AIAG CQI-9 Special Processes

CQI-9 Special Process: Heat Treat System Assessment

Automotive Industry Acti on Group

Version 2, Iss ued 8/07

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CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07

Automotive Industry Action Group

ABOUT AIAG Purpose Statement Statement Founde Founded d in 1982, 1982, AIAG AIAG is a global globally ly recogn recognize ized d organi organiza zatio tion n where where OEMs and and suppli suppliers ers unite unite to addres address s and resolv resolve e issue issues s affect affecting ing the worldw worldwide ide automo automotiv tive e supply supply chain. chain. AIAG's AIAG's goals goals are to reduce reduce cost cost and complex complexity ity throug through h collab collabora oration tion;; improve improve produc productt quality quality,, health, health, safety safety and the enviro environme nment; nt; and optimize speed to market throughout the supply chain.

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CQI-9 Special Process: Heat Treat System Assessment Version 2, Iss ued 8/07

FOREWORD Auto Automo moti tive ve Indu Indust stry ry Acti Action on Grou Group p (AIA (AIAG) G) com committ mittee eess are are made ade up of volu volunt ntee eers rs from from memb member er compan companies ies in the autom automoti otive ve indus industry try.. The work work of prepa preparin ring g proces processs audit auditss is done done by AIAG AIAG techni technical cal committees. The The main main task task of tech techni nica call comm committ ittee eess is to prepa prepare re Autom Automot otive ive Stan Standa dards rds and and Syst System em Requ Require ireme ment nts. s. Draft Draft docume documents nts adopte adopted d by the techni technical cal commit committee teess are circula circulated ted to the Steeri Steering ng Commit Committee tee for review review and and cons consen ensu suss appr approv oval al.. Publ Public icat atio ion n of the the docu docume ment ntss requ requir ires es appr approv oval al by the the Qual Qualit ity y Stee Steeri ring ng Committee. The Quality Quality Steerin Steering g Commit Committee tee would would like like to acknow acknowledg ledgee and thank thank the follow following ing indivi individua duals ls and their companies who have contributed time and effort to the development of this document.


















ACKNOWLEDGEMENTS

Core Members: Pete Batche — Robert Bosch LLC Mel Dilley — DaimlerChrysler DaimlerChrysler Corp. Corp. Curt Holmes — Commercial Commercial Steel Treating Treating Corp. Ed Jamieson — Bodycote Bodycote Thermal Processing Processing Young Kim — Ford Motor Company Brett Lenhausen — General Motors Corporation Philip Mikula — TRW Automotive, Inc. Murli Prasad — General Motors Motors Corporation

Supporting Members: Todd Bensinger — DaimlerChrysler DaimlerChrysler Corp. Scott Brodersen Brodersen — DaimlerChrysle DaimlerChryslerr Corp Dave Calkins — DaimlerChrysler Corp Leonard Leonard Gadzinski — Acument Global Technologies Technologies North America Tim Green — BSI Americas, Inc. Dave Hernacki Hernacki — Commercial Commercial Steel Treating, Treating, Corp. Dean Higdon — Acument Acument Global Technologies Technologies North America Jeff Martin — ZF Friedrichshafen, AG M i k e O b e r g — I n d u c t i on on S e r v i c e s , I n c . Mike Wiezbowski Wiezbowski — DaimlerChrysler DaimlerChrysler Corp. Corp.




















TABLE OF CONTENTS ABOUT AIAG ...................................................................................................................................................................................................... 1 FORWORD ............................ ................................................ .................................. ................. ................. ............................ .................................. .................................. ................. ................. ............................ .............................. ................ 3 ACKNOWLWDGEMENT ACKNOWLWDGEMENTS........ S...................... .................................. .................................. .................................. .................................. .................... ................... ........................... .................................. ........................... ....... 4 INTRODUCTION............... INTRODUCTION............................. ................. ................. ............................ .................................. .................................. ................. ................. ............................ .................................. .................................. .................... ...... 6 1 SCOPE............................... SCOPE................................................... ........................................ .................................. ......................... ........................ ........................... .................................. .................................. ................. ................. ................... ..... 8 1.1 GENERAL.............................................................................................................................................................................................. 8 1.2 APPLICATION APPLICATION............. ........................... .................................. .................................. ................................... ................................... ............................ ............................ .................................. ................................ ............ 8 1.3 REFERENCE......................................................................................................................................................................................... 9 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE ........................... ................................ ................... ............................ .................................. .............................. .......... 10 3 SP ECIAL PRO CESS: HEAT TREAT SYSTEM ASSES SMENT PR OCEDU RE ........... ................ ........... ........... .......... ........... ........... ........... ........... ........... ........... ........... ......... ... 11 INSTRUCTIONS INSTRUCTIONS FOR COMPLETING COMPLETING THE COVER SHEET............................. SHEET................................ ................. ............................ .................................. .............................. .......... 12 SPECIAL PROCESS: HEAT TREAT ASSESSMENT ASSESSMENT FORMS............ FORMS.......................... .................................. .................................. .................. ................. ......................... ............ 18 INSTRUCTIONS INSTRUCTIONS FOR COMPLETING COMPLETING THE JOB AUDIT................................ AUDIT............................................. ........................... .................................. .................................. .................... ...... 37 JOB AUDIT FORM................................ FORM............................................ .......................... ................................... ................................... .................................. .................................. ................. ................. ....................... ......... 38 APPENDIX A — PROCESS TABLES.........................................................................................................................................................42 APP END IX B — GLO SSA RY .................................................... ....................................................................................................... ............................................................................................................ ................................................................. ........ 66 MAINTENANCE REQUEST................................................................................................................................................... 69



















INTRODUCTION General The work of prepar preparing ing CQI 9: Special Special Process: Process: Heat Heat Treat Treat System System Assess Assessment ment (HTSA), Second Second Edition Edition,, was was carr carrie ied d out out thro throug ugh h the the AIAG AIAG Heat Heat Trea Treatt Work Work Grou Group. p. Thes These e hea heat tre treat requ requir irem emen ents ts are complementary to customer and product standards. The HTSA can be used used to assess assess an organi organiza zatio tion's n's ability ability to meet the requi requireme rements nts in this this asses assessme sment, nt, as well well as cust custome omer, r, regu regula lato tory ry,, and and the orga organiz nizati ation on's 's own own requir requireme ement nts. s. The The HTSA HTSA can can also also be used used between between an organization and its suppliers. suppliers. In the the HTSA, HTSA, the the word word "shal "shall" l" indic indicate ates s a requi requireme rement nt for purp purpos oses es of the the self self asse assess ssmen ment. t. Fail Failure ure to meet meet the the requ require iremen ments ts resu results lts in an asse assess ssmen mentt that that is eithe eitherr “Not “Not Satis Satisfac facto tory ry”” or “Need “Needs s Immed Immedia iate te Action”. The word “should” indicates a recommendation. Where the term "such as" is used, any suggestions suggestions given are for guidance only.

Process Approach The HTSA supports supports the automotive process approach as described described in ISO/TS16949:20 ISO/TS16949:2002. 02.

Heat Treat System Assessment Goals The goal of the HTSA HTSA is the develo developme pment nt of a heat heat treat treat manage management ment system system that that provid provides es for contin continual ual improvement, improvement, emphasizing emphasizing defect prevention prevention and the reduction of variation variation and waste in the supply chain. The The HTSA HTSA,, coup couple led d with with an inte intern rnat atio iona nally lly reco recogn gniz ized ed qual quality ity manag manageme ement nt syste system m and and appl applic icab able le customer-specific requirements, defines the fundamental requirements for heat treat management systems. The HTSA HTSA is intend intended ed to provid provide e a common common approach approach to a heat heat treat treat manag manageme ement nt syste system m for automo automotiv tive e production and service part organizations.

Assessment Process Ongo Ongoin ing g asse assess ssmen ments ts shal shalll be condu conducte cted d annu annuall ally, y, unles unless s othe otherwi rwise se speci specifie fied d exam examin ine e the the cont contin inui uing ng comp compli lian ance ce with with the the HTSA HTSA.. Each Each asse assess ssme ment nt shal shalll organ organiza izatio tion' n's s syste systems ms usin using g the HTSA. HTSA. Succ Succes essi sive ve Job Job Audit Audits s (Secti (Section on 4.0 4.0 sample sample parts parts from from differe different nt automo automotiv tive e compon component ent manufact manufacture urers rs that that requi require re document.

by the custo customer mer,, to reincl includ ude e a revi review ew of the the of this this docu documen ment) t) shal shalll compli complian ance ce to the HTSA HTSA

The assess assessmen mentt shall shall use the proces process s approa approach ch to auditi auditing ng as identi identified fied by the requir requireme ements nts of ISO/TS ISO/TS 16949:2002.





















Assessor Assessor Qualifications Qualifications Assessors(s) shall have the following specific experience to conduct the HEAT TREAT SYSTEM ASSESSMENT :

1. Be an expe experi rien ence ced d qual qualit ity y mana manage geme ment nt syst system em (QMS (QMS)) inte intern rnal al audi audito torr (for (for exam exampl ple, e, ISO/TS 16949:2002, ISO 9001:2000) 2. Asse Assess ssor or shal shalll posse possess ss heat heat treati treating ng knowl knowled edge ge.. Evide Evidenc nce e shal shalll inclu include de a minimu minimum m of 5 years years expe experie rienc nce e in heat heat treat treatin ing g or a combi combina natio tion n of forma formall metal metallu lurgi rgical cal educ educati ation on and and heat treating experience experience totalling totalling m inimum of 5 years. years. 3. Asse Assess ssor or shal shalll poss posses ess s know knowle ledg dge e of and and be famil familia iarr with with the appli applica catio tion n of auto automot motiv ive e qual quality ity core core tools tools inclu includin ding g statis statistic tical al proc proces ess s contro control, l, measu measurem remen ents ts syste system m analy analysis sis,, part approval, failure mode and effects analysis, and advanced quality planning.

Note Note:: If more more than than one one asse assess ssor or is requ requir ired ed to meet meet the the abov above e qual qualif ific icat atio ions ns,, the the lead lead assessor shall be the person meeting the requirements in item #1.

Other Requirements Requirements The orga organiz nizat atio ion n shall shall keep keep reco records rds as evide evidenc nce e of compl complian iance ce to the the requir requireme ements nts ident identifi ified ed in the the HTSA, HTSA, as well well as appr appropr opria iate te acti action on plans plans to addr addres ess s any unsati unsatisfa sfacto ctory ry ratin ratings gs.. Thes These e reco record rds s shal shalll be read readily ily availa available ble for for review review by any custo customer mer requ requiri iring ng compl complian iance ce to the the requ require iremen ments ts withi within n this this document.



















1 SCOPE 1.1 General This This docum documen entt specif specifies ies proces process s requir requireme ements nts for an organiz organizati ation on or its suppli suppliers ers perfor performin ming g appli applicab cable le heat treating, who need to 



demonstr demonstrate ate abilit ability y to consiste consistentl ntly y provid provide e produc productt that that meets meets custom customer er and and applic applicabl able e regulatory requirements, and enhanc enhance e custom customer er satisf satisfact action ion throug through h the effect effective ive applic applicati ation on of the syste system, m, includ including ing processes for continual improvement of the system.

The Heat Heat Treat Treat Syste System m Asses Assessmen smentt is applic applicabl able e to sites sites where where custom customer er-speci -specifie fied d parts parts for produ productio ction n and/or service are processed throughout throughout the a utomotive utomotive supply chain.

1.2 Application All requirements of the HTSA are generic and are intended to be applicable to all organizations performing the heat treat operations addressed in this document, regardless of type, size, and product. Note: Process Table E is only applicable to process affecting the final characteristics of the part. Five Five Proces Process s Tabl Tables es have have been been deve develo lope ped d and and the the appr approp opria riate te tabl table( e(s) s) is to be refe referen rence ced d durin during g the assessment. assessment. The Process Process Tables are specific to heat treat processes processes as noted below: Process Process Table A – Ferrous 

Carburizing



Carbonitriding



Carbon Restoration or Correction



Neutral Hardening Hardening (Quench (Quench and Temper)



Austempering



Martempering




















Note: Material producers of primary or raw materials, or any intermediate thermal treating process step(s) that do not affect the final characteristics characteristics of the part are exempt from conforming to the requirements in CQI-9. These Process Tables contain requirements for:

1. 2. 3. 4. 5.

Process and Test Equipment Pyrometry Process Monitor Frequencies In-Process/Final Test Frequencies Quenchant Quenchant and Solution Solution Test Frequencies Frequencies

The Process Tables specify the tolerances tolerances of process process parameters parameters and the frequencies frequencies for checking checking process process cont contro roll param paramet eters ers and and parts. parts. The Requ Require iremen ments/ ts/Gu Guide idelin lines es in the HTSA HTSA form form will will notif notify y the asse assess ssor or when to refer to the Process Tables.

1.3 Reference The followin following g standa standards rds are referen referenced ced in this document. document. The applic applicabil ability ity is limited limited to the subject subject matter referenced.

Standard Number

Title

Standard’s Organization

AMS 2750D

Pyrometry

SAE J415

Definition of the Heat Treating Terms Suface Hardness Testing With Files

SAE Aerospace www.sae.org SAE International International www.sae.org SAE International International www.sae.org

SAE J864



















2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE 1.

Obtai btain n curre current nt copy copy of CQI-9 CQI-9 Spec Specia iall Proc Process ess:: Heat Heat Treat Treat Syste System m Asse Assess ssme ment nt,, 2nd 2nd edit editio ion n from AIAG.

2.

Iden Identi tify fy all all heat heat trea treatt proce roces sses ses to which ich CQICQI-9 9 Speci pecia al Proce rocess ss:: Hea Heat Trea Treatt Syst Syste em Assessment 2nd edition applies (see CQI-9, CQI -9, 1 .2). Record these processes pr ocesses on the HTSA, Page 1.

3.

Comp Comple lete te the the HTSA HTSA,, dete determ rmin inin ing g the the leve levell of comp compllianc iance e. A min minimum mum of one one job job audit udit (Section 4) shall be performed during each assessment.

4.

Addr Addres ess s each each "Not Sati Satisf sfac acto tory ry"" item item and and dete determi rmine ne corre correcti ctive ve actio action, n, incl includ udin ing g root root caus cause e anal analy ysis sis and and impl implem emen enta tati tion on of the the corr corre espon spondi ding ng corr correc ecti tive ve acti action on(s (s). ). The The corr correc ecti tive ve acti action on(s (s), ), shal shalll be comp comple lete ted d with within in 90 days. ays. Reco Record rds s of the the corr correc ecti tive ve acti action on,, incl includ udin ing g verificatio verification, n, shall be be maintained. maintained.

5. “Need “Needs s

Imme Immedi diat ate e Acti Action on”” requ requir ires es imme immedi diat ate e cont contai ainm nmen entt of susp suspe ect prod produc uct. t. Addr Addres ess s each each “Need “Needs s Immed Immedia iate te Acti Action on”” item item and and deter etermin mine e corr correc ectiv tive e acti action on(s (s), ), incl includ udin ing g root root caus cause e anal analy ysis sis and and impl implem emen enta tati tion on of the the corr corre espon spondi ding ng corr correc ecti tive ve acti action on(s (s). ). The The corr correc ecti tive ve acti action on(s (s)) shal shalll be comp comple lete ted d with within in 90 day days. Reco Record rds s of the the corr correc ecti tive ve acti action on,, incl includ udin ing g verification, shall be maintained.

6.

Assessments shall be be conducted annually unless unless otherwise specified specified by the customer. customer.



















3 SPECIAL SPECIAL PROCESS: PROCESS: HEAT TREAT ASSESSMENT INSTRUCTION FOR COMPLETING THE COVER SHEET.....................................................................12

COVER SHEET FORM..........................................................................................................................14 INSTRUCTIONS FOR COMPLETING SECTION 1-3 ................................................................................15

SECTION 1: MANAGEMENT MANAGEMENT R ESPONSIBILITY ESPONSIBILITY & QUALITY PLANNING ................. .......................... ............... .......18 .18 SECTION 2: FLOOR AND MATERIAL HANDLING RESPONSIBILITY......................... RESPONSIBILITY........................................25 ...............25 SECTION 3: EQUIPMENT .......................................... .................. ........................................... ........................................... ................................... ........... ....................31 .................. ..31 INSTRUCTIONS FOR COMPLETING THE JOB JOB AUDIT ........................................... ................... ........................ ..................... ................... ..........37 ........37

SECTION 4: JOB AUDIT.......................................................................................................................38





















Instructions for completing the Cover Sheet 1.

2.

Facility Name: Name of the facility being assessed. One form shall be used for each facility. The facility may have several buildings or physical locations in the same general area. If there is a separate management team (Quality Manager and Metallurgist) or different management system, then these locations shall be considered as separate facilities.

Address: The The stree streett addre address ss of the faci facilit lity y being being asses assessed sed;; P.O P.O Box numbers numbers may be given given as additi additiona onall information.

3.

Phone Number: The phone number of the facility. If there there is no commo common n phone phone numbe numberr for the the facil facility ity,, the the phone phone number number of the the Opera Operatio tions ns Manager Manager or Qualit Quality y Manager shall be used.

4.

Fax Number: The fax number of the facility.

5.

Number of Heat Treat Employees Employees at this Facility: Facility: The The number of employees, salaried and hourly, associated with the heat treat operation at this facility.

6.

Captive Captive Heat Treater (Y/N): (Y/N): Enter "Y" if this facility heat treats components for their own company. Enter "N" if the company does not heat treat any components for their own company.

7.

Commercial Commercial Heat Treater (Y/N): Enter (Y/N): Enter "Y" if this facility heat treats components for companies other than their own company. Enter "N" if this facility does not heat treat any components for other companies.

8.

Date of Assessment: Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be used to avoid confusion with different numeric formats.





















14. 14 . Auditors/Assessors: List Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the auditor/assessor(s).

15. 15 .

Number Number of "Not "Not Satisfa Satisfactor ctory" y" Findin Findings: gs: Enter Enter the number of "Not Satisfac Satisfactory tory"" findings findings observed during the assessment.

16. 16 .

Number of “Needs “Needs Immediate Immediate Action” Action” Findings: Findings: Enter Enter the number of “Needs Immediate Action” finding observed during the assessment. assessment.

17. 17 .

Number of “Fail” “Fail” Finding in the Job Audit Audit(s): (s): Enter the number of “Fail” findings observed from the job audit.





















Special Process: Heat Treat Process Assessment Facility Name: ddress

Phone Number ax Number umber of Heat Treat Em lo ees at this Facilit a tive Heat Treater Y/N

Type(s) of Thermal Processing at this Facility: Process Process Table – Ferrous Ferrous Carburizin Carbonitridi idin Carbon Correction Neutral Hardenin

uench uench & Tem Tem er Commercial Heat Treater (Y/N)

Austempering / Martempering

Date of Evaluation:

Tem erin Precipitation Hardening /Aging

ate of Previous Evaluation: Process Process Table Table B Ferrous Ferrous Nitriding (Gas) FerriticNitrocarburizing FerriticNitrocarburizing (Gas or Salt) Process Table C Aluminum luminum Heat Treatment Process Process Table Table D Fe rous rous Induction Heat Treatin






















Instructions for completing Sections 1 - 3 Sections Sections 1 - 3 contain questions and the requirements/guidanc requirements/guidance e for each question. The Sections are: 

Section Section 1 – Management Management Respons Responsibility ibility & Quality Planning Planning



Section Section 2 – Floor Floor and Material Material Handling Handling Responsibility Responsibility



Section Section 3 – Equipment Equipment

The asse assesso ssorr shal shalll asse assess ss the the heat heat treate treater's r's compl complian iance ce to Secti Section ons s 1 – 3 by compa compari ring ng the evid eviden ence ce presented presented by the heat treater to the requirements requirements listed in the "Requirements "Requirements and Guidance" Guidance" column.

NOTE NOTE 1:

In the the "Req "Requi uire reme ment nts s and and Guid Guidan ance ce"" col colum umn, n, the the word word "sh "shal all" l" ind indic icat ates es a requ requir irem emen entt and and the the term term "suc "such h as" as" indi indica cate tes s that that any any sugg sugges esti tion ons s given given are for guidance guidance only.

NOTE NOTE 2:

The The "Re "Requ quir irem emen ents ts and and Guid Guidan ance ce"" col colum umn n wil willl indi indica cate te to the the asse assess ssor or when when the the Proc Proces ess s Tabl Tables es are perti pertine nent nt to the Ques Questi tion ons. s. When When the the Process Tables are pertinent to the Question, the assessor shall assess the heat heat treater' treater's s complia compliance nce to the specifi specified ed section section(s) (s) in the Proce Process ss Tables.





















General Notes for AMS 2750D AMS 2750D is refer enced in the Pyrometr y Section Secti on (Section (Sect ion 2.0) of the Process Proces s Tables . Organizati Organ izati ons and suppliers suppliers shall comply with the sections sections of AMS 2750D 2750D that reference reference thermoco thermocouple uples, s, the calibration of thermoco thermocoupl uples es and instrume instrumentatio ntation, n, and the procedu procedure re for conduc conducing ing furnace furnace temperatu temperature re unifor uniformity mity surveys surveys (TUS) see below. Exceptions Exceptions to this requirement requirement are listed below below in the respective sections. sections. Thermocouples and Instrumentation – Section Section 3.1 – Temperature Temperature Sensors (Thermocouples) (Thermocouples) – Secti Section on 3.2 3.2 –Instru –Instrumen menta tati tion on –Note: Note: Frequ Frequen ency cy reduc reductio tions ns per per AMS 2750 2750D D are

not allowed by CQI-9 Exceptions Exceptions (Compliance (Compliance to the following sections sections are not required required b y CQI-9) Sectio Section n Number Number

Expl Explan anati ation on

3. 2. 2.5.1 & 2

Temperature controlling instruments purchased prior 1 year after le release of AM S 2750D are exempt 3.2.5.1 and 3.2.5.2. 3.2.5.2.

3.2. 3.2.5. 5.3. 3.1 1

One One poin oint sen sensor sor inp input is acce accep ptabl table e.

3.2.5.5

Sensit nsitiv iviity chec hecks during ing calibrati ratio on are not required.

System System Accuracy Accuracy Test (SAT) Procedure Procedure ( Section Section 3.4) – SAT shall be performed by by one of the two methods listed below. below.

to of
























– Section Section 3.5.5 – Initial TUS 



Section Section 3.5.6 – Periodic Periodic TUS (For CQI-9. a m inimum of once per year periodic TUS is required) required) Mini Minimum mum and and maxim maximum um temp temper erat atur ure e rang ranges es shal shalll be test tested ed per per AMS 2750D. Exception: If the operating range of the Qualified Wor Work Zone is equal ual to or less that 35C 35C (15 (153F) 3F) then hen only one temp temper eratu ature re is requ requir ired ed to be test tested ed.. The The temp temper erat atu ure shal shalll be within the operating range of the Qualified Work Zone. Section Section 3.5.8 - Furnace Furnace Parameters During TUS Section Section 3.5.9 - Furnace Furnace Temperature at Insertion Insertion of TUS Sensors Sensors 



Mini Minimu mum m and and maxi maximu mum m temp temper eratu ature re rang ranges es shal shalll be test tested ed per per AMS 2750D. Exception: If the operating range of the Qualified Wor Work Zone is equal to or less than 85C (15 (153F) the then only one temp temper eratu ature re is requ requir ired ed to be test tested ed.. The The temp temper erat atu ure shal shalll be within the operating range of the Qualified Work Zone.






















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PROCESS TABLE E


– Annealing / Normalizing /

Stress-Relieving 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 performing the job audit, the auditor shall verify heat treater is conforming to the customer 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 #

Related HTSA Question #

1.0

Category Process Steps

Batch Furnace

Continuous Furnace * Furnace *

Generators

PROCESS AND TEST EQUIPMENT REQUIREMENTS

E1.1

3.1 3.7

All furnaces, generators and quench systems (where applicable) shall have temperature indicating instruments. Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer,etc.

Yes

Yes

Yes

E1.2

3.1 3.7

Yes

Yes

Yes

E1.3 1.3

3.2

Furn Furna ace weig weigh h scal scales es shal shalll be verif erifie ied d quar quarte terrly and calibrated calibrated annually annually at a minimum

Yes

Yes

-----

E1.4

3.2

Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, furnaces, shall be calibrated annually at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.

-----

-----

-----

E1.5 E1.5

3.2 3.2

Veri Verifi fica cati tion on of cali calibr bra ation tion of spec spectr trom omet eter ers, s, and and carb carbon on IR combustion analyzers, shall be checked daily or prior to use. This is applicable when used in controlling carbon-bearing atmospheres.

-----

-----

E1. E1.6

3.2

Veri Verifi fica cati tion on of cali calibr bra ation tion of 3-ga 3-gas s anal analyz yzer ers s with with zero zero and span gas shall be performed weekly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.

-----

-----

-----

E1. E1.7

3.2

Oxy Oxygen gen probe robe cont contrrolle ollerrs shal shalll be cali calib brate rated d quar quarte terrly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.

Yes

Yes

Yes

E1. E1.8

2.1 2.16

All hard ardnes ness test equi equip pment ment (fo (for each ach sca scale use used) shal shalll be calibrated semi-annually semi-annually minimum, and verified daily minimum per the applicable applicable ASTM standard.

-----

-----

-----

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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, testing, greater frequencies, etc. When perfo rming the job audit, the auditor shall verify heat treater is conforming to the customer 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 #


2.0


Batch Furnace


Generators

PYROMETRY

E2.1

3.2 3.3

Thermocouples and calibration of thermocouples shall conform to AMS 2750D.

Yes

Yes

Yes

E2.2

3.2 3.3

Instrument Calibration per AMS 2750D shall be quarterly at a minimum. minimum.

Yes

Yes

Yes

Yes

Yes

Yes

Frequency reductions per AMS 2750D are not allowed. E2.3

3.2 3.3

CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated temperature sensor (CTTS) or, (2) resident thermocouple thermocouple (R-T/C). (1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly. (2) The relationship between the CTS and R-T/C at the operating operating temperatur temperature e range range shall shall be be within within +/-1 +/-1 C (or (or +/+/2F) of relati relationshi onship p determ determined ined at the time of the the most recent recent temperature uniformity survey; this checked shall be performed weekly. Any action to correct a failing reading or validate a test result shall be documented. Additionally, Type K and N thermocouples shall be checked monthly for equipment equipment operating at or above above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked for equipment operating below 760C (1400F) and changed every two years at a minimum. Type R and and S thermocou thermocouple ple shall be checked checked monthly monthly for equipment operating at or above 760C (1400F) and changed every tow years at a minimum. Protection Tubes shall be visually checked at


















PROCESS TABLE E




All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer 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 # E2.4 E2.4

Related HTSA Question # 3.4 3.4


Temp Temper erat atur ure e Unif Unifo ormit rmity y Survey rvey (TU (TUS): S): refer efer to AMS 2750D for procedures. TUS frequency shall be annually and alter major rebuild.

Temperature uniformity tolerance for annealing furnaces furnaces shall be +/- 14 C (+/- 25 F). Temperature Temperature uniformity uniformity tolerance tolerance for tempering tempering furnaces furnaces shall be +/- 11 C ( or +/+/20 F). Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range range of the Qualifies Qualifies Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.

Frequency reductions per AMS 2750D are not allowed. E2.5 E2.5

3.5 3.5

Recor ecorde ded d temp tempe eratu rature re((s) sha shall be con control trolle led d with ithin +/+/9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance tolerance limit (as defined defined above). above).

atch Furnace


Generators




















PROCESS TABLE E



All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, testing, greater frequencies, etc. When perfo rming the job audit, the auditor shall verify heat treater is conforming to the customer 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 #


3.0


Batch Furnace

Generators


PROCESS MONITOR FREQUENCES

E 3.1

1.4 2.14

Monitor primary temperature control instrument(s).

E 3.2

1.4 2.14 3.7

Monitor generator atmospheres.

E 3.3

1.4 2.14 3.7

Monitor primary furnace atmosphere control(s)**.

E 3.4

Each batch or continuous recording with sign-off sign-off every2 hours. Alarm systems satisfy the sign-off requirement

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the signoff requirement

-----

Each Shift

-----

Continuous recording with sign-off every 2 hours. Alarm systems

Continuous recording with sign-off every 2 hours. Alarm systems

satisfy the sign-off requirement

satisfy the sign-off requirement

Continuous

-----

1.4 2.14 3.7 1.4 2.14 3.13

Verify primary atmosphere control method by back-up method**.

Dialy

Dialy

For salt baths: check salt chemistry ( soluble oxides ) in salt baths or decarburization on the parts.

Dialy

Dialy

E3.6

1.4 2.14

Monitor time in furnace, cycle time or belt speed.

Each bat ch ch

Twice/shif t & afte r a ny ny change in the belt speed

-----

E3.7

1.4 2.14

Monitor load size or fixturing or loading rate as

Each bat ch ch

Twice/shif t & afte r a ny ny change in the belt speed

-----

E 3.5

4.0

applicable.

Dialy

-----

IN-PROCESS/FINA IN-PROCESS/FINAL L TEST FREQUENCIES

E.4.1

1.4 2.15

Microstructure (when specified)

Dail Daily y per per furn furnac ace e

Dail Daily y per per furn furnac ace e

E.4.2

1.4 2.15

Surface hardness (when specified)

Each bat ch ch

Ever y 4 hours minimum

E.4.3

1.4 2.15

Core hardness (when specified)

Each batch

Every 4 hours

2x / week

2x / week

- Concentration Concentration of cleaner

Daily

Daily

- Temperature of solution (required if temperature is

Each shift

Each shift

5.0 E.5.1

----

-----

-----

SOLUTION TEST FREQUENCIES 2.13

Rust Preventive– Soluble Oil - Concentration

E.5.2

2.11

-----

Washers

-----



















GLOSSARY

See also SAE J415 for additional definitions of heat treating terms AIAG: Automotive Industry Action Group AMS: Aerospace Aerospace Material Specifications Specifications ASTM: American Society for Testing and Materials CTS: Control Temperature Sensor CTTS: Calibrated Test Temperature Sensor Capability: The total range of inherent variation in a stable process. Control Control Plans: Plans: Writte Written n descri descripti ption onss of the syste system m for contro controlli lling ng proce processe ssess for produ producti ction on of parts parts or bulk materials. Control Plans are written by organizations organizations to address the important characteristics characteristics and engi engine neer erin ing g requ requir irem emen ents ts of the the prod produc uct. t. Each ach part part m st hav have a Cont Contro roll Pla Plan, but but in many any case cases, s, "family" Control Plans can apply to a number of parts produced using a common process.

service parts parts critical critical for the operatio operation n of equipm equipment. ent. Extended Extended delay delay Critical Spare Parts List: A list of service obtaining spare parts would result in unacceptable delays in the heat treat operation.

in

team of empl employ oyee eess tha that repr repres esen entt the the diff diffeeren rent func functi tion onss with within in an Cross-Functio Cross-Functional nal Team: A team orga organi niza zati tion on.. The The team team will will typi typica call lly y cons consist ist of an oper operat ator or,, line line supe superv rvis isio ion, n, proc proces esss engi engine neer er,, metallurgist, metallurgist, and quality personnel. Customer: The recipient of the organization's or supplier's product or service. Customer Customer Requirement Requirements: s: This This term term refe refers rs to the the requ requir irem emen ents ts or spec specif ific icat atio ions ns from from the the orig origin inal al equipm equipment ent manuf manufac actu turer rer (typic (typical ally ly the autom automobi obile le compa company) ny).. These These may may be ident identifi ified ed in the contra contract ct or purchase order, in engineering engineering standards, part specifications, specifications, etc. Dew Pointer: A meter especially suited for measuring the dew point of carbon-bearing atmospheres. Dew point is used to indirectly determine the carbon potential of the atmosphere. Energy Monitor: Monitor: An electr electron onic ic monit monitor or that that measu measures res and and displa displays ys the actua actuall energy energy delive delivered red to the induction heating coil. Furnace Monitoring Systems: A system that monitors the operation of the furnace.

organiza izatio tion n that that perfo perform rmss heat heat treat treating ing (see (see 1.2 Appli Applica catio tion) n) to produc productio tion n and/o and/or r Heat Treater: Treater: An organ serv servic icee part parts. s. The The heat heat treat treatin ing g may may be inte intern rnal al or "cap "capti tive ve"" to a manu manufa fact ctur urin ing g orga organi niza zati tion on,, or a separate commercial commercial heat treating supplier. HTSA: Heat Treat System Assessment IR: Infrared Nonconforming Product: Product that does not conform to the customer requirements. Oxidizing Oxidizing Burn-Out: A proce process ss to remove remove any residu residual al ammo ammonia nia from the furna furnace. ce. The proce process ss usual usually ly





















Process Process Tables: Tables: Table Tabless in the HTSA HTSA that that list list fue required required proces processs contro controls ls for the heat heat treat treat proce processe ssess covered. These tables contain minimum requirements. Qualified Qualified Work Zone: The defined portion of a furnace volume where temperature variation conforms to the required uniformity tolerance. Quenchability Check: A measure of the cooling dynamics of the quench media. A quenchometer is the inspection machine that displays the cooling curve of the quench media. Quench Delay: Delay: The tim time dela delay y betw betwee een n the the end end of the the heat heat tre treat cycl cyclee and and the the star startt of the the quen quench ch operat operation ion.. For furna furnace ce heat heat treati treating, ng, this this is perio period d from from the time time the parts parts exit exit the the furnace furnace qualif qualifie ied d work work zone zone to the the time time the parts parts are at the bottom bottom of the quench quench tank. tank. For induc inductio tion n harde hardenin ning g system systems, s, this this is the time from the end of the heat cycle to the start of the quench flow (or when the parts enter a quench tank).

medium m used used to quenc quench h parts parts after after heat heat treat treating ing,, e.g., e.g., oil, oil, water water,, polym polymer, er, and Quenching Quenching Medium: Medium: The mediu salt. R-T/C: Resident Thermocouple used for comparative check of the control temperature sensor (CTS). Recipe: This This term term is typi typica call lly y used used when when a comp comput uter er--base based d syst system em sets sets and and cont contro rols ls the the proc proces esss parameters, parameters, e.g., temperature, temperature, cycle time, carbon potential. The “recipe” refers to the settings of the process parameters. Reprocessing: Any proce process ss that that is perfor performe med d on nonco nonconfo nform rming ing produ product ct so that that it will will meet meet the speci specifie fied d requirements. Responsibility Matrix: A responsibility matrix defines the designated personnel for all key functions. This matrix includes the primary and secondary designees. SAE International: Society of Automotive Engineers International Shop Traveler: Traveler: A docum document ent usuall usually y create created d in the receivi receiving ng depart departme ment nt for each each batch batch or lot of parts parts received. The document defines the process routing of the parts. Signature Signature Monitor: Monitor: An electron electronic ic monitor monitor used to monitor monitor inductio induction n heat heat treating treating systems. systems. The monitor monitor plots the energy unit, e.g., voltage or kilowatt, vs. time or distance. Special Special Characteris Characteristics: tics: are produc productt chara characte cteris ristic ticss or manuf manufac actur turing ing proce process ss param paramete eters rs which which can can



















Three-Val ThreeValve ve Fail-Safe Fail-Safe Vent (for ammonia ammonia fines): fines): An arrangem arrangement ent of three three valves valves that that preven prevents ts ammonia ammonia from from inadv inadvert erten ently tly ente enterin ring g the furna furnace ce during during carbu carburiz rizing ing or neutr neutral al harde hardenin ning g operat operation ions. s. The valv valves es are arranged in such a way that, when the ammonia fine to the furnace is shut off, any ammonia that might leak leak past past the valv valvee is vente vented d to the atmosp atmosphe here re and and thus thus preve prevent nted ed from from enter entering ing the furnace furnace.. See See the diagrams below.

Figure 1 — Valves 1 and 2 are opened to allow ammonia flow into the furnace.

Figure 2 — Valves 1 and 2 are closed to prev preven entt ammo ammoni nia a flow flow to furn furnac ace. e. If Valve 2 inadvertently leaks, ammonia is vented (Valve 3) to the atmosphere.

Trap Points – Areas in containers (baskets, fixtures, shipping boxes, etc.) or equipment that may inadvertently

trap parts, allowing the potential for parts to be mixed between batches. Work Instruction Instructionss – Instruc Instruction tionss that that describ describee work work conduc conducted ted in one function function in a company company,, e.g., e.g., setup, setup, insp inspec ecti tion on,, heat heat trea treatt oper operat atio ion, n, proc proces esss para parame mete terr tole tolera ranc nces es,, etc. etc. The The term term "wor "work k inst instru ruct ctio ions ns"" is




















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