PROCESS CHECK REPORT

Transcription

1 Process Title Category(s) of Approval Process Check Report Ref. No: Date Of Process Audit: Auditor (please print name): Nadcap Reference (if applicable): ADHESIVE BONDING METAL-TO-METAL AND SANDWICH CONSTRUCTION 19n Invoked Documents:- HBIFSAS/QA/SC1, QAIS Doc Ref Q5B-008H QA Element Calibration Status: All Inspection, Measuring and Test Equipment used in this Process is calibrated, and certified against equipment traceable to National Standards Yes No X Materiel Usage: All Materiel used in this Process is in accordance with requirements of the relevant Process Specification/Standard BAEP/BS: All work has been processed in accordance with the latest issue of the relevant BAEP(s) and/or National Standards Technique Sheets: All applicable Technique Sheets used, including Inspection Plans, are to the latest issue and have been approved by HBQSC Training/Qualification: All relevant personnel involved with this Process are appropriately trained, qualified and assessed periodically Internal Audit: The Internal Audit for this Process is current, with no outstanding CAs If No to any of the above QA Elements - give details below: Audit Comments: Auditor: QA Manager: Approved by (HBQSC): HBQSC/QA/SC136(M).XLS Issue 1 1

2 Invoked Documents Listing 1. Process Specifications Reference No. BS2647 Title Adhesive Bonding Metal-To-Metal And Sandwich Construction L Issue 2. Quality Assurance Instructions To Suppliers Reference No. Title Issue 3. Other Technical Documents Invoked Reference No. Title Issue 4. General For any devations to the appliable BAEP please see the Processor Surveillance Questionnaire Pack HBQSC/QA/SC136(M).XLS Issue 1 2

3 Details Of Check Is BS 2647 available and at the correct issue. Does an internal procedure exist and what is its reference/issue status. Result / Remarks Action Required Is the operation for the adhesive bonding process satifactorily incorporated into the planning. Are the history sheets available and fully endorsed. Are all the production adhesive materials and secondary materials used certified and approved to section 2 of BS Is the temperature capability of the autoclave ± 5 F ± 2 C and presses ± 10 F. Is the pressure capability ± 5 psig for both. Are the instruments and equipment certified and maintained per BS Are the air circulating ovens capable of maintaining temperatures of ± 10 F for drying and airing bonded parts. HBQSC/QA/SC136(M).XLS Issue 1 3

4 Is there a vacuum system capable of a minimum of 20mm of Hg. Do the gauges used for vacuum checking have a minimum of ± 1 inch mercury accuracy and 0.5 inch per division. Are the pressure gauges to an accuracy of ± 1% of the reading. Are the thermocouples of the type J to BS Does refrigeration exist which is capable of storing prepreg and adhesive materials at both 0 F and lower or 40 F and lower. Are the units equipped with temperature recorders that are certified and maintained per BS Are the lay up operations conducted in an area per the requirements of F and 60% RH max. Prior to starting production bonding of assemblies are test samples produced and qualified of lap shear, honeycomb peel and metalto-metal. HBQSC/QA/SC136(M).XLS Issue 1 4

5 Are these samples cleaned, layedup, bonded and tested, using the same production process. Are the lap shear panels as per BSD , with ½ inch overlap and 36 samples tested (12 at room temperature, 12 at -67 F and 12 at 180 F). Is the load rate applied at rate of psi per minute. The tests performed at -67 F and 180 F, are they done so at a minimum of 10 minutes after reaching the temperature. Is 1 sandwich panel (3 specimens) produced and tested in accordance with the ASTM-D-1782 figure 1). Are the metal-to-metal peel specimens tested for a minimum peel strength per ASTM-D Are 5 samples tested at room temperature. Are all detail parts to be bonded free from burrs, dimples and other surface imperfections which may be of detriment to the bond. HBQSC/QA/SC136(M).XLS Issue 1 5

6 Have all the surfaces of the parts been anodised as per BS and or After cleaning are all detail parts stored in area as per BS Are the preparation of surfaces for composite bonding (which is a film adhesive precured to metal skins for subsequent cold bonds) as per BS For class 1A, 1B and 11A assemblies, is at least one standard test piece per panel supplied (for class 11B, no test pieces are required). Is second or third stage bonding appropriate, if so are test specimens provided for each stage. Are standard test pieces fabricated as follows:- i) Sandwich construction, 0.5" thick 7.9 x ¼ x 4N5052 alloy honeycomb core 3" x 16" ribbon direction (BS ) with 2 skins 0.020", 2024-T3 clad alloy (BS ). ii) Lap shear as per PS (2 per panel). HBQSC/QA/SC136(M).XLS Issue 1 6

7 Are all adhesive materials recorded and controlled with a material tracking system (computer or documented). Are materials that have been cut off rolls tagged up immediately for traceability. Do metal bonded parts use primer as per BS Is the reticulation process used as per para A. Is one layer of film placed between all surfaces to be bonded. What is used to cut adhesives and prepegs for binding. Are assemblies cured before the shop life of the adhesive has expired. Are overlap adhesives splices between 1/8 to 1.5 inches. Are clean lint free gloves per BS used when handling adhesives and clean metal components. Are hot air guns used to tack adhesives to metal details. HBQSC/QA/SC136(M).XLS Issue 1 7

8 Is the direction of the film quoted on the drawing or is this optional. Are the items bagged accordingly and leak checked for seconds. Does a process data sheet exist with the production shop order quoted and the cure cycle data. Is the vacuum vented to the atmosphere after the autoclave psi exceeds the vacuum psi. Is the pressure applied before the bond line temperature reaches the minimum flow temperature of the adhesive being used. Is the temperature checked using devices to ensure than an adequate temperature is maintained over the total area being bonded. For each autoclave load is a minimum of 5 thermocouples used i.e., in the front third, 2 in the back third and 1 in the middle. If bonding one assembly, are a minimum of 2 thermocouples used. HBQSC/QA/SC136(M).XLS Issue 1 8

9 If presses are used to cure are the correct number of thermocouples utilised to determine the temperature. When curing assemblies is a minimum of 1 inch kept between the tools to allow air flow. Is full pressure maintained until the temperature is reduced to 180 F (a minimum of 10 psi or 5 inches of Hg shall be used). Are all bonded assemblies run in the autoclave checked for leaks for a maximum pressure build-up under the bag of 5 psi checked over a 30 second period or 10 psi over a 60 second period. Is each autoclave load monitored throughout the process. What is the maximum width of the bonded areas and does it exceed 2 inches, if so has process engineering approval been granted. Are the cure times and temperatures specified on the process data sheet. Has more than 4 cure cycles been carried out on assemblies and if so has approval been granted. HBQSC/QA/SC136(M).XLS Issue 1 9

10 Where are the areas that have been bonded, are they removed of adhesive flash in the correct manner. For rework and/or repair has authorisation been granted and documented. Are interior surfaces (except fuel cell panels) finished as per BS 361. Are interior fuel cell panels finished as per BS Is each assembly usually inspected to the requirements of the table 111 for:- i) Discontinuities, foreign material, warpage, thick bondlines. ii) Surface imperfactions. iii) Lack of squeeze out or pressure during the cure. iv) Voids. Where is this documented? Has a bond tool/thermal survey been carried out. Has a prefit check of the assembly details in the bond tool been conducted. HBQSC/QA/SC136(M).XLS Issue 1 10

11 Has the tool been checked by running a verifilm. Has the bonded assembly been non-destructively tested in accordance with 4.10 of BS Has the assembly been destructively tested for 1st article in accordance with previously stipulated requirements. Are the metal bond curing equipment and operators qualified per RAC PQCM For personnel performing NDT, are they certified to QA HBQSC/QA/SC136(M).XLS Issue 1 11