#
B2.3
Category/Process Steps
CQI-9 requires a comparative check ofthe control temperature sensor(CTS) inthe Qualified Work Zone to a (1)calibrated test temperature sensor
(CTTS) or, (2) resident thermocouple(R-T/C).
(1) The CTS shall be within an operatingtemperature range of +/- 5C(or +/- 10F) ofthe CTTS. This check shall be performedmonthly.
(2) The relationship between the CTS andR-T/C at the operating temperature rangeshall be within +/- 1C(or +/-2F) of theirrelationship determined at the time of themost recent temperature uniformitysurvey. This check shall be performedweekly.
Any actions to correct a failing reading orvalidate a test result shall be
documented. Additionally, Type K and Nthermocouples shall be checked monthlyfor equipment operating at or above
760C(1400F) and changed annually at aminimum. Type K and N thermocouplesshall be checked quarterly for equipmentoperating below 760C(1400F) and
changed every two years at a minimum.Type R and S thermocouples shall bechecked monthly for equipment operatingat or above 760C(1400F) and changedevery two years at a minimum.Protection Tubes shall be visuallychecked at the same frequency asthermocouples.
BatchFurnace
Yes
ContinuousFurnace *
Yes
Generators
Yes
Salt Bath
Yes
B2.43.4
Temperature Uniformity Survey (TUS):refer to AMS 2750D for procedures. TUSfrequency shall be annual and after majorrebuild.
Temperature uniformity tolerance shall be+/- 9 C (25 F).
Minimum and maximum temperatureranges shall be tested per AMS 2750D.Exception: If the operating range of theQualified Work Zone is equal to or lessthan 85C(153F) then only one
temperature is required to be tested. Thetemperature shall be within the operatingrange of the Qualified Work Zone.
Frequency reductions per AMS 2570Dare not allowed.
Yes
Yes - In QualifiedWork Zone
-----Yes
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.-----indicate \"not applicable\".
RelatedHTSAQuestion #
3.5
Item#
B2.5
Category/Process Steps
Recorded temperature(s) shall be
controlled within +/- 9C (15F) of the setpoint as evidenced by continuousrecording pyrometers.Furnace
temperature shall be controlled with soaktimes starting at the lower tolerance limit(as defined above)
Infrared pyrometers shall be calibrated toa black body furnace annually.
PROCESS MONITOR FREQUENCIESMonitor primary temperature controlinstrument(s).
BatchFurnace
Yes
ContinuousFurnace *
Yes - In QualifiedWork Zone
Generators
-----
Salt Bath
Yes
B2.63.0B3.1
3.2
1.42.14
B3.2
1.42.143.71.42.143.7
Monitor generator atmospheres
Each batch orcontinuousrecording withsign-off every 2hours. Alarmsystems satisfythe sign-off
-----Each lot orcontinuousrecording withsign-off every 2hours. Alarmsystems satisfythe signoff
-----
Each Shift
Every 2 hours &after any change
Continuous -----
B3.3
Monitor primary furnace atmospherecontrol(s).
B3.4
1.43.71.43.71.42.143.131.42.12
Each batch (rotaryfurnace only) orcontinuousrecording withsign-off every 2hours. Alarmsystems satisfythe sign-off
itDissociation of ammonia shall be checkedEach batch and
in gas nitriding.every 4 hours
minimum
Each batch
-----
Continuousrecording withsign-off every 2hours. Alarmsystems satisfythe sign-offrequirementEvery 4 hours
-----Daily
Daily -----
B3.5B3.6
Gas ratios for ferritic nitrocarburizing shallbe checked.
Check salt chemistry (souble oxides) insalt baths used for autenitizing, ordecarburization on the parts.
Quench Media Process Parameters--Temperature
Every 2 hoursminimum
-----
----- -----
-----Daily
B3.7
--Quench Level--Agitation
Each batch orcontinuousrecording withsign-off every 2hours. Alarmsystems satisfythe sign-offrequirement
Daily--Daily
--Monitor eachload in theabsence of analarm system.
Each lot orcontinuousrecording withsign-off every 2hours. Alarmsystems satisfythe signoffrequirement
Daily--Daily
--Monitor every 2hours in theabsence of analarm system
-----
Each batch orcontinuous
recording with sign-off every 2 hours.Alarm systemssatisfy the sign-offrequirement
DailyDaily
----- -----
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.-----indicate \"not applicable\".
RelatedHTSAQuestion #
1.42.141.42.71.42.12
Item#
B3.8
Category/Process Steps
Monitor time in furnace, cycle time or beltspeed
Monitor load size or fixturing or loadingrate as applicable.
Quench Delay Time if applicable -Alarm system shall be based on the timethat the load exits the furnace to the timethe load is at the bottom of the quenchtank.
IN-PROCESS/FINAL TESTFREQUENCIESMicrostructureSurface hardness
Core hardness (when specified)Case depth (when specified)
QUENCHANT AND SOLUTION TESTFREQUENCIES
Quench Media Controls If Applicable
BatchFurnace
Each batch
ContinuousFurnace *
Twice/shift & afterany change in thebelt speedTwice/shift & afterany change inloading rateEach basket ifapplicable
Generators
-----
Salt Bath
Each batch
B3.9Each batch -----Each batch
B3.10Each batch -----Each batch
4.0B4.1B4.2B4.3B4.45.0
1.42.151.42.151.42.151.42.15
Daily per furnaceDaily per furnaceEach batchEach batch Each batch
Every 2 hoursminimumEvery 4 hoursEvery 4 hours
----- ----- ----- -----
Daily per furnaceEach batchEach batch Each batch
B5.1
2.123.14
Polymer Quench Media- Concentration
- Quenchability Check; e.g., coolingcurve, viscosity, or titration
Daily
Daily
----- ----- ----- -----Every six monthsEvery six months
B5.2
2.123.142.123.142.123.14
Water Quench Media- Suspended solidsSalt Quench Media- Analysis & ContaminantsBrine or Caustic Quench Media- Concentration and/or Specific Gravity- Suspended solidsOil Quench Media
- Water content, suspended solids,viscosity, cooling curve, total acid,and flash point.
Rust Preventive - Soluble Oil- Concentration
2x / weekDaily
2x / weekDaily
----- -----2x / weekDaily
Washers
- Concentration of cleaner
Quarterly
Quarterly
----- -----DailyDaily
Every six monthsEvery six months
----- ----- ----- -----Every six monthsEvery six months
-----Every six months
Every six monthsEvery six months
----- -----
B5.3B5.4
B5.5
2.123.14
B5.6B5.7
2.132.11
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.-----indicate \"not applicable\".
RelatedHTSAQuestion #
Item#Category/Process Steps
- Temperature of solution (required iftemperature is specified to be aboveambient temperature).
BatchFurnace
Each shift
ContinuousFurnace *
Each shift
Generators
-----
Salt Bath
Each shift
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE C - Aluminum Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer requirements.
*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.-----indicate \"not applicable\".
HTSAQuestion#
Treating and AgingSolution Treating
Furnacesand Aging Furnaces
Annealing
Furnace
Item#
1.0C1.1C1.2C1.3
Category/Process Steps
PROCESS AND TEST EQUIPMENTREQUIREMENTS
All furnaces and quench systems shall havetemperature indicating instruments.
Continuous strip charts and/or data loggers arerequired for temperature sensors.
All hardness test equipment (for each scaleused) shall be calibrated semi-annually
minimum, and verified daily minimum per theapplicable ASTM standard.
Furnace weigh scales shall be verified quarterlyand calibrated annually at a minimum
Refractometers (typically used to check polymerquenchants and washer solutions) shall be
verified daily (with distilled water) and calibratedannually (per manfacturer's requirements) at aminimum.
PYROMETRY
Thermocouples and calibration of thermocouplesshall conform to AMS 2750D.
Instrument Calibration per AMS 2750D shall bequarterly at a minimum.
Frequency reductions per AMS 2750D are notallowed.
CQI-9 requires a comparative check of the
control temperature sensor(CTS) in the QualifiedWork Zone to a (1) calibrated test temperaturesensor (CTTS) or, (2) resident thermocouple(R-(1) The CTS shall be +/- 5C(or +/- 10F) of aCTTS at the operating temperature range; thischeck shall be performed monthly.
(2) The relationship between the CTS and R-T/Cat the operating temperature range shall bewithin +/- 1C(or +/-2F) of their relationshipdetermined at the time of the last temperatureuniformity survey; this check shall be performedAny actions to correct a failing reading orvalidate a test result shall be documented.
Additionally, Type K and N thermocouples shallbe checked monthly for equipment operating ator above 760C(1400F) and changed annually ata minimum. Type K and N thermocouples shallbe checked quarterly for equipment operatingbelow 760C(1400F) and changed every twoType R and S thermocouples shall be checkedmonthly for equipment operating at or above760C(1400F) and changed every two years at aminimum.
Protection Tubes shall be visually checked at thesame frequency as thermocouples.
3.13.73.13.72.16
YesYes -----
YesYes -----
YesYes -----
C1.43.2YesYesYes
C1.53.2 ----- ----- -----
2.0C2.1C2.2
3.23.33.23.3
YesYes
YesYes
YesYes
C2.3
3.23.3
YesYesYes
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE C - Aluminum Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer requirements.
*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.-----indicate \"not applicable\".
HTSAQuestion#
3.4
Item#
C2.4
Category/Process Steps
Temperature Uniformity Survey (TUS): refer toAMS 2750D for procedures. TUS frequency shallbe quarterly and after major rebuild.
Temperature uniformity tolerance for solutiontreating and aging furnaces shall be +/- 6 C (+/-10 F). Temperature uniformity tolerance forannealing furnaces shall be +/- 14 C (+/- 25 F).Minimum and maximum temperature rangesshall be tested per AMS 2750D. Exception: If theoperating range of the Qualified Work Zone isequal to or less than 85C(153F) then only onetemperature is required to be tested. The
temperature shall be within the operating rangeof the Qualified Work Zone.
Frequency reductions per AMS 2570D are notallowed.
Treating and AgingSolution Treating
Furnacesand Aging Furnaces
Yes
Yes - In Qualified Work
Zone
AnnealingFurnace
Yes
C2.53.5
Recorded temperature(s) shall be controlledwithin +/- 6C (10F) of the set point as evidencedby continuous recording pyrometers. Furnacetemperature shall be controlled with soak timesstarting at the lower tolerance limit (as definedabove).
Recorded temperature(s) shall be controlledwithin +/- 9C (15F) of the set point as evidencedby continuous recording pyrometers. Furnacetemperature shall be controlled with soak timesstarting at the lower tolerance limit (as definedabove).
Infrared pyrometers shall be calibrated to a blackbody furnace annually
PROCESS MONITOR FREQUENCIESMonitor primary temperature controlinstrument(s).
Yes
Yes - In Qualified Work
Zone
-----
C2.63.5 ----- -----Yes
C2.73.0C3.1
3.2
1.42.14
Each batch or
continuous recordingwith sign-off every 2hours. Alarm systemssatisfy the sign-offrequirement
Each lot or continuousrecording with sign-offevery 2 hours. Alarmsystems satisfy thesignoff requirement
Each batch orcontinuousrecording withsign-off every 2hours. Alarmsystems satisfythe sign-offrequirement
C3.2
1.42.12
Quench Media Process Parameters- Heat treater shall specify temperature rangebased on product form and material.
Temperature shall be monitored as noted.
Each batch or
continuous recordingwith sign-off every 2hours. Alarm systemssatisfy the sign-offrequirementDaily
- Daily visual check isrequired
- Monitor each load inthe absence of an alarmsystem.
Each lot or continuousrecording with sign-offevery 2 hours. Alarmsystems satisfy thesignoff requirementDaily
- Daily visual check isrequired
- Monitor every 2 hrs inthe absence of an alarmsystem
-----
- Quench Level- Agitation
----- -----
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE C - Aluminum Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer requirements.
*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.-----indicate \"not applicable\".
HTSAQuestion#
1.42.141.42.71.42.12
Item#
C3.3
Category/Process Steps
Monitor process cycle time
Treating and AgingSolution Treating
Furnacesand Aging Furnaces
Each batch
Twice/shift & after any
change in the indexingspeed
Twice/shift & after anychange in loading rateEach load
AnnealingFurnace
Each batch
C3.4C3.5
Monitor load size or fixturing as applicable.Quench Delay Time -Quench delay time shall be based on the timethat the load exits the furnace to the time theload is at the bottom of the quench tank.IN-PROCESS/FINAL TEST FREQUENCIESHardness or tensile testing (post aging)
Each batchEach batch
Each batch
-----
4.0C4.1
1.42.15
Each batchEvery 4 hours
Each batch orevery 4 hours forcontinuousfurnaces
5.0C5.1
2.123.14
QUENCHANT AND SOLUTION TESTFREQUENCIES
Polymer Quench Media- Concentration- Suspended solids
- Quenchability Check; e.g., cooling curve,viscosity, or titration
Daily
Every six monthsEvery six months
Daily
Every six monthsEvery six months
----- ----- -----
C5.2C5.3
2.123.142.11
Water Quench Media- Suspended solidsWashers
- Concentration of cleaner
- Temperature of solution (required if
temperature is specified to be above ambienttemperature).
DailyEach shift
Daily Each shift
Daily Each shift
Every six months
Every six months
-----
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE D - Induction Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer requirements.-----indicate \"not applicable\".
Item#
1.0D1.1D1.2
HTSAQuestion#
----2.16
Category/Process Steps
PROCESS AND TEST EQUIPMENT REQUIREMENTSPer customer requirement
All hardness test equipment (for each scale used) shall be
calibrated semi-annually minimum, and verified daily minimum perthe applicable ASTM standard.
Files shall be verified daily (or prior to use) with provers per SAEJ8
Refractometers (typically used to check polymer quenchants andwasher solutions) shall be verified each shift (with distilled water)and calibrated annually (per manfacturer's requirements) at aminimum.PYROMETRY
Infrared pyrometers shall be calibrated to a black body furnaceannually
PROCESS MONITOR FREQUENCIES
Per Coil
-----
D1.3D1.4
2.163.2
----- -----
2.0D2.13.0
3.2
-----
All process parameters shall be checked the beginning of every shift, tool change, or any equipment repair. In absence of processparameter alarms, also check process parameters at end of shift or lot (whichever is the greater frequency).D3.1
1.42.12
Quench media process parameter- Temperature--Quench Level
- Quench Pressure and Flow
Alarm system for high and low temperature isrequired.Daily
- Quench pressure and flow may checked atmanifold. Quench flow shall be checked visuallyat each coil.
- In the absence of an alarm system, monitorevery 2 hours or after any changeCheck cycle time at start up and after anyprocess change.
- This requirement applies to each power supply(not per coil)
- In the absence of an alarm system, monitorevery 2 hours or after any change
Production Setup or Coil Change - Per Coil(1st Piece Inspection)
1 part at start-up, end of production run, and
every 4 hours minimum, and 1 part pre and 1 partpost tool change, equipment repair, station alarm(shutdown, malfunction, etc.)
1 part at start-up, end of production run, and 1part per 8 hours minimum, and 1 part pre and 1part post tool change, equipment repair, stationalarm (shutdown, malfunction, etc.)
1 part at start-up, end of production run, and
every 4 hours minimum, and 1 part pre and 1 partpost tool change, equipment repair, station alarm(shutdown, malfunction, etc.)
D3.2D3.3
1.42.141.42.143.16
Monitor cycle time
Monitor:
1) Volts or Amps, and2) Kilowatts
Use of an energy monitor or signature monitor satisfies 1) and 2)IN-PROCESS/FINAL TEST FREQUENCIES
4.0D4.4
1.42.15
Induction pattern length
D4.5
1.42.15
Total or Effective Case depth
D4.6
1.42.15
Surface hardness
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE D - Induction Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer requirements.-----indicate \"not applicable\".
Item#
D4.7
HTSAQuestion#
1.42.15
Category/Process Steps
Core hardness (when specified)
Per Coil
1 part at start-up, end of production run, and
every 4 hours minimum, and 1 part pre and 1 partpost tool change, equipment repair, station alarm(shutdown, malfunction, etc.)
1 part at start-up, and 1 part pre and 1 part posttool change, equipment repair, station alarm(shutdown, malfunction, etc.)
D4.8
1.42.15
Microstructure
5.0D5.1
2.123.14
QUENCHANT AND SOLUTION TEST FREQUENCIESQuench Media Controls If ApplicablePolymer Quench Media- Concentration
- Quenchability Check; e.g., cooling curve, viscosity, or titration
Once per dayMonthly
D5.2
2.123.142.123.14
Water Quench Media- Suspended solids
Quarterly
D5.3Brine or Caustic Quench Media- Concentration and/or Specific Gravity- Suspended solids
MonthlyQuarterly2x / weekDaily
D5.4D5.5
2.132.11
Rust Preventive - Soluble Oil- ConcentrationWashers
- Concentration of cleaner
- Temperature of solution (required if temperature is specified to beEach shiftabove ambient temperature).
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).-----indicate \"not applicable\".
RelatedHTSAQuestion #
Item#
1.0E1.1
Category/Process Steps
PROCESS AND TEST EQUIPMENTREQUIREMENTS
All furnaces, generators and quench systems(where applicable) shall have temperatureindicating instruments.
Continuous strip charts and/or data loggers arerequired for temperature and carbon monitoringunit, e.g., dew point, oxygen probe, IR gasanalyzer,etc.
Furnace weigh scales shall be verified quarterlyand calibrated annually at a minimum.
Dew pointers, 3-gas analyzers, spectrometers,and carbon IR combustion analyzers (shim stockanalysis), used to verify carbon potential infurnaces, shall be calibrated annually at aminimum. This is applicable when used incontrolling carbon-bearing atmosphere.Verification of calibration of spectrometers, andcarbon IR combustion analyzers, shall be
checked daily or prior to use. This is applicablewhen used in controlling carbon-bearingatmosphere.
Verification of calibraion of 3-gas analzers withzero gas and span gas shall be performed weeklyat a minimum. This is applicable when used incontrolling carbon-bearing atmosphere.Oxygen probe controllers shall be calibratedquarterly at a minimum. This is applicable whenused in controlling carbon-bearing atmosphere.All hardness test equipment (for each scale used)shall be calibrated semi-annually minimum, andverified daily minimum per the applicable ASTMstandard.PYROMETRY
BatchFurnaceContinuousFurnace *
Generators
3.13.73.13.7
YesYesYes
E1.2YesYesYes
E1.3E1.4
3.23.2
Yes -----
Yes -----
----- -----
E1.53.2 ----- ----- -----
E1.63.2 ----- ----- -----
E1.73.2YesYesYes
E1.82.16 ----- ----- -----
2.0E2.1E2.2
3.23.33.23.3
Thermocouples and calibration of thermocouplesshall conform to AMS 2750D.
Instrument Calibration per AMS 2750D shall bequarterly at a minimum.
Frequency reductions per AMS 2750D are notallowed.
YesYes
YesYes
YesYes
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).-----indicate \"not applicable\".
RelatedHTSAQuestion #
3.23.3
Item#
E2.3
Category/Process Steps
CQI-9 requires a comparative check of the controltemperature sensor(CTS) in the Qualified WorkZone to a (1) calibrated test temperature sensor(CTTS) or, (2) resident thermocouple(R-T/C).(1) The CTS shall be +/- 5C(or +/- 10F) of theCTTS at the operating temperature range; thischeck shall be performed monthly.
(2) The relationship between the CTS and R-T/Cat the operating temperature range shall be within+/- 1C (or +/- 2F) of their relationship determinedat the time of the most recent temperature
uniformity survey; this check shall be performedweekly.
Any actions to correct a failing reading or validatea test result shall be documented.
Additionally, Type K and N thermocouples shallbe checked monthly for equipment operating at orabove 760C(1400F) and changed annually at aminimum. Type K and N thermocouples shall bechecked quarterly for equipment operating below760C(1400F) and changed every two years at aminimum.
Type R and S thermocouples shall be checkedmonthly for equipment operating at or above760C(1400F) and changed every two years at aminimum.
Protection Tubes shall be visually checked at thesame frequency as thermocouples.
BatchFurnace
Yes
ContinuousFurnace *
Yes
Generators
Yes
E2.43.4
Temperature Uniformity Survey (TUS): refer toAMS 2750D for procedures. TUS frequency shallbe annual and after major rebuild.
Temperature uniformity tolerance for hardeningfurnaces shall be +/- 14 C (25 F). Temperatureuniformity tolerance for tempering furnaces shallbe +/- 11C (or +/- 20F).
Minimum and maximum temperature ranges shallbe tested per AMS 2750D. Exception: If theoperating range of the Qualified Work Zone isequal to or less than 85C(153F) then only onetemperature is required to be tested. The
temperature shall be within the operating range ofthe Qualified Work Zone.
Frequency reduction per AMS 2750D are notallowed.
Yes
Yes - In Qualified Work
Zone
-----
CQI-9
Special Process: Heat Treat System Assessment
Version 2, Issued 8/07
PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performingthe job audit, the auditor shall verify heat treater is conforming to customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).-----indicate \"not applicable\".
RelatedHTSAQuestion #
3.5
Item#
E2.5
Category/Process Steps
Recorded temperature(s) shall be controlledwithin +/- 9C (15F) of the set point as evidencedby continuous recording pyrometers. Furnacetemperature shall be controlled with soak timesstarting at the lower tolerance limit (as definedabove).
PROCESS MONITOR FREQUENCIES
BatchFurnace
Yes
ContinuousFurnace *
Yes - In Qualified Work
Zone
Generators
-----
3.0E3.1
1.42.14
Monitor primary temperature controlinstrument(s).
Each batch or
continuous recordingwith sign-off every 2hours. Alarm systemssatisfy the sign-offrequirement
-----
Each lot or continuousrecording with sign-offevery 2 hours. Alarmsystems satisfy thesignoff requirement
-----
Each Shift
E3.2
1.42.143.71.42.143.7
Monitor generator atmospheresContinuous
E3.3
Monitor primary furnace atmosphere control(s)**.Continuous recording
with sign-off every 2hours. Alarm systemssatisfy the sign-offrequirementVerify primary atmosphere control method bybackup method**.
For salt baths: check salt chemistry (solubleoxides) in salt bath or decarburization on theparts
Monitor time in furnace, cycle time or belt speed
Daily
Continuous recordingwith sign-off every 2hours. Alarm systemssatisfy the sign-offrequirement
Daily
-----
E3.4
1.42.143.71.42.143.131.42.141.42.71.42.151.42.151.42.152.132.11
Daily
E3.5DailyDaily -----
E3.6Each batch
Twice/shift & after anychange in the beltspeed
Twice/shift & after anychange in loading rate
Daily per furnaceEvery 2 hours minimum
Every 4 hours
-----
E3.74.0E4.1E4.2E4.35.0E5.1E5.2
Monitor load size or fixturing or loading rate asapplicable.
IN-PROCESS/FINAL TEST FREQUENCIESMicrostructureSurface hardness
Core hardness (when specified)SOLUTION TEST FREQUENCIESRust Preventive - Soluble Oil- ConcentrationWashers
- Concentration of cleaner
- Temperature of solution (required if temperatureis specified to be above ambient temperature).
Each batch -----
Daily per furnaceEach batchEach batch
----- ----- -----
2x / weekDailyEach shift
2x / weekDaily Each shift
----- ----- -----
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