NADCAP Checklista
NADCAP Checklista
NADCAP Checklista
C
Issued 1993-05
AUDIT CRITERIA
Revised 2011-05
161Thorn Hill Road
Warrendale, PA 15086-7527 Superseding AC7101/7 Rev. B
TO BE USED ON AUDITS CONDUCTED ON OR AFTER AUGUST 28, 2011
Nadcap
AUDIT CRITERIA FOR MATERIALS TESTING LABORATORIES -
MECHANICAL TESTING SPECIMEN PREPARATION
1.0 SCOPE
This checklist supplements PRI AC7101/1. This checklist applies to suppliers seeking Nadcap
accreditation for Materials Testing Laboratories – Mechanical Testing Specimen Preparation. It is intended
to establish the criteria for proper machining of test specimens to be used in Mechanical Testing.
2.1 Laboratory
2.3 Auditor
NOTE: The Bold sections in this document represent the interpretations for each section of this checklist. Items
noted with a single asterisk (*) are additional Nadcap requirements.
NOTE: Applicable definitions can be found in AC7101/1 General Requirements for Laboratories.
2.5 Capability and equipment - Attach an equipment and capability matrix that includes a list of specimen types
machined and major equipment used for the machining by preparation method (test code).
2.6 Preparation: Specimen preparation requires accreditation to Specimen Preparation Code Z for all general
specimen preparation and to Codes Z1 and Z2 for Cyclic Test Codes O and Y and for any other test for
which the material specification or prime requirements require Low Stress Grinding (LSG). Codes Z3 and
Z4 are additional specialty codes that may be required by some prime specifications.
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 there from, is the sole responsibility of the user."
2.7 Outside sources. If a Mechanical Testing Laboratory utilizes an outside source for specimen machining
(e.g. issues a PO), the laboratory shall ensure that configuration and preparation are documented. The
outside source shall be a documented supplier meeting the requirements of AC7101/7.
Note: this requirement applies to PO’s for machining originating from the laboratory. Sources of pre-
machined specimens that are submitted to the laboratory are the responsibility of the customer.
2.8.1 Source is to be audited as follows (on site audit required for all):
[ ] Code Z1 and Z2
[ ] Code Z (located at same facility as testing laboratory)
[ ] Code Z (not located at same facility as testing laboratory)
2.8.2 Code Z - The source is to be accredited for the following test specimens types (one or more) which require
100% machined or ground surfaces (Check all that apply):
2.8.3 Code Z1 (Low Stress Grind) / Code Z2 (Low Stress Grind And Polish) - The source is to be accredited
for the following test specimen types (Check all that apply):
2.8.4 Code Z3 (Cast Specimens) - The source is to be accredited for the following cast specimen types, which
may not require 100% machined or ground surfaces (Check all that apply):
2.8.5 Code Z4 (Special Purpose Specimens) - The source is to be accredited for "Special Purposes" specimen
types (Check all that apply):
Describe:
2.8.6 Describe Quality Systems responsibility (between the Specimen Preparation Source and the Mechanical
Testing Laboratory). Check all that apply:
Describe:
2.8.7 Dimensional inspection control - Describe Quality Acceptance disciplines. (This may comprise several
disciplines; check all that apply and explain below):
Describe:
PRI AC 7101/7 Revision C -4-
3.2 Written procedures are maintained which establish specific values for each YES NO
combination of specimen and material, for each process variable (e.g., speed, feed,
grinding wheel type). Reasonable tolerances may be included.
3.3 100% verification or SPC is required for all dimensions from which testing parameters YES NO
or results are calculated, and the dimensions that may affect testing axiality or stress
concentration.
Equipment operated
5.2 Preventive maintenance plan is followed and maintenance operations are YES NO
documented.
Blanking may be done by machining, grinding, Electrical Discharge Machining (EDM), pressing (flat specimens),
or other methods.
6.1 Blanking is performed by methods which do not distort the material or produce YES NO
surface effects deeper than would be removed by final finishing. (Explain as
necessary.)
Comments
7.1 Describe the specimen preparation practices. Use the capability matrix and note below
(as required):
7.2 Specimen preparation shall be performed in such a manner that the effect on material
properties is minimal. Preparation procedures and controls consider the following:
[ ]Grinding
[ ]Other
Describe:
Surface Finish conforms to customer requirements (LIST). May use microscopic YES NO
a. comparison with surface finish block.
Actual
b. Notch surfaces have no visible nicks or scratches. Describe frequency/method of YES NO
verification below.
Actual
8.1 Notch Dimensions: Must be provided with the specimen drawing. List specimen YES NO
drawing number(s) below.
Comments:
9.1 Documentation of Residual stress analysis is required for accreditation for Code Z2. X-Ray Diffraction
testing is the industry recognized technique for conformance to the residual stress specification. Other
methods may be acceptable if rigorous comparison testing is performed. Requirements are shown in
section 12.1
9.2 Low Stress Grinding Parameters - The machine shop shall have procedures defining the process for
which they achieve an acceptable low stress grinding operation. Table 2 references a set of parameters for
Low Stress Grinding dependent on the source of grinding wheels and machining equipment which may be
capable of meeting the required residual stress range. Any combination of grinding wheels and machining
equipment may be used that meets the residual stress specification.
PRI AC 7101/7 Revision C -6-
Comments
9.3 Final grinding of smooth gage sections conforms to values as specified by customer
for:
Axial (traverse)
Actual
Radial (plunge)
Actual
Note: For sections 10.1.1 – 10.1.8, alternate method acceptable if machine shop has documented acceptable residual
stress measurements and a specific procedure for achieving these results. Alternate method shall be approved by
customer. Document procedure used.
PRI AC 7101/7 Revision C -7-
10.1.1 Abrasive Paper: Silicon Carbide for Titanium Alloys & Aluminum Oxide for all other YES NO
alloys is used.
10.1.2 For round bars, automated polishing is used, unless otherwise specified by customer. YES NO
10.1.3 Round bars: Automatic polishing device controls polishing so that contact between YES NO
the specimen and a specific area on the abrasive is one stroke on the paper in the
axial direction (i.e. use that area on the paper only once).
10.1.5 Paper is backed during polishing with rubber 3/16 inch (4.8 mm) minimum thickness: YES NO
applied contact force - 6 lbs (2.7 kg) maximum.
10.1.6 Polishing is controlled so that contact between the specimen and a particular area on YES NO
the paper occurs only once and polishing is axial.
10.1.7 Circumferential grinding marks are removed with 180 – 240 (or finer) grit paper before YES NO
proceeding with finer grit.
10.1.8 Surfaces are polished with each finer grit paper until all longitudinal marks left by the YES NO
previous paper are removed.
10.2 Process aims for metal removal increments is as follows, as required to meet final YES NO
dimensions. List actual values used, or attach a copy of detailed instructions. As a
minimum material removal per step shall not exceed a total of 0.003 inches (76.2 µm)
of material removal on the gauge diameter.
Note – These requirements are intended to be minimum removal requirements (i.e. - in all cases finer grit paper may be
used as long as the following steps employ increasingly finer grit and the process is documented in procedure).
10.3 Final polished surface finish is 8 to 12Ra µinches (0.2 - 0.3 µm) or as customer YES NO
specified. Describe verification frequency/method below.
11.1 20X optical inspection, for surface anomalies, are performed on code Z2 bars. YES NO
Optical inspection (20X) of finished specimens is required for Code Z2 and is recommended for all other
specimens.
11.2 For notched and combination notched specimens, the required notch dimensions YES NO
(typically angle and notch radius) are verified at 10X minimum magnification.
PRI AC 7101/7 Revision C -8-
11.4 The finished surface exhibits uniform surface texture free from machining YES NO
irregularities such as undercuts or high spots (View the specimen.) Describe finish
and frequency/method.
11.5 Each specimen is dimensionally inspected prior to forwarding to the testing YES NO
laboratory, using at a minimum the following: 100% inspection, all dimensions of the
reduced section-sample inspection of other dimensions including notch;
measurements recorded.
11.5.1 Internal sampling plans (if used) are based on documented procedures. YES NO
11.5.2 Specimen preparation anomalies and conditions that may affect the testing results YES NO
are recorded in the dimensional report prior to sending specimens to testing
laboratory.
12.1 Residual stress shall be determined for each preparation procedure. A follow on plan YES NO
for periodic subsequent verification of all affected processes shall be in place. (one
procedure per year minimum)
12.2 Residual Stress on the surface of a representative specimen verified by X-Ray YES NO
Diffraction. Specific requirements shall be as specified by customer (Code Z2 only).
Note – if specific guidelines are not supplied the corrected (relaxed) residual stress measurements shall fall
within the historic range of 20 to 85 ksi compressive for an IN 718 cylindrical specimen.
At least 5 measurements (1 surface and 4 below) are needed to obtain a valid residual stress profile.
12.3 Residual stresses were determined initially for each procedure. YES NO
13.1 Each specimen is packaged and labeled in a manner to protect its integrity and YES NO
unique identity.
PRI AC 7101/7 Revision C -9-
EXPLANATION SHEET