Process : Penetrant Inspection

Transcription

1 1 of 7 1. Audit No: 2. Audit Date : 3. Audit Area: 4. Auditor Name & Sign: Process : Penetrant Inspection 1 Materials and equipment List all penetrant/combination used at this facility. Materials shall be listed on QPL of the latest AMS-2644 Level Type/Method/Form Penmetrant Emulsifier Developer 2 Does the facility have traceability to manufacturer's certifications for each material use? 3 Verify the penetrant inspection system A. Describe penetrant application system. B. Descrine emulsifier application system. C. Describe developer application system. 4 Is spray penetrant application available? 5 Is automated equipment in use at this facility? 6 Is electrostatic spray utilized? 7 List the generic types of parts that are penetrant inspected at this facility A. Manual process B. Automatic process 8 Is there a general procedure for processing and inspecting parts using liquid penetrant technique? A. Procedure No B. Rev. Date 9 Do the written inspection procedure, general or specific contain the following information as applicable?

2 2 of 7 1) The procedure I.D, number, applicable program, if program specific, and the date the procedure was approved? - Date of approval and Approval of Level 3 2) Listing of deviation and approval by customer 3) Requirement that all personnel are qualified and certified to an appropriatelevel. 4) The part number and material, to be examiner 5) Equipment to be used including any unique requirements for automated Vs manual equipment 6) Requirement for pre-cleaning and/or etching process including material, processing time, metal removal, and dry parameter? 7) Brand name and specific type of penetrant, sensitivity level, emulsifier, developer classification in accordance with AMS ) Complete processing parameter - dwell time, application method, dry times, concentration of emulsifier temperature and control to prevent excessive dry or overheating? 9) Method of removing excessive penetrant and drying the surface prior to developer application. - spray water nozzle type, water pressure and temperature, hydro-air nozzle and air pressure - method of developer application, complete post-cleaning 10) Evaluation procedure including - black light intensity, inspection booth ambient white light intensity, dark adaption time, prohibition of photo chromic lenses, acceptance criteria and controls for mechanical evaluation and solvent cleaning evaluation. 11) Identification of components or areas within a component to be inspected. 12) Applicable acceptance class and zone per engineering drawing specification 13) Part masking when required (method and location of marking parts) Method for control of software or programming used for automated processing equipment as applicable? 14) A statement to the effect that quality assurance provisions will be met 10 Statement to the effect that the procedure complies with the applicable specification requirements? A. BOEING : BAC 5423, BSS 7039 B. BELL : BPS 4089 C. DE-HAVILLAND : PPS D. KFP : NDTS 1101 E. T-50 : 85MP0411 F. KT-1 : ASTM E1417, MIL-STD-6866, NDTS 1101 G. LEARJET : P300 H. GKN : WHPS 007, WHPS 606 I. G-V : CVA 1-6, , , J. C-130 : STP K. AH-64 : HP 6-35

3 3 of 7 11 Provisions for process control tests and checks to be performed? 12 Approved deviation is listed and validated? 13 Are procedure for special material handling and processing parts defined? Procedure Title : Procedure Number : 14 Are technique cards prepared by Level 2 and approved by Level 3? These technique cards incorporate required information performing inspection? 15 Laboratory Test Control Penetrant brightness test ⑴ Is the fluorescent brightness of in use penetrant being tested and documented? - Frequency : Quarterly - Test procedure in accordance with AMS Is the minimum acceptance 90 %? ⑵ Are records of this test on file and do they provide acceptable values? ⑶ Can the facility demonstrate this check? 16 Water Content Description Water washable penetrant Emulsifier Is the water content or water tolerance in-use Requirements material being tested and documented? Interval Procedure Acceptable Limit 17 Concentration of hydrophilic emulsifier ⑴ Is the concentration in-use hydrophilic emulsifier being tested and documented? ⑵ Is this check being performed weekly? ⑶ Is a refractometer is used to perform this test? ⑷ What is the maximum variation allowed? ±3 % or other ⑸ Are concentration kept below - 20 % for immersion application - 5 % for spray application ⑹ Are records of this test on file and do they provide acceptable values? ⑺ Can the facility demonstrate this check?

4 4 of 7 18 Dry developer characteristic ⑴ Is the dry developer in use being checked and documented daily? ⑵ Does this check ensure that the developer is not caked and that recycled dry developer has not picked up excessive fluorescent material? ⑶ Is there a procedure requirement the periodically add/replace developer? ⑷ Are records of this test on file and do they provide acceptable values? ⑸ Can the facility demonstrate this check? 19 Aqueous developer ⑴ Is the concentration of in-use form b, c being checked & documented weekly? ⑵ Is a hydrometer being used for this test? - What are the acceptance limit? ⑶ Does the aqueous developer wet the test panel and not contain fluorescent material? ⑷ Are records of this test on file and do they provide acceptable values? ⑸ Can the facility demonstrate this check? 20 System performance ⑴ Is the system performance checked and documented daily? ⑵ List known defect standard and the acceptance criteria. ⑶ Are records of this test on file and do they provide acceptable values? ⑷ Can the facility demonstrate this check? ⑸ Known defect standard - properly identified and maintained? - checked at least monthly to detect degradation of its sensitivity 21 Sensitivity of in-use penetrant ⑴ Is the sensitivity of in-use penetrant checked monthly against unused and the results documented? ⑵ List known defect standard and the acceptance criteria. 22 Removability of penetrant and emulsifier Description Water washable penetrant Emulsifier Is the water content or water tolerance in-use Requirements material being tested and documented? Interval Procedure Acceptable Limit

5 5 of 7 23 Dry control ⑴ Is a dryer oven used at the facility? - thermostatically controlled? - temperature indicator & its reading? ⑵ Is the calibration current? (calibration frequency & due date) 24 Light meters and measurement Description Blacklight White Light Instrument List up Calibration Intensity Frequency Frequency check Requirement Requirement 25 Penetrant and Process Control Pre cleaning ⑴ Is an equipment in place to adequately clean parts to remove grease, oil, rust, etc? ⑵ List the alloy groups and cleaning methods utilized. Alloy group Cleaning method 26 Pre-penetrant etching ⑴ Does the facility have the capability to perform pre-penetrant etch inhouse ⑵ List the alloy groups and etching solution Alloy group Etching solution Acid Caustic ⑶ Are process controls in place to ensure consistent etch rate? ⑷ Do operator instructions adequately address circumstances for pre-penetrant etching? ⑸ Do operator instructions adequately describe the etching process procedure? ⑹ How does the supplier verify the etching solution has been completely removed from the hardware? ⑺ List the name and address of the subcontracting facility 27 Penetrant application ⑴ Are components, penetrant and ambient temperature maintained between 40 ~ 120?

6 6 of 7 27 ⑵ Do the means exist for controlling penetrant dwell time? List : ⑶ If the temperature of the parts or penetrant material is below 50, is penetrant dwell time doubled? ⑷ Are electrostatic spray operations controlled to ensure complete coverage of parts? ⑸ Are parts dried prior to penetrant application? ⑹ Are the contents of all tanks labeled and are all tanks in system arranged to prevent mixing of materials? 28 Use of emulsifier ⑴ Does a means exist for controlling emulsification time? ⑵ Are methods of emulsifier properly controlled? (application / removability) 29 Penetrant removal ⑴ Is rinse water controlled to provide coarse and conical spray? - List nozzle (mfg'r) : ⑵ Is the rinse water temperature controlled between 50 ~ 100? How is the rinse water temperature monitored? ⑶ Is the rinse water pressure controlled to 40 psi maximum? How is the water pressure monitored? ⑷ Check the calibration frequency of temperature and pressure gage? ⑸ Are hydro nozzles used only for level 1, 2 sensitivity? - air pressure controlled to 25 psi maximum? - How is the air pressure monitored? - The monitoring gage is calibrated? ⑹ If compressed air is used, is it filtered? ⑺ Is penetrant removal verified under black light? ⑻ Are the temperature and pressured checked at the start of each shift 30 Developer application ⑴ Are all agitated dry developer tanks equipped with dehumidifier filers and oil separators? ⑵ Do the means exist for controlling developer dwell time? ⑶ Are parts dried properly prior to developer application? ⑷ Are methods for applying and removing excess developer properly controlled? 31 Inspection Area ⑴ Is magnifying glass available? List : 3x, 5x, 7x, 10x, etc ⑵ Is bore scope available for evaluating indication (black light, white light)? ⑶ Are calibrating measuring devices available? ⑷ Is the area free of fluorescent material or other contamination that may interfere with the inspection process?

7 7 of 7 32 Impression stamp Provide impression stamps(s) used to denote final penetrant inspection. 33 Customer specifications ⑴ All the detail and unique customer requirements are available? ⑵ Check the actual parts in accordance with purchase order. ⑶ Document control, processing, inspection record, etc all the items which were defined previous check sheet shall be checked in accordance with unique customer requirements? 34 Job audit Select 3 lots of parts at random from current production to determine the compliance with these requirements. Part Description Audit#1 Audit #2 Audit #4 Customer Spec DWG Rev. PL Rev. Used penetrant Used emulsifier Used developer SOIR No Results 35 Verify the previous corrective action items.

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