AC 7101/5 REV.

C

AUDIT CRITERIA
161Thorn Hill Road Warrendale, PA 15086-7527

Issued 1993-05 Revised 2011-05 Superseding AC7101/5 Rev. B

TO BE USED ON AUDITS CONDUCTED ON OR AFTER AUGUST 28, 2011
Nadcap AUDIT CRITERIA FOR MATERIALS TESTING LABORATORIES – HARDNESS TESTING (MACRO)

1.0

SCOPE This checklist supplements PRI AC7101/1. This checklist applies to suppliers seeking Nadcap accreditation for Materials Testing Laboratories – Hardness Testing (Macro).

2.0 2.1 2.2 2.3 2.4 NOTE:

GENERAL INFORMATION Laboratory Laboratory Contact Auditor Initial Accreditation Re-accreditation Follow-up

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. Applicable definitions can be found inAC7101/1 General Requirements for Laboratories.

NOTE:

2.5

Tests Audited: TEST CODE M1 M2 M3 CHECKLIS T AC7101/5 AC7101/5 AC7101/5 TEST TYPE Hardness HB Hardness HR Hardness HV EQUIVALENT TEST METHODS ASTM E10 ASTM E18 ASTM E92 ISO 6506 ISO 6508 ISO 6507 EN ISO 6506 EN ISO 6508 EN ISO 6507

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01-Jan-11

YES NO *Reading techniques for non-digital readout testing (e.0 3. Laboratory Name Testing Equipment Hardness Type Location (lab or shop) Digital. . 3. operators may choose to disregard test impressions they suspect of being irregular.6 *External Proficiency Testing (PT) and Internal Round Robin (RR) Programs: TEST TYPE Brinell Hardness (HB) Rockwell Hardness (HR) Vickers Hardness (HV) Other (List) NONE INTERNAL RR EXTERNAL PT Reference Appendix B per AC7101/1 for the requirements relative to External Proficiency and Internal Round Robin Testing. Provided two additional impressions are made.2 Daily verification process and recording of results. YES NO YES NO c. both of which give conforming values and whose variations are typical for the material and hardness procedure. d.5 for indentation spacing requirements.7 The laboratory shall maintain an equipment inventory list used for acceptance testing of material with the following information: a. Analog (Dial) or Brinell scope Scales or Brinell loads used Equipment Calibration Frequency Indenter Type(s) Inspection Frequency PROCEDURES AND DOCUMENTS Written instructions shall cover the following testing variables: a. 3. Written procedures cover operator options for hardness re-test. Preclude the use of correction factors to compensate for machine error. 2. Reading techniques for non-digital readout testing. b. parallax considerations in reading Rockwell dials). (Some operator discretion is permitted) YES YES YES NO NO NO Hardness Re-Test: Because problems such as specimen wobbling may occur which are apparent only to the operator and only at the time of testing. c. b.1 Refer to section 10.g.PRI AC 7101/5 Revision C -2- 2. Number of impressions for each test value reported. the suspect test may be disregarded and need not be recorded in the log or on the certificate.

with no rocking or lateral movement of the specimen. Make three or five impressions.PRI AC 7101/5 Revision C -3- 3. The preventive maintenance plan is followed and logged.5 YES NO 5. .3 The supplier has a written preventive maintenance plan in place.1 4.0 4.3 Written procedures cover hardness referee test. PERSONNEL AND TRAINING Verify personnel training for one testing discipline. Training includes testing of irregular shapes. Operators who read test machine dials or microscopically measure indentations shall be evaluated against other operators for consistency. Re-preparation of the specimen to improve surface finish. and without impact (overload) forces being applied. NOTE: 4. The base of the equipment shall be constructed such that it is sufficiently rigid to react to the test load. soft materials.1 Hardness testing equipment shall be designed to ensure that the force of the indenter is applied smoothly. All readings should conform to specification. and any special applications. YES YES NO NO Review plan and log for preventive maintenance.0 5. YES NO YES YES YES NO NO NO c. For Brinell hardness testing. which includes at least one of the following: a.3 4. 5. d. use of a hardness method or scale that best represents the material being tested: for example.4 Training is documented. • Use of spherical indenter methods when material is work-hardenable.2 4. Use of direct-reading digital equipment instead of equipment requiring human interpretation of readings. parallelism. b. and/or flatness. Function: Equipment operated: 4.2 5. report at least the median value. Median is used because it is an actual test reading. FACILITIES AND EQUIPMENT Hardness equipment is capable of performing the tests in accordance with all applicable requirements. the system utilized shall dampen acceleration of the load as it approaches the intended level.) YES NO The laboratory shall have a procedure addressing Hardness Referee tests. Required training is referenced via the Quality Manual. (May be checked against applicable standard test methods. When “alternate” test methods are permitted. • Use of Brinell hardness when “Brinell or alternate” is specified. • Use of Brinell hardness on castings or other large-grain material. • Selection of load which produces maximum sensitivity of readings (higher loads for higher hardnesses).

to ensure traceability from the certificate issued to the customer order.PRI AC 7101/5 Revision C -4- 6. or if ASTM E 140 conversion values do not hold true when load is changed for the same indenter). 2. Records show calibration is traceable to national standards (NIST.0 7. material tested.4 CALIBRATION Calibration records are available. A ball indenter holder shall have a serial number. Specimens shall be stamped. test results and original cutting plan. a cap and a ball.5 YES NO Indenters consist of: 1. and shall remain identifiable until disposal. Ball indenters which frequently consist of a holder. tagged or otherwise identified to avoid inter-mixing. 7. 8. (Rockwell only) YES YES YES YES NO NO NO NO 6. All indenters shall be serialized. HARDNESS CONVERSIONS Alternative methods are used only if permitted by one of the following (Check all applicable items below): Material specification Other as described below: YES NO 8. UKAS.1 MATERIAL IDENTIFICATION AND CONTROL Using general questions from PRI AC7101/1.1 6. etc). The laboratory’s systems shall provide for tracking and accountability of all specimens.0 6. A review of the calibration certificates by the QA function or the defined technical representative has been performed and documented. Diamond indenters.1 ALTERNATE METHODS. verify through specific jobs in process that this area complies.0 8. A diamond indenter shall have a serial number.2 6. The calibration is performed in accordance with all applicable requirements.3 6. When it is not practical to mark the serial number on the indenter due to size limitations.3 A conversion chart is used if one of the following conditions exist: Alloy groups not covered by ASTM E 140 Work-hardenable materials (these may be noted if Rockwell hardness testing shows needle movement more than 2 seconds after the loading lever has stopped moving. the serial number shall be marked on the container. YES NO A unique set of identifying numbers shall be assigned to each test.2 Hardness conversions are performed to: ASTM E 140 ISO 18265 Other documents (describe below): YES NO 8. test methods used. YES NO .

2. the inspection records show the measured values as well as the converted values (i.2 YES NO Hardness block identification shall consist of the following: • An official mark on the test surface or the thickness to an accuracy of ±0.2 .2. HARDNESS VERIFICATION YES NO 10.2 If conditions are other than normal operating conditions (ball diameter/load/load time/etc.005 inches (0.). YES NO Prior to use of ASTM E140 or other conversions. the mean hardness value. YES YES NO NO 10. or vice versa. including: Surfaces are not re-ground/re-polished.4 When conversion is used. those conditions are reported as required.1 mm).e.1. Indentations are only on the allowable test surface. YES NO For Brinell only when using a Type A measuring device a statement must be included on the test certificate to the effect that a Type A measuring device was used. YES NO 10. indentations should include several grains) using microhardness in lieu of Rockwell or Brinell. Alternate hardness methods. and free from scratches that may affect current indentation.0 9. a conversion report is required (primary versus equivalent method) for the following: • Alloy groups not covered by ASTM E140.2. • Microhardness in lieu of Rockwell or Brinell. Standard blocks are available for the scales and loads that are to be used for testing. as described below Describe: 8. Alternate hardness methods incorporating automatic test machines shall validate software performing hardness conversions to ensure adherence to ASTM E140.PRI AC 7101/5 Revision C -5- Castings and other coarse grained material (in general.1. to verify the original surface has not been ground.1 10. or vice versa. tolerance (if given) and the supplier’s identification. 10. conversion from another hardness scale or from tensile test).0 The Auditor is to check several standard test blocks.1 Standard blocks appear to be in a condition suggesting acceptable verification. the operator checks the anvil/fixture to ensure the absence of damage or foreign material.1 CERTIFICATE OF TEST / CONFORMANCE Test reports shall include all information required by the applicable industry standard/material specification and customer specification/requirements. • Each block shall be marked with the serial number traceable to its certification.1 Prior to verification. • Castings and other coarse-grain materials. The surface shall be uniformly polished. • Work-hardenable materials. 9. 10. 9.

anvil.3 At least one test block shall be used. (Rockwell only) The hardness tester is periodically checked against standard test block(s) at the following minimum frequencies: *Once each working shift during which acceptance testing will be performed.1 11. 10.1 10. Averaging of the reading is not to be used as acceptance criteria for the daily verification process.0 11. Diagonals for Vickers. METHOD Brinell Rockwell Vickers NOTE: 11. YES NO Periodic checks shall consist of at least two indentations for Brinell and Rockwell and five indentations for Vickers. This inspection shall include anvil and indenter. YES NO 10.tolerance of the standard test block. All individual test block readings must be within +/.4. or indenter are changed (Prior to each test run. and when commercially available.) at acceptable distances per the given test method. Frequency: Check once each working shift during which the tester will be used.1 11. and before the machine is checked with a test block.1 CENTER TO CENTER 3 3 2½ CENTER TO EDGE 2½ 2½ 2½ YES NO Diameters for Brinell and Rockwell.1. etc. * When load.5 Indentations are spaced (center to center. YES NO YES NO N/A See guidance in section 10.4 Hardness tester periodic checks are recorded and the test block identified. 10. the technician shall visually inspect the anvil and indenter. the hardness range of the test block shall be chosen to be within 15 Rockwell points of the hardness value that the testing machine is expected to measure. center to edge of block. anvil or indenter is changed.2 11.2. Preliminary indentations (may be on scrap stock) shall be made to ensure seating of the anvil and indenter. 11. defined as testing of materials using the same equipment set-up while the machine is under the control of the same operator).3. BRINELL HARDNESS TESTING Brinell Equipment Periodic Checks Periodic checks have been performed to the loads that have been used. to ensure that there is no damage. unless marked to disregard.2.3 Specimens for Brinell Testing . Brinell Set-Up Periodic Check (Before Acceptance Testing of Material) The periodic verification records are current and complete.3.1.2 YES YES NO NO Whenever the load.PRI AC 7101/5 Revision C -6- 10. • Brinell and Vickers: 1 indentation minimum • Rockwell: 2 indentations minimum The Operator shall inspect the equipment prior to the periodic check.3 10.

2. the indenter diameter. When indentations are made on a curved surface.4.3 YES YES NO NO 11. without a jerk.4. operator training ensures that parallax (line of site) error is not introduced.4 11.004”).1. the minimum radius of curvature of the surface shall be two and a half times the diameter of the indenter ball. Brinell Hardness Readings For each indentation two readings shall be taken 90 degrees apart around the diameter of the indentation and the mean is used to calculate hardness.2 12. The periodic verification records are current and complete.1. Load is applied for a time of 10 to 15 s unless otherwise required by the product specification.1 12.3 YES YES NO NO 12.3. Brinell Test Cycle (For one indentation) Selection of the load and indenter ball diameter is determined using the applicable standard in order to produce an indentation diameter in the range of 24 to 60% of the ball diameter.5 11.3) When the operator reads an analog dial.4.3 12.2 12.PRI AC 7101/5 Revision C -7- 11. the difference between the smallest and largest diameter readings of the same indentation shall be less than 0. The Major Load is removed as defined in the applicable testing specification.1 N/A YES NO 12. If times greater than stated in the application testing specification are used.3. If test conditions are different than a 10 mm indenter. YES NO 11.2 11.2 YES NO 12.1 YES YES NO NO YES NO 12.1 The thickness of the specimen tested is such that no bulge or other marking shows the effects of the test force on the side opposite the indentation. 3000 kgf scale and 10s to 15s dwell time.1.3. (see 10.1 YES NO 11.5.2 YES NO 11. those times are specified in the product specification.1mm (0. the thickness should be at least 10 times the depth of the indentation).1 YES NO 11.3.4.) ROCKWELL HARDNESS TESTING Rockwell Equipment Periodic Checks and Calibrations The hardness test blocks being used are appropriate for the materials being tested. and dwell time are reported. Manual Control (if applicable) The Minor Load is applied smoothly to reach +/-5 divisions of the “SET” position before re-setting the dial to zero. (To verify compliance.1.1 YES NO 12. (NOTE: Automated test machines may convert from indentation depth.2.0 12.4 YES NO . Any dwell time greater than that required by the applicable testing specification shall be recorded and reported after the test results.4 12.2.2 above.2. The major load is applied steadily.2. (As a general rule.1. Internal procedures address items 12.3 YES NO 11.1. The angle between the indenter force line and the surface of the specimen is a right ange / perpendicular.1 through 12.1. test force.

may be used only for tests which require minimum limits only.3.3 12.4.3.4 13. YES NO YES YES YES NO NO NO YES NO 13. 13.0005 mm or ±0.3. 13. two diagonals at 90° are measured and the mean used to calculate hardness.1 13. The periodic verification records are current and complete. whichever is larger. cylinders) are made in accordance with the applicable standard.3. YES NO YES NO N/A 13.1 For Vickers.3 13.2. unless otherwise required by the product specification.2.5%. Load is applied for a time of 10 to 15 seconds. Time used is reported if other than 10 to 15 seconds. YES NO *A minimum of two indentations shall be made and compared for consistency to insure that the specimen did not move. Vickers Hardness Readings For each indentation.1.1 VICKERS HARDNESS TESTING Vickers Equipment Periodic Check At least five hardness readings have been made on a standard test block on the scale and at the hardness level at which the machine will be used. Magnitude of test load is reported. such as large parts which require special fixtures or parts of irregular geometry.00002”).0 13. Vickers Test Cycle for One Indentation Magnitude of test is from 1 to 120 kgf.3 13.PRI AC 7101/5 Revision C -8- 12.3.4 13.1 Hardness Readings Non-Optimum specimens.3 YES NO 13.0005 mm (0.2 13. Specimens for Vickers Testing The surface of the specimen is sufficiently smooth enough to permit the reading of the indentation diagonal to 0.2 13.1 YES NO . the accuracy to measure the diagonals shall be within ±0.2 Corrections for radii of curvature (spheres.2.1 13. Test load is applied and removed smoothly.

PRI AC 7101/5 Revision C -9- EXPLANATION SHEET PARA NO. COMMENT .

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