AC7102/1 REV.

AUDIT CRITERIA
161Thorn Hill Road Warrendale, PA 15086-7527

Issued 1995-11 Revised 2007-09 Superseding AC7102/1 Rev. C

Baseline Nadcap AUDIT CRITERIA For BRAZING

1. 1.1 SCOPE This checklist supplements PRI AC7102. This checklist shall apply to suppliers who are performing furnace or dip brazing and who are seeking Nadcap accreditation. The requirement for job audits shall be completed for one (1) furnace brazing job and one (1) dip brazing job, as applicable. If the brazing supplier performs Induction Brazing or Torch Brazing, then the auditor shall use PRI AC7110/1. GENERAL INFORMATION This checklist shall be treated as an in-process job audit. QUALIFICATION Is the brazing work instruction certified or approved through conforming inspection/test results on representative parts/coupon? Does the brazing work instruction conform to the applicable part drawing and specification requirement? Do the procedures require that customer approval of brazing work instruction is obtained when required? Is the re-certification/re-approval of the certified or approved work instruction performed when there are changes in stop off, brazing aids, chemical solvents, surface preparation or other chemicals used as part of the certified or approved brazing procedure, unless customer permitted alternatives are permitted? MATERIAL CONTROL 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? 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 YES NO NA

2. 2.1 3. 3.1

3.2

YES

NO

3.3

YES

NO

3.4

YES

NO

4. 4.1

NA

4.2

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

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4.3

Does the supplier review the raw materials certifications to ensure that the specifications requirements are met? Is there objective evidence that the raw materials certifications are reviewed? Is there a controlled brazing filler metal storage area where the alloys are labeled and segregated, and where the employees access is limited? Are the raw materials containers traceable to a material certification for the applicable lot? BRAZE FILLER METAL APPLICATION FACILITY Does the supplier have a braze filler metal application area so parts can be prepared for brazing in a clean environment? Is the area well lighted? Are the braze filler metals properly identified at the individual workstations? BRAZING EQUIPMENT Vacuum Brazing Is the gas dew point monitored? Is the dew point monitored at the appropriate furnace location? Is there a procedure for periodic high temperature bake out of the vacuum brazing chamber when required? Is the vacuum brazing equipment capable to maintain a vacuum level required by the customer? Salt Bath Brazing Does the dip brazing salt pot have adequate volume to preclude the parts touching the electrodes? Does the supplier have adequate procedures for conducting the following periodic tests of the salt bath, when required: a. b. c. d. e. Pyrometry? Dehydration of the bath? pH of the bath? Scum and sludge removal from the bath? Periodic bath composition?

YES

NO

4.4 4.5

YES YES

NO NO

4.6

YES

NO

5. 5.1

NA YES NO

5.2 5.3 6. 6.1 6.1.1 6.1.2 6.1.3

YES YES

NO NO

NA YES YES YES NO NO NO

6.1.4

YES

NO

6.2 6.2.1

NA YES NO

6.2.2

YES

NO

6.2.3

Do the records show that these tests are current and conform to the requirements?

YES

NO

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6.3 6.3.1 6.3.2 7. 7.1 7.2 7.3

Atmosphere Brazing Is the gas dew point monitored? Is the dew point monitored at the appropriate location? BRAZE FILLER METAL APPLICATION AND ASSEMBLY PLANNING Does the planning include the removal of all burrs that could inhibit the braze flow? Are the assembly methods fully defined? Have the resultant dimensional change from the thermal treatment being considered in the planning? Do procedures state that the tack welding shall be used only when permitted by the engineering drawing or specification? Are the parts inspected for cleanliness immediately prior to assembly? If the parts do not pass the visual inspection for cleanliness, are they reprocessed through the cleaning operation? Does the braze filler metal application/assembly work instruction/procedure contain the following, if required: a. b. c. d. e. f. Gap control requirements and what to do if they are not met? Cleaning instructions? Grit blasting instructions (including the limitations and process control plan)? Assembly instructions? Shimming material type and placement instructions? Fusion or Resistance weld tacking instructions (including the location, sequence, size of the tack welds and tack weld filler metal)? The training of welders and inspectors to conform to contract requirements? The type of braze filler metal? The form of braze filler metal? The location of filler metal application? The amount of the braze filler metal? The stop off requirement (including the location)? Handling instructions for protection of parts from contamination? YES YES YES NO NO NO YES YES NO NO

NA

NA

7.4

YES

NO

7.5 7.6

YES YES

NO NO

7.7

YES

NO

g. h. i. j. k. l. m.

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8. 8.1

BRAZE PROCESSING Does the braze part sequencing and work instruction contain the following information, if required: a. The furnace fixturing (when used) or part orientation in the furnace? b. Precautions to prevent interaction of the fixture or furnace materials with the parts at the planned process temperatures? Brazing atmosphere or dip brazing salt type? Vacuum limits or atmosphere control throughout the braze cycle? Heat rates and soak times for preheat and brazing? Directions for determining when to start the brazing time and when to complete the brazing time? Specific equipment certified to run the parts? Test sample preparation, when required? For titanium brazing, provisions made for alpha case testing of coupons? Alpha case testing done to customer requirements? Placement of test samples during the brazing cycle? Temperature and cycle time? Cooling requirements? Directions when to remove parts from the brazing equipment? Cooling gas type and directions for its introduction? NA YES NO

c. d. e. f.

g. h. i. j. k. l. m. n. o. 9. 9.1 9.1.1 9.1.2 9.2 10. 10.1

POST-BRAZING CLEANING Does the post-brazing cleaning work instruction contain the following, if required: Flux removal check after the post-brazing cleaning for parts brazed with flux? Stop off and/or salt residue removal? Does the cleaning method conform to the customers requirements? POST-BRAZING INSPECTION Do planning sheets account for the customers requirements? YES NO YES YES YES NO NO NO

NA

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11. 11.1

POST-BRAZING TESTS Are the destructive and/or non-destructive inspection sources approved by the customer when required? Are records of tests documented Are the test data and the specimens traceable to the parts which they represent? BRAZING REWORK 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 YES NO

NA

11.2 11.3 12. 12.1

YES YES

NO NO NA

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13.

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.

13.1

Job 1 Identity: (Information) a. b. c. d. e. Purchase order number (when applicable): Customer (and prime, if known): Part number: Part description: Date of job and job number: Material/alloy Material specification Heat treating/Braze specifications: Braze Filler Metal Specification Braze Alloy Lot Number Heat treat and other process and test requirements specified (e.g. fixed process approval):

(EC) (EC) (EC) (EC) (EC) (EC)

f. g. h. i. j. k.

l. m. 13.2 13.2.1

Part size: Number of parts

Pre-brazing requirements Prior to brazing, have cleaned parts been protected from contamination? YES NO

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13.3 13.3.1

Cleaning Does the area have the proper equipment to clean the parts by the approved procedures? Are cleaning/surface preparation methods performed as allowed by the process specification or engineering drawing? Are parts cleaned by the certified or approved braze procedure? If a thermal cleaning process is used for surface preparation, does the time/temperature cycle meet the requirements of the approved work instruction? Does the delay time between cleaning and brazing conform to the braze procedure? Are cleaning solutions subject to periodic evaluation by a documented process control plan? Grit Blasting Are blasted parts cleaned in accordance with the approved procedure? Does the delay time between the grit blasting and brazing conform to the brazing procedure? Plating Plating by the Brazing Source Are plating solutions subject to periodic evaluation by a documented process control plan? Does the plating work instruction define the plating thickness and location of the deposited material? Are the parts plated in accordance with a work instruction based on the engineering drawing and/or specification requirements? Are plating requirements, including all process parameters (surface area, current requirement, etc.), and setup procedure defined in the work instructions? Plating by an Outside Supplier Has the outside supplier been approved by the customer? Has the outside plating supplier certified that the parts were plated in accordance with the brazing work instruction, engineering drawing or specification requirement? Braze Gap Control Is there evidence the braze gap has been verified? YES NO YES YES NO NO YES NO YES YES NO NO YES NO

NA

13.3.2

YES

NO

13.3.3 13.3.4

YES YES

NO NO

13.3.5

YES

NO

13.3.6

YES

NO

13.4 13.4.1 13.4.2

NA

13.5 13.5.1 13.5.1.1

NA NA

13.5.1.2

YES

NO

13.5.1.3

YES

NO

13.5.1.4

YES

NO

13.5.2 13.5.2.1 13.5.2.2

NA

13.6 13.6.1

NA

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13.7 13.7.1 13.8 13.8.1

Welding Is there evidence that the procedures are being followed? Alloying Are the materials specified on the braze work instruction allowed by the engineering drawing or customer approval? Is the proper braze filler metal type, form, and amount applied in accordance with the approved braze work instruction? Is the braze filler metal lot entered on the router form and traceable to a braze filler metal certification? Is flux used as required (type, amount) by the engineering drawing listed on the braze work instruction? Brazing Aids Is the proper stop off applied in the correct locations in accordance with the approved brazing work instruction? Is the proper aid (shim, feltmetal, etc.) applied in the correct manner as defined in the brazing work instruction? Dip Brazing Salt Is the specified brazing salt in use? Atmosphere/Surface Protection a. Atmosphere(s) (including vacuum) required by specification, drawing or purchase order: YES NO YES NO YES NO YES NO

NA

NA

13.8.2

YES

NO

13.8.3

YES

NO

13.8.4

YES

NO

13.9 13.9.1

NA

13.9.2

YES

NO

13.10 13.10.1 13.11 (EC)

NA

(EC)

b.

Atmosphere specified on the shop paper:

(EC)

c.

Atmosphere used:

13.12

Racking YES NO

NA

13.12.1 Are customer racking or batching requirements specified? Describe: (EC) Not to describe 13.12.2 Are the racking or batching specified as requirements on shop paper?

YES YES

NO NO

13.12.3 Verify the racking or batching used. Are they complying? Describe: (EC) Not to describe

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13.13 13.13.1

Thermal Treatment (EC) Brazing Operation Temperature REQUIREMENT (EC) SHOP PAPER REQUIREMENT (EC) SET TEMPERATURE (EC) ACTUAL TEMPERATURES (EC)

NA NA

Temperature Check if used Indicator (EC)

Recorder Multipoint Load Thermocouples 13.13.1.1 Were dip brazed parts preheated for the specified time immediately prior to dipping?

(EC) (EC) (EC)

YES

NO

NA

13.13.1.2 13.13.2 13.13.2.1 13.13.2.2 13.13.2.3

Was the furnace stabilized at or below the set temperature before loading parts? Offsets Is the offsetting performed? Is the offsetting permitted by the customer? What offset is made? Describe:

YES

NO NA

YES YES

NO NO

13.13.3

Does the furnace instrumentation meet the requirements of the customers specification? Is the temperature uniformity specified, or is the furnace number specified on the shop paper? List the specified furnace number(s), or the uniformity:

YES

NO

13.13.4

YES

NO

13.13.5

Does this furnace meet the uniformity requirements?

YES

NO

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13.13.6

(EC) Brazing Operation Time REQUIREMENT (EC) SHOP PAPER REQUIREMENT (EC) ACTUAL (EC)

Atmosphere Time and Tolerance Time loaded into furnace Time instrument at temperature Time start of soak Time end of soak Media for Cooling Cooling Rate 13.13.6.1 (EC) (EC) (EC) (EC) (EC) (EC) (EC)

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

13.13.6.2 13.13.6.3 13.13.6.4

Does the start and end of soak meet the customers requirements? Does the soak time meet the customers requirements? Does the post brazing cooling method/rate conform to the brazing work instructions? Does all thermal treatment meet the specified requirements? Load Thermocouples (Batch Furnaces Does Not Apply to Dip Brazing Pre-Heat) Are the load thermocouple requirements specified by the customer (Info Only)? Are the load thermocouples specified by the supplier? Did the type/number/location and attachment of the load thermocouples conform to the requirements?

YES YES YES

NO NO NO

13.13.6.5 13.13.7

YES

NO NA

13.13.7.1 13.13.7.2 13.13.7.3

YES YES YES

NO NO NO

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13.13.8 13.13.8.1

Post Brazing Cleaning Are work instructions available at the work station describing how to clean the parts after brazing? Are these instructions being used at the work station and followed? Are the parts (when brazed with flux) checked for flux removal after the post brazing cleaning? Is the stop off residue removed from the brazed parts? Does the cleaning method conform to the customers requirements? Post Brazing Inspection Are the parts visually inspected for external coverage in the required areas and surface condition in accordance with the customers requirements? Are records of tests documented and comply with the customers requirements? If the lot contained reworked parts, were the rework cycles or the maximum time at temperature requirements fulfilled? Operator Control and Job Acceptance Certification and Reports or Test Reports (Independent Heat Treaters) Does the certificate show compliance to all applicable drawing, specification and PO requirements? Does the certificate list the revision level of the specification to which the parts were processed? Certification and Reports or Test Reports (Manufacturers) Is the shop paper/traveler verified and accepted by authorized personnel? Did this job comply with all the requirements? YES YES NO NO YES NO YES NO YES NO

NA

13.13.8.2 13.13.8.3

YES YES

NO NO NA

13.13.8.4 13.13.8.5 13.13.9 13.13.9.1

YES YES

NO NO

NA

NA

13.13.9.2 13.13.9.3

YES YES

NO NO

13.13.10 13.13.10.1 13.13.10.1.1

NA

13.13.10.1.2

YES

NO

13.13.10.2 13.13.10.2.1 13.13.11

NA