NADCAP热处理工作组审核手册

1、NADCAP热处理工作组审核手册发布日期：2013年10月28日目录1. 范围. 3 2. 定义 . 3 3. 依据Nadcap审核准则实施审核 . 6 4. 质量体系 . . 21 5. 热处理审核清单. 23 6. 附录A：铝合金标准. 32 7. 附录B: 主要客户标准矩阵图. 38 8. 附录C: 主要客户对保温开始时间与保温时间的定义. 42 9. 附录D: 审核员公告. 43 9.1 主题. 43 9.1.1 高温测量. 43 9.1.2 工序控制测试. 51 9.1.3 主要客户的关注内容. 53 9.1.3.1审核员公告11-001 HT罗罗公司. 53 9.1.4 作业审核.

2、 59 9.1.5 审核管理. 60 9.1.6 其他内容. 64 10. 附录 E:文件修订历史. 651. 范围This Audit Handbook has been prepared to assist the Heat Treating Auditors and Suppliers as follows: 此审核手册在以下方面给予热处理审核员和供应商相应指导：1. Where necessary, provide clarification on the intent and rationale of the Heat Treating Task Group as it pertai

3、ns to specific questions contained in the current revision of AC7102 and its corresponding slash sheets, as well as heat treating specific issues with Materials Testing Laboratories (MTL) checklists commonly used during heat treating audits. 需要时，说明热处理工作组的目的和理论依据。因为这是热处理审核时经常用到的AC7102标准和其相应斜格表，以及材料实验

4、室（MTL）审核清单所要求的具体内容。2. Clarify the material to be reviewed in addressing audit questions 在处理审核问题时，应理清评审需要的资料。3. Standardize the audit from Auditor to Auditor 使每个审核员的审核表标准化。4. Standardize definitions 使定义标准化5. Provide general guidance on Task Group expectations as to the Suppliers preparation for an au

5、dit and on an auditors execution of the audit 提供以下两方面的通用指南：工作组要检查的供应商所作的审核前期准备过程以及审核员实施审核过程。6. Provide general information on unique requirements of participating prime contractors to aid the Auditor in determining supplier conformance to customer requirements 提供有关主要客户特殊要求的基本资料以便审核员能够确定供应商是否符合客户要求。

6、This handbook was prepared to directly reference the most current audit checklist revision. Sections are divided to correspond to audit criteria slash sheets. Current Heat Treating controlled checklists are: 此手册直接引用审核清单的现行有效版本。各章节也按照审核准则斜格表而划分。现行有效的热处理审核清单包括：l AC7102 Nadcap Audit Criteria for Heat T

7、reating Nadcap热处理审核准则l AC7102/S Nadcap Supplemental Audit Criteria for Heat Treating (Primes specific requirements) Nadcap热处理审核补充准则（重要客户具体要求）l AC7102/1 Nadcap Audit Criteria for Brazing Nadcap钎焊审核准则l AC7102/2 Nadcap Audit Criteria for Aluminum Heat Treating Nadcap铝合金热处理审核准则l AC7102/3 Nadcap Audit Cr

8、iteria for Carburizing Nadcap渗碳审核准则l AC7102/4 Nadcap Audit Criteria for Gas and/or Ion Nitriding Nadcap气体和/或离子渗氮审核准则l AC7102/5 Nadcap Audit Criteria for Hardness Testing for Heat Treating Nadcap热处理硬度试验审核准则l AC7102/6 Nadcap Audit Criteria for Hot Isostatic pressing (HIP) Nadcap热等静压审核准则l AC7102/7 Nadc

9、ap Audit Criteria for Induction Hardening Nadcap电磁感应硬化审核准则l AC7101/3 Nadcap Audit Criteria for Material Testing Laboratories Mechanical Testing Nadcap材料实验室力学测试审核准则l AC7101/4 Nadcap Audit Criteria for Material Testing Laboratories Metallography and Microindentation Hardness Nadcap材料实验室金相和微型压痕硬度审核准则l

10、AC7110/1 Nadcap Audit Criteria for Brazing (Torch/Induction) Nadcap钎焊（火焰/电磁感应）审核准则Additional checklists may be required during an audit (including AQS and/or MTL Task Group checklists). This handbook will not give guidance for questions based on other Task Groups checklists; however, if an interpret

11、ation conflicts between Task Groups, the Task Group that controls the given checklist will be the governing body.审核时也可要求提供其他审核清单（包括AQS和/或MTL工作组审核清单）。此手册不适用于其他工作组审核清单；但若不同工作组的解释相冲突，则以控制此审核清单的一方为主。2. 定义 NOTE: Many of the detailed requirements for the items defined below are found in the applicable spe

12、cification. These definitions apply ONLY if no customer requirements are specified. 注：下列规定各项内容的许多具体要求均来自适用的产品标准。这些定义仅当客户无特殊要求时才适用。Activation - A process by which the surface to be Nitrided is prepared by using various processes (chemical/mechanical) to minimize the risk of non-uniform nitriding (het

13、erogeneous in depth and superficial hardness). 活化通过各种工艺对需要进行氮化的表面进行处理以降低不均匀渗氮风险的过程（各种深层和浅层硬度）Conversions from Fahrenheit °F into Celsius °C - When assessing Suppliers against customer requirements which are expressed in degrees Celsius take a special note of conversions from degrees Fahren

14、heit in TUS, SAT, etc. Customer and governing specifications, especially of European origin, may have temperature tolerances which are less than the similar North American (e.g. AMS) material. For example, solution treatment of aluminium alloys is typical +/- 10 °F in AMS, but +/- 5°C (

15、77;9°F) in European standards. 把华氏度°F转换为摄氏度°C在依据用摄氏度描述的客户要求对供应商进行评估时，应为TUS和SAT等测试标注其相应的华氏度数值。客户及三方机构标准（尤其是来自欧洲的标准）中的温度公差有时要比相应北美资料（如AMS标准）的要求更严格。例如铝合金固溶热处理在AMS标准中的公差通常为+/-10°F，但在其相应欧洲标准中则为+/- 5°C (±9°F)。North American standards for heat treatment may also have defi

16、nitions which are not in line with the European Prime requirements (e.g. AMS-H-81200, clause 6.3.9 Metrication). 北美标准对热处理的定义有时也与欧洲主要客户要求不一致（如标准AMS-H-81200中条款 6.3.9公制单位） 例如: A European Prime requires an aluminium solution heat treat temperature of 475 °C +/- 5°C. In the case where the Suppl

17、ier is working and calibrating in Fahrenheit they have to be within the +/- 5°C (±9°F) maximum allowable tolerance. If the furnace(s) are tested/certified to a uniformity of +/- 10 °F, this converts to +/- 5.6 °C and exceeds the required tolerance. This is a NCR. 欧洲主要客户要求铝合金

18、固溶热处理温度为475 °C +/- 5°C。当供应商采用华氏度实施校准时则必需控制最大允许公差+/- 5°C (±9°F)以内。如果炉子测试验收的结果为均匀性+/- 10 °F，转换成摄氏度为+/- 5.6 °C，超过了规定公差。则为不符合项。Final heat treatment: Heat treatment which confers to items the required mechanical and/or physical properties.最终热处理：为材料实现规定力学性能和/或物理性能的热处理。Fu

19、rnace Recording Any records (either hard paper or electronic) generated by the furnace itself representing the time, temperature, vacuum level, or atmosphere data associated with the processing of parts or raw material. 炉子控温记录炉子本身生成的任何记录（纸质版或电子版），包括有关部件或原材料处理的时间、温度、真空度或气氛数据。Industrial Soaking time:

20、Temperature-soaking time of the furnace at the setting temperature. 行业保温时间： 炉子在设定温度的保温时间。Intergranular Oxidation/Intergranular Attack (IGO/IGA) Per ASTM definitions. 晶间氧化/晶间腐蚀（IGO/IGA）- 参考ASTM定义。Intermediate Temperature - A temperature that the part must be cooled to (or below), or heated to (or abo

21、ve), prior to continuing the next sequence stage of the heat treat process. 中间温度在继续热处理下道工序前必须对部件冷却（或更低）或加热（或超过）的温度。Leak Up Rate (leak rate) - A test in which the furnace chamber is evacuated, isolated from the evacuation source, and the leakage determined within the system by observing the pressure

22、rise per unit of time. NOTE: Leak up rate expressed in microns/hours. 1 micron is approximately = 1 X 10-3 Torr = 0.001 mm Hg = 133 X 10-3 Pascal. 漏气率对炉膛进行评估、与泄漏源隔离，并通过对单位时间内气压上升量的观察确定系统内的漏气情况的测试。注：漏气率用微米/小时表示。1微米约=1 X 10-3托=0.001 mm Hg = 133 X 10-3帕For example, when 1 micron is specified, an increa

23、se of 0.1 micron is a higher Vacuum or lower pressure limit.例：当规定为1微米时，0.1微米的增量则为较高真空极限或较低压力极限。Long Job Audit Audit of multi-step heat treat process on a job which has been completed (sections 12 and 13 in AC7102 checklist). Long jobs MUST be selected from history and MUST include the completed test

24、ing results for the jobs. 长作业审核对已完成的多重热处理工序工作的审核（AC7102审核清单第12和13章）。长作业必须从历史经验中选定且必须包括此工作已完成的测试结果。Material Specification Industry or Prime specification which defines the properties of the parts or raw material. 材料标准规定部件或原材料性能的行业标准或客户标准。Metal Temperature When called out in a spec or procedure, manda

25、tes the use of load thermocouples unless otherwise specified by the Prime. 金属温度当产品标准或工艺规程中对金属温度有相关规定，需规定对负载热电偶的使用，除非客户另有规定。Metallurgical soaking time Minimum amount of time required by Material specification for any point of parts to be at set temperature, taking into account the applicable heat tre

26、atment tolerance. 金相保温时间材料标准要求部件任一点均达到设定温度的最短时间，考虑相应的热处理公差。NCR Non-Conformance Report, findings during an audit that require the full five part response as outlined in the Suppliers guide. NCR不符合项报告，需要采取供应商指南中指定的完整五步法的审核结论。Nonsustaining / Repeat Findings Non-conformances that are generated as a resu

27、lt of not implementing corrective actions from the last performed full audit or those where corrective actions may have been implemented but were determined to be ineffective. 无支持/重复结论自上次实施全面审核以来，因未落实纠正措施而导致的不符合项，或落实纠正措施后发现措施无效而导致的不符合项。Objective Evidence Will include, but may not be limited to: job

28、travelers, furnace charts, various types of logs and logbooks, training records, document change records, customer documents such as purchase orders, packing slips, etc. that do not contain Export Controlled Data. Objective evidence is required to be submitted for all findings, regardless of their d

29、esignation. 客观证据包含但不限于：生产工艺卡、炉温记录、各种生产记录、培训记录、文件更改记录、客户文件，如：采购订单、装箱单等，不包括出口管制数据。所有客观证据均须附在相应的结论下方。Parts (Extracts from AMS-H-6875, AMS-H-6088, AMS-H-81200, etc.) Usually identified by a part number, produced from raw material in accordance with the requirements of a drawing, and are usually tested b

30、y nondestructive techniques only. They are heat treated, by or for a fabricator, in accordance with a drawing, purchase order, fabrication order, or heat treat specification. At the time of heat treatment, they may resemble raw material. 部件（定义来自标准AMS-H-6875、AMS-H-6088、AMS-H-81200等） 依据图纸要求从原材料加工而成，通常

31、用部件编号来识别，仅用无损技术进行检测。部件是由生产商依据图纸、采购订单、生产订单或热处理标准生产或为其生产的产品。热处理过程有时与原材料相似。The Heat Treating Task Group further states: The primary difference in interpretation of parts vs. raw materials focuses on Castings and Forgings. Some Primes consider Castings and Forgings as Parts, while others consider them a

32、s Raw Materials. It is the responsibility of the Supplier to know and demonstrate compliance with the policy of each individual Prime Customer. 热处理工作组强调声明：部件和原材料的主要描述区别在于铸件和锻件。有些主要客户认为铸件和锻件是部件，但有些则认为是原材料。供应商有责任了解并证明与每个主要客户方针的一致性。Raw Material (Extracts from AMS-H-6875, AMS-H-6088, AMS-H-81200, etc.)

33、Usually includes, but is not limited to, such items as sheet, plate, wire, rod, bar, forgings and extrusions. It is usually identified by a heat or lot number and is usually tested destructively for acceptance. It is heat treated, by or for a material producer, in accordance with a material specific

34、ation which may require, by reference, conformance to a heat treating specification. 原材料（定义来自标准AMS-H-6875、AMS-H-6088、AMS-H-81200等）通常包括但不限于板材、线材、棒材、锻件和挤压件。通常以热处理编号或批号来识别，采用无损检测进行验收。原材料是由材料生产商依据材料标准（材料标准有时引用并要求满足热处理标准的要求）热处理生产，或为其生产的产品 NOTE: The table below it is a guide that was put together by the H

35、eat Treating Task Group Primes to help Suppliers and Auditors when they perform/audit Pyrometry testing. It is intended to be used when there is no clear flowdown information from the Customers. 注：下表是由热处理工作组主要客户整理而成，以为供应商和审核员在进行高温测量操作/审核时提供指导。此表可在客户未提供相关要求时使用。 The table below is not intended to repl

36、ace the Customer Primes flow down 下表不可替代主要客户具体要求Does your company consider Castings and Forgings Parts or Raw Material?贵司觉得铸件和锻件属于部件还是原材料?公司铸件和锻件部件（指定了部件号和/或进行了最终热处理的硬件）原材料Alenia阿莱尼亚XBAE Systems英国BAE系统XBoeing波音XCessna美国赛斯纳XEurocopter欧直XGE Aviation通用航空XHamilton Sundstrand汉胜XHawker Beechcraft豪客比奇XHone

37、ywell霍尼韦尔XMTU德国MTUXParker派克XRaytheon美国雷声XRolls Royce Corporation罗罗XSikorsky美国西科斯基XSonaca索纳卡XSAFRAN赛峰XTriumph Group黛安芬集团XRound Robin An internal Round Robin is an intra-laboratory study or measure of the reproducibility of results generated by the laboratory personnel using the laboratory procedures.

38、 The intent of the internal Round Robin is to address the reproducibility of the results by operators and test equipment. Round Robin is described in AC7101. 内部比对内部比对是指对实验人员通过实验步骤得到结果的再现性在实验室内部进行研究或测量。内部比对是操作者利用实验设备对结果的再现性进行确定的过程。内部比对在AC7101中有具体规定。Slash Sheet Audit criteria on a specific area that m

39、ay be optional dependent on a Suppliers facilities. 斜格表特定领域的审核准则可依据每个供应商的设施而进行选择性使用。Slash sheets are numbered on the base checklist as “AC7102/X”. 斜格表在基础审核清单上的编号为“AC7102/X”Soak Time The amount of time required by specification, blueprint, purchase order or operation sheet approved by the customer (f

40、ixed process) for the furnace/parts to be at the specified temperature soak range.保温时间客户认可的标准、设计图、采购订单或生产工艺卡所规定的炉子/部件在特定保温温度范围所需时间长度（固定工艺）。Short Job Audit A single thermal cycle that may be in-process during the audit, or completed at the time of the audit. 短作业审核审核时正在进行的或已完成的单一热处理工艺周期。Systemic Proce

41、dures, actions, or events that are not isolated, but found to be part of the Suppliers system. When multiple occurrences of the same violation are observed, it is termed as being systemic. 体系性程序、措施或项目不是孤立存在的，而是作为供应商体系的一部分。当发现同一不符合项反复出现时，可称之为体系性。Vacuum Heat Treating and/or Brazing A heat treating and

42、/or brazing performed at any pressure below atmospheric pressure (760 mm Hg). 真空热处理和/或钎焊在低于大气压强的任一压强下（760 mm Hg）进行的热处理和/或钎焊操作。Vacuum Level "Higher" or "better" vacuum means "lower" pressure. Required levels will usually be specified by the drawing or material specificat

43、ion, and unless otherwise stated are maximum pressure levels. For conversion: 1 Torr= 1mm Hg = 133 Pascal = 1x103 microns. For examples, when 1 micron is specified, a deviation of 0.1 micron is a higher Vacuum or lower pressure limit. 真空度“较高”或“更好”的真空度是指压强“较低”。需要的真空度通常在图纸或材料标准中有明确规定，且为最大压强度，除非另有规定。转换

44、时，1 Torr= 1mm Hg = 133 帕 = 1x103 微米。例如，规定为1微米时，0.1微米的偏差则为较高真空度或较低压强极限。Voided Nonconformance A nonconformance generated as the result of a clear misunderstanding by the Auditor and struck out as a “void”. Requires rationale for voiding and will require review by Task Group or Staff Engineer. Number a

45、ssigned should not be re-used. 不符合项作废“废除”由于审核员的明显误解而导致的不符合项。废除时需要废除证据，并由工作组或主管工程师进行评审。分配的编号不可重复使用。 3. AUDITING TO Nadcap AUDIT CRITERIA 依据Nadcap审核准则实施审核Since the number of cycles is counted and can lead to an audit failure if it exceeds a threshold defined in NOP-011, Supplier is invited to avoid us

46、ing eAuditNet as a mail box in order to obtain some explanations from the Staff Engineer.由于限制周期次数，且超过NOP-011中规定次数后会导致审核失败。建议供应商不要把eAuditNet作为邮箱来使用以获得主管工程师的相关答复。3.1 Specification Adherence 与标准的符合性The Heat Treating Task Group identifies industry specifications for use and guidance as applicable. 热处理工作

47、组按照需要对行业标准进行识别以便使用和指导。Suppliers are not allowed to automatically default to those requirements. They are to adhere to whatever their Customer requires of them by Engineering Drawing or Purchase Order. As a general reference, a matrix of Nadcap Mandating Primes and the specifications they generally r

48、equire their Suppliers can be found at the end of this document in the Appendixes A & B. 供应商不可主动放弃任何要求，而应该符合客户通过技术图纸或采购订单对其规定的任何要求。总参照最后的附录A和附录B为Nadcap受权的主要客户及其对供应商总要求标准的矩阵图。 3.1.1 Industry Specification Supersession 行业标准的替代标准Each Prime, and in some cases individual programs within a Prime, have

49、 different policies for the acceptance of superseding or replacement industry specifications. There is no default policy. Each Supplier must be knowledgeable of the supersession policy for each individual Prime and program for each job of parts or raw material processed. This knowledge must be docum

50、ented to the satisfaction of the Nadcap auditor for each job processed. 每个主要客户（有时是主要客户内部的独立项目）对行业替代标准的接受方针不同。没有哪个方针是默认的。所有供应商均应掌握每个独立主要客户和项目对每个部件或原材料处理工作的替代方针。每个完成工作的替代方针必须记录下来以满足Nadcap审核员的要求。 Question: What is the Nadcap Auditor to do when during a job audit they find that the Supplier has a P/N fr

51、ozen/ fixed planning process signed by the Prime Customer that deviates from the specification referenced in the frozen/fixed planning? See Table below for guidance.问：作业审核中Nadcap审核员发现，供应商主要客户认可的部件固定策划过程与固定策划中引用的标准相左时，审核员应该怎么办？请参照下表。Nadcap主要客户是审核员应该开具不符合项报告。因为我公司只用固定策划来保证与引用标准的符合性。审批此固定策划的供应商和人员失误了。否

52、审核员不应开具不符合项报告。我公司用固定策划过程来认可与标准要求的偏差。如果主要客户认可了此固定过程，则不需要做进一步调查。不适用我公司不使用固定策划或过程Airbus SAS空客SASX注：供应商应有供应商PFA（替代许可）偏差必须由客户认可并接受，否则为不符合项Alenia Aeronautica阿莱尼亚航空若供应商有认可的PSD（工艺标准偏差），则允许与标准的偏差BAE Systems英国BAE系统XBell Helicopter贝尔直升机XBoeing波音"Heritage" Douglas (DPS)“传统”道格拉斯X"Heritage" Boeing (BAC) “传统”波音X*见下评论&quo