Automotive Industry Action Group cal -9 Special Process: Heat Treat System Assessment 3d Edition . » > > J , » , , ® ® , , » ® _Mungedrucites Dokument untertegt nisht dem Aanderureclore:,‘eUUUCEUSUEE EES p OC CCU KUN SESE See eKeCeeeeES’ , , , , , , , , ’ ’ , , ’ ’ ) , ’ ’ ’ ’ ’ ’ ’ ’ , , > > > , > , > » , > J . J J > D AIAG 2m a8 Special Process: Heat Treat System Assessment Tre cata for peak perfomance Version 3, issued 10/2011 ABOUT AIAG Purpose Statement Founded in 1982, AIAG is a globally recognized organization where OEMs and suppliers unite to address and resolve issues affecting the worldwide automotive supply chain. AIAG's goals are to reduce cost and ‘complexity through collaboration; improve product qually, health, safety and the environment; and optimize speed to market throughout the supply chain AIAG Organization AIAG is made up of a board of directors, an executive director, executives on loan from member companies, associate directors, a full-time staff, and volunteers serving on project teams. Directors, epartment managers, and program managers plan, direct and coordinate the association's activities Under the direction of the executive director. Fre Projects 9) Volunteer committees focus on vusele' ‘de Supporting tectnblogies and methodologies. They conduct research and develop, muh oe provide. tel standards, conventions, standard business practices, white papers, and|Duitielings-in the ate#s 6 autojiatic identification, CAD/CAM, ED\ielectronic commerce, continuous quality Steere heal bale meters on proent management, occupational health & safety, returnable containersyand packaging systems, transportation/customs and truck & heavy equipment. ‘AIAG PUBLICATIONS 1 1 ‘An AIAG publication reeets 2 consensus of those Sdbetandalybaicemed with ts scope and provisions. An ‘AIAG publication is otended as a guide o eid the manufacturer, the consumer, and the publi. The existence of an AIA pubeatin coos non any rape proche anypo a merfatiig,araing purchasing. oF using products, prooasses, or procedures not conforming 16 the publtion. CAUTIONARY NOTICE AIAG publications are subject to perodle review and users are cautioned to obtain the fatest econ. MAINTENANCE PROCEDURE Recognizing thet this AIAG pubication may not cover all cxcumstances, AIAG tas estabiished a maintenance procedure, Please refer fo the Maintonance Request Form at the back ofthis document to Submit a raquest Published by: Automotive industry Action Group "26200 Lahser Road, Suite 200 ‘Southfield, Michigan 48033 | Phone: (248) 398-3570 + Fax: (248) 958-3259 APPROVAL STATUS | the AlAG Qualty Steering Commitee and designoted stakeholders approved this document for pubication in October 201%. AIAG COPYRIGHT AND TRADEMARK NOTICE: ‘The Automotive Industry Action Group copyrights the contents ofall published meters unloss othensise indcatod. Copyright is not laimed as to any part af en orginal work propared by @ U.S, or state government offer or empioyse as part ofthe person's oficial ‘duties. Allrights are preserved by AIAG, and content may no! be atered ay disseminated, publisted, or transterred in part of such ‘conten. The information isnot to be sod n part or whole fo anyone within your organization ar o another compeny. Copyright lntingement& a voleion of fecerel law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks ofthe Auiometive Industry Action Group. © 2011 Autometive incusty Aetlon Group shy #9 781 60936 2568 more Onan eg cen tenagave AIAG Special Process; Heat Treat System Assessment ! Vorsion 3, issued 10720 Tho cata or pool pephainarney SORA ARAAAHAORAA HARA RRR RRR R RRR RRR ABR eReeeee3 . a 2 9 9 2 9 2 2 » 8 ° 2 2 9 2 2 > a a > > > 2 » a 2 > > 2 2 > > a » 2 2 2 a » » 2 » es AIAG = Special Process: Heat Treat System Assessment The cata peak pertrmerce Version 3 ssued 10/2014 FOREWORD Automotive Industry Action Group (AIAG) committees are made up of volunteers from member companies in the automotive industry. The work of preparing process audits is done by AIAG technical ‘committees. ‘The main task of technical committees is to prepare automotive standards and system requirements. Draft documents adopted by the technical committees ate circulated to the Steering Committee for review and consensus approval. Publication of the documents requires approval by the Quality Steering Committee. ‘The Quality Steering Committee would like to acknowledge and thank the following individuals and their companies who have contributed time and effort to the development of this document. Philip Mikula (CQL-9 Chairper son SOL GR Dean Higdon ~ Acument Global Rabid fee Nt) Sve }) Pete Batche - Akebono Brake Corporation, Noi mh Aner Stefan Bruder ~ Bodycote Warmebehandlung GmbH | Madhu Chatterjee ~ Bodycote Thermal Processing, Notth|America akg Rick Howell —Chrysler Group LLC, North Ambtica Darrell Rydzewski ~ Controls Serviee, Inc. Virender Choudhti ~ Delphi Corporation Stephen Toltesi — Eaton Corporation ‘Suranjeeta Dhar ~ Ford Motor Company Peter Schiefer~ Ford Motor Company, Getmany Medina Kaknjo ~Ford Motor Company Rick Metcalf ~ General Motors Company, North America David Paluch ~ General Motors Company, North America ‘Werner Schwan — Robert Bosch GmbH Germany Jeff Martin - ZF Friedrichshafen, AG Luiz Tubino - LTC Desenvolvimento Empresarial LTDA, Brasil Kevin Bauer ~ Keystone Powdered Metal Company Delbert Clubine, Advance Heat Treat Corporationae AIAG 2a Special Process: Heat Treat System Assessment Version 3 Issued 1012011 The cata for pane CHANGES TO CaQl-9 3°° EDITION ‘The Special Process: Heat Treat System Assessment, 3° edition contains some new requirements, changed requirements, and clarifications that the supply organization will need to consider in making its self-assessment, This 3" edition is a collaborative work of OEM, Tier 1 suppliers, heat treat suppliers, and calibration companies that service the heat treat industry. Below is a summary of the important changes in this 3" edition, 1 ‘Three new Process Tables have been added © Low Pressure Carburizing © Sinter Hardening © on (Plasma) Nitriding eho tee 2 ‘The format and layout of the LSI fave betn-titprdved to facilitate the heat treat system assessment, An moO ) with AIAG CQI-9 specific 3. References wo Ms 27500 IN Lhe Feplaced requirements. 09. 4. Frequency for SAT and Instrument Calibration have been changed, The requirement in the 3' Edition allows the heat treater to chogse-onejaf the two- following options: Option 1 Quarterly SAT (Probe Mthéd A“br'B) or Monthly SAT (Comparative Method), and Quarterly Control Instnument Calibration (single-point or multi-point calibration). 7 Option 2: Quarterly SAT (Method A only) and Semi-Annual Control Instrument Calibration (multi-point calibration; 1-point calibration not allowed with sem annual fiequency), 5. The 3" Edition allows two options for the frequency for calibrating oxygen probe controllers (used in carbon-bearing atmospheres) * Quarterly (single-point calibration or multi-point calibration is allowed) + Semi-annual (malti-point calibration method; single-point calibration is not allowed) 6. Frequency for checking the quench oil cooling curve was changed to semi-annual (2" Edition required quarterly frequency checks). 7. ‘The temperatures given in °C and °F were harmonized. That is, the direct conversion from °C to “F is not used but rather the common tolerances for °C and °F were used, For example, the TUS tolerance for carburizing furnaces is + 13 °C (+ 25°F). Questions 1.20, 3.20, and 3.21 were added to the CQI-9 Heat Treat System Assessment. 9. Question 1.11 was modified. This question addresses re-processing procedures. 10. Question 3.7 ~The oaygen probe controller (carbon controller) shall control the carbon potential “1- 0.05%, 11, Question 3.12 was modified. This question addresses the proper height of the workload on a continuous belt furnace. * ee - co 7 ee * we cd Cd e Cs 7 o es ca . * « * co «s * - *. « - - C7 - - *. * = -~ «- * * * . - *. ss es:AIAG 2a oe Special Process: Heat Treat System Assessment Tho catayst fer peek perermance Version 3, issued 1072011 TABLE OF CONTENTS ABOUT AIAG sisnsnnneneninnnininneneen FOREWORD... TABLE OF CONTENTS snsnesninsnsninnnnoe INTRODUCTION. Generar 7 PROCESS APPROACH Heat TreAr SvsTeM ASSESSMENT Goals... ASSESSMENT PROCESS: ASSESSOR QUAUIFICATIONS. OTHER RequiReEMeNts 1 SCOPE... L.A Genenar 1.2 APPLICATION 1.3 ReFenENce.. 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURG i. 3 SPECIAL PROCESS: HEAT TREAT ASSESSMENT 3.1 Twermocourtes jersion 39 3.2 InsTRUWENTATION, se 3.3 System Accuracy Test (SAT). 49 3.4 TeMPERATURE UNIFORMITY SURVEYS (TUS) . 57 APPENDIX A ~ PROCESS TABLES PROCESS TABLE A: CARBURIZING / CARBON CORRECTION / NEUTRAL HARDENING / AUSTEMPERING / MARTEMPERING / TEMPERING / PRECIPITATION HARDENING - AGING... PROCESS TABLE B: NITRIDING (GAS) AND FERRITIC-NITROBARBURIZING (GAS OR SALT)... PROCESS TABLE C: ALUMINUM HEAT TREATMENT sn. PROCESS TABLE D: INDUCTION HEAT TREATING .. PROCESS TABLE E: ANNEALING / NORMALIZING / STRESS-RELIEVING .. PROCESS TABLE F: LOW PRESSURE CARBURIZING PROCESS TABLE G: SINTER HARDENING svn PROCESS TABLE H: ION NITRIDING .. 88 GLOSSARY... VPIYVBVIIVVIIVIVIVIIIIIIVIVIVIISVIS TVS BHVIBDBODSY oe I I sreegale AIAG Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 The catalyst or pose ose 6= > > AIAG a cats » Special Process: Heat Treat System Assessment Ihe ats er peak pertamnnce Version 3. Issued 10/2011 > > s INTRODUCTION a > General > The work of preparing CQI 9: Special Process: Heat Treat System Assessment (HTSA), Third Edition, was carried out through the AIAG Heat Treat Work Group. These heat treat requirements are complementary to customer and product standards. ‘The HTSA can be used to assess an organization's ability to meet the requirements in this assessment, as well as customer, regulatory, and the organization’s own requirements. The HTSA can also be used between an organization and its suppliers. Inthe HTSA, the word “shall” indifates.9-reanirement fox puurposes-of the self assessment, Failure to meet the requirements results in an assesment thal is ithe “Not Sutisfactory” or “Needs Immediate Action”. ‘The word on ete rt aes Where the fem ven as” is used, any suggestions given are for guidance only. Process Approach ‘The HTSA supports the automotive process approbeh ss desttbes in ISO/TS 16949. Heat Treat System Assessment Goals. The goal of the HTSA is the development of a heat treat management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain, ‘The HTSA, coupled with an internationally recognized quality management system and applicable customer-specifie requirements, defines the fundamental requirements for heat treat management systems, ‘The HTSA js intended to provide a common approach to a heat treat management system for automotive production and service part organizations. Assessment Process ‘Ongoing assessments shall be conducted, at a minimum, annually, unless otherwise specified by the customer, to ensure continuous compliance with the HTSA. Each assessment shall include a review of the organization's systems using the HTSA. Successive Job Audits (Section 4.0 of this document) shall sample parts from different automotive component manufacturers that require compliance to the HTSA document. ‘The assessment shall use the process approach to auditing as identified by the requirements of ISO/TS 16949, ee ee eee ee ee ee ee ee ee ee ee) - |ene AIAG_2— Special Process: Heat Treat System Assessment Version 3, issued 10/2071 a or poak parymaney Use of CQI-9, HTSA, and Process Tables CQI-9 HTSA and Process Tables address the most common thermal processes employed by the automotive industry. Due to the vast differences in the various thermal processes currently available, it may be necessary to incorporate requirements across the provided process tables, ‘The assessor has the availability to employ requirements from multiple Process Tables if an element of the thermal process being assessed requires such. Assessor Qualifications Assessor(s) shall have the following specific experience to conduct the HEAT TREAT SYSTEM ASSESSMENT: 1, Be an experienced quality mann sement syste (QMS) internal auditor (for example, ISO/TS 16949, 180 9901) SUG S GS SST! 2. Assessor shall pose it aes jae. Bvitleige shall include a minimum of 5 years experience in heal treating a combination‘of formal metallurgical education and heat treating experience totaling a minimum of 5 years. 3, Assessor shall possess knowledge of and be familiar with the application of automotive quality core tools including, statisticgl proceys control, measurement systems analysis, part approval, failure mode and effeets an ine ‘and advanced quality planning. Note: If more than one assessor is required to, meet the above qualifications, the lead assessor shall be the person meeting the requfréments in item #1 Other Requirements The organization shall keep records as evidence of compliance to the requirements identified in the HTSA, as well as all appropriate action plans to address any unsatisfactory ratings. These records shall be readily available for review by any customer requiring compliance to the requirements within this document. Documentation recovery shall meet T$16949 or ISO 9001 requirements for process control and inspection records,ee ee ee ee ee ee ee AIAG 2 cars Special Process; Heat Treat System Assessment ‘The etait or poak porkamanca Version 3 Issued 10/2011 1 SCOPE 1.1 General This document specifies process requirements for an organization or its suppliers performing applicable heat treating, who need to: + demonstrate ability to consistently provide product that meets customer and applicable regulatory requirements, and ‘* enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system. ‘The Heat Treat System Assessment is applicable to sites where customer-specified parts for production and/or service are processed throw af tbe vomative supply chain, JIWSG GUS 41.2 Application 1 Alllrequitements of the HTSA are generic and are intended to be applicable to all organizations performing the heat treat operations addressed in this docaiment; regardless of type, size, and product. Bight Proc assessment, Tables have been developed and the appropriate table(s) is to be referenced during the he Process ables ate specific to heat treat plocesses as noted below: Process Table A — Ferrous . Carburizing. . Carbonitriding . Carbon Restoration or Correction . ‘Neutral Hardening (Quench and Temper) . Austempering . Martempering . Tempering, . Precipitation Hardening ~ Aging Process Table B— Ferrous . Nitriding (Gas) . Ferritic-Nitrocarburizing (Gas or Salt) Process Table C ~ Aluminum . Aluminum Heat Treating Process Table D -Ferrous . Induction Heat Treating Process Table E - Annealing, Normalizing, and Stress-Relieving © Conformance t CQI-9 is required for all organizations that perform annealing, normalizing, o stress-relieving to achieve desired final characteristics of the part. Process Table F - Low Pressure CarburizingSpecial Process: Heat Treat System Assessment Version 3, Issued 10/2011 AIAG 2a The cata for peak perbanar Process Table G ~ Sinter Hardening Process Table H - lon Nitriding Note: Material producers of primary or raw materials, or any intermediate thermal treating process step(s) that do not affect the final characteristics of the part are exempt from conforming to the requirements in CQI-9. ‘These Process Tables contain roan ic “ 1 Process and Test Equipment gy 2. Pyrometiy Il 3. Process Monitor Frequencies oot 4. In-Process/Final Test Frequencies 5. Quenchant and Solution Test Frégueigich NUS | ‘The Process Tables specify the tolerances of prdile pavaileters and the frequencies for checking process control parameters and parts, The requirements atidigtiidande in the HTSA form will notify the assessor when to refer to the Process Tables. 1.3 Reference The following standards are referenced in this document. The applicability is limited to the subject matter referenced, Se AT ISO/TS16949 Quality management systems SDR Uz International Organization for Standardization ISOMEC 17025 General Requirements for the International Organization for ‘competence of testing and Standardization calibration laboratories - 150 9007 Quality management 5 International Organization for requirements | Standardization a THC 60584-1 Thermocouples Reference Tables | Intemational Electrotechnical eee eee ____| Commission ‘ASTM E230 Standard Specification and ‘American Standards of Testing and ‘Temperature-Electromotive (EMF) for Standardized Thermocouples Methods | -10- ee % & * «e * « e& ee ee e e es e * e « « « * « cd « « * e * * « *. cd * * « C3 « « * * « «e e * esSUVRIIVIVIIIVIIVITIIIIVIVIBVIVO BeBe HVeEBeevBvES AIAG 2a cats Special Process: Heat Treat System Assessment The catayst er peek pefamance Version 3, Issued 10/2011 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE 1 6 Obtain current copy of CQI-9 Special Process: Heat Treat System Assessment, 3rd edition from AIAG. Identify all heat treat processes to which CQI-9 Special Process: Heat Treat System Assessment, 3rd edition applies (see CQI-9, 1.2 Application). Record these processes on the HTSA, Page 1 Complete the HTSA, determining the level of compliance. A minimum of one job audit (Section 4) shall be performed during each assessment. Address cach “Not Satisfactory” item and determine corrective action, including root cause analysis and implementation ofthe corresponding corrective action(s). The corrective action(s) shall be completed within 90 days, Records of the corrective action, including verification, shal be miintatoa ) OO OVO “Needs Immediate Action! requites immediate conta pie of suspect product. Address each “Needs Immediate A eat stetrHine corzebtive action(s), including root cause analysis and mmpemettaito of th corresponding corrective action(s). The corrective action(s) shall be completed Within 90 days: Recotds of the corrective action, including verification, shall be maintained. ‘Assessments shall be conducted sully untdss dtherwise specified by the customer. “Heou AIAG Special Process: Heat Treat System Assessment : Version 3, lssued 1072011 The catalyat for nook parks « « « « & « e « e « « « « « « « « « e e e « e e e « .° « . « s * « « « e * « « « « e *7 ’ , ; . . ' > . » » » , . > » , . , 7 » y . » » » . » » . » » AIAG 2 cars Te cota for peok perfomance Version 3, issued 1072011 3 SPECIAL PROCESS: HEAT TREAT ASSESSMENT INSTRUCTIONS FOR COMPLETING THE COVER SHEET COVER SHEET FORM. INSTRUCTIONS FOR COMPLETING SECTIONS 1 ~ 3..... SECTION 1: MANAGEMENT RESPONSIBILITY & QUALITY PLANNING SECTION 2: FLOOR AND MATERIAL HANDLING RESPONSIBILITY SECTION 3: EQUIPMENT.. INSTRUCTIONS FOR COMPLETING THE JOB AUDIT: SECTION 4: JOB AUDIT FORW.. “13“14 care AIAG 2m Version 3, Issued 10/2011 To cates for pak paxtormare Instructions for completing the Cover Sheet 12, 13, Facility Name: Name of the facility being assessed. One form shall be used for each facility. The facility may have several buildings or physical locations in the same general area. If there is a separate management team (Quality Manager and Metallurgist) or different management system, then these locations shall be considered as, separate facilities. Address: The street address of the facility being assessed; P.O. Box numbers may be given as additional information. Phone Number: The phone number of the facility. {F there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used. Fax Number: The fax numbébor Hee fieiigo MIGVQGOWS Number of Heat Treat Emy nee at this ee ‘The number of employees, salaried and i hourly, associated with the beat fat epelatioh 3 this tacit.) Captive Heat Treater (Y/N): Enter “Y” if this facility heat treats components for their own company. Enter “N” if the company does tot heat ‘treat ny components for their own company. Commercial Heat Treater (Y/N): Enter*Y7 if this city heat treats components for companies other than their own company Emer SNTUF this facility does not heat treat any components for other companies. Date of Assessment: Enter the date(s) of te’ AdSasSitient, An alphanumeric format shall be usedl to avoid confusion with different numeric formats, Example: May 3 - 4, 2011 Date of Previous Assessment: List the date of the previous CQI-9 Special Process: Heat Treat System Assessment of this facility ‘Type(s) of Thermal Processing at this Facility: Place a checkmark to designate all thermal process(es) performed at this facility, This information determines the appropriate Process Table that shall be used during the assessment, Processes not listed on the cover sheet are not part of the Heat Treat System Assessment. Current Quality Certification(s): The heat treater shall list their current quality certifications, £.g., ISO/TS 16949, ISO 9001. Certifications may be from 3rd party sources or customer quality certifications, If customer quality certification is given, then the year of the last assessment by the customer shall also be given. Date of Re-assessment (if necessary): If “Not Satisfactory” findings were observed from the original assessment, then the heat treater shall address each item and determine correct action, including root cause analysis and implementation of the corresponding corrective action(s). ‘The date of the re-assessment shall be given here, and the appropriate Question(s) from Sections 1 ~4, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the comective action(s), has been observed, Also, the “Number of Not Satisfactory Findings” shall be modified as appropriate, Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the prineipal participants from the heat treater”s organization, Seteweeeeeeeeneeeene eee eee Rhee heehee RARER9 E) a a ® a LJ 3 J e LJ a 2 a a a a a a ® a a a a a 2 = 2 a a > = > = a = > 2 = > = = = 2 AIAG 2 cae Special Process: Heat Treat System Assessment Tre cata for peak porormarce Version 3, Issued 10/2041 14, Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the auditor/assessor(s). 15, Number of “Not Satisfactory” Findings: Enter the number of “Not Satisfactory” findings observed during the assessment, 16, Number of “Needs Immediate Action” Findings: Enter the number of “Needs Immediate Action” findings observed during the assessment. 17, Number of “Fail” Findings in the Job Audit(s): Enter the number of “Fail” findings observed from the job audit, -15- ‘eccnias ye“16. caQl-9 Special Process: Heat Treat System Assessment Version 3, issued 10/2011 AIAG 2» The catalyst for pook parka Cover Sheet Form [Special Process: Heat Treat System Assessment Fete [Ronberot Hen Tew Eanes a RSS fer apie st Teter [Genres eat nats [baearasmstnt [Sse of ue Actor aaa Cay Conta [eof Re seascape eceaaa [FoxomerConacea = [Humber orl Staion edge [Hania SNe is eta Ta [Ramber ora Ree ae (ot Taal Processing a Oe FS [Pocess Table A=Ferrous Iesturars [cabana [Satan Reston Newt Hardening sauenen Temper [Austerperng Matenorn eT SOMET roenee Tabi = Far Gi ze Tables Alum rit Heal eatery Hee lecete abe ———— [annexin ai (Svece Ret (process Tab Low Proeane Couns [Process Taba. [Ener Harder Frocees Tb fan te RPRPCRPRP PRK RHRARAHRAH KRAMER RRRARRRERRAKRRee KEEAIAG 2m cats The cat for peak perfomance Vorsion 2 Issued 1012011 Instructions for completing Sections 1-3 Sections 1 - 3 contain questions and the requirements and guidance for each question, The Sections are: © Section 1 ~ Management Responsibility & Quality Planning, © Section 2 ~ Floor and Material Handling Responsibility © Section 3 ~ Equipment The assessor shall assess the heat treater's compliance to Sections 1 ~3 by comparing the evidence presented by the heat treater to the requirements listed in the "Requirements and Guidance” column. NOTE I In the “Requirements and Guidance” column, the word “shall” indicates a requirement and the ferm “such as” indicates that any suggestions given are forfpuidaed ory) QQ) NOTE 2 The “Requirements and Guidance” column will indicate to the assessor when the Prt f Tables, lp Chie ‘ath Questions, When the Process ‘Tables are pertinent tothe question, the assessor shall assess the heat treater's compliance to the specified section(s) in the Process Tables. NOTE 3: If the question is not applicable to the heat treater, then the assessor shall place a checkmark iti the “N/A” Asbessmtent column. If the observed | evidence is in compliaridbto: the question, the assessor shall note the evidence in the “Objective Evidence” column and place a check mark in the “Satisfactory” column. I? thé observed evidence is not in compliance to the question, then the assessor shall note the non-compliance in the “Objective Evidence” column and place a check mark in the “Not Satisfactory” column. 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ol on Aarceurpectos,fToeREESESUOUOSOCOSOSIOCOCOOS OSES eee ee ce -9 s $ #] f z 5 es g | 3 | 3 Jarret anae] STREES | Koren [ome] sompnseurden eee voaseo | agai & 5 = 8 = ‘Woussassy uisy6hg yor, earl i9e990%0 FraedS i * i g & cal Varsion 3, sued 10/2014 -30-9 ‘Special Process: Heat Treat System Assessment 31. sl cee Aenerungecene cal Version 9, Issued 1072011 seo pum poet sas saan jemo9ss200 Sedamynumniacoam| yt wiauidinba= CwoNBeS ‘aan sopusnes | wn oouepna apetso 2ouepio pur saan woason, fk | a woUssessy worsAg 181) 129} :s89001g [eIoads, Section 3: Equipment The cata! fer peak partomace AlA\ SOMMCAEHOASHREHRCEREKRAEREHRERHERKEREEKREEHKR EH eePCPOP TOV ARPT TARR VTP HET TTT eee eee eee g 3 Tha catalyst for paok perlrmanco Ausio.s 59 woos w posi] ewounop agate scone usa oa seen spay) “STEERS | wecesee |v usps ssh0 supa poe sousarboy wogsono a -9 Special Process: Heat Treat System Assessment Vorsion 2 esued 1072011 Woussossy Wosshg yea4) YEOH =ss90014 feIDOds. cal. 32.3 -9 Special Process: Heat Treat System Assessment cal Version 3, lesued 10/2011 ssuspaaontso soarine poe ous onsen = heres | yusuissasay ursyakg eal] Jeol :959001¢ eID8dS The catayst or pook performance AIAG CEHPHHH ROHR ECCHE HERR RAHA RA RR RAR RARER RRR RR RR ERE|e G Tie etait or peak oaomance -9 cal AlA Spocial Process: Heat Treat System Assessment Version 3, Issued 10/2011 spouts pee apeduoneripin og sop! eso eereamnte ma mena unpna eaowan, ‘utpng ue sau ene, wetussessy Worshs ywa4y WOH :959D0K¢ Jerseds 34cal-9 Version 3 Issued 10/2011 peniraep oq ee joe, pn wo a ie ososop pa eo Special Process: Heat Treat System Assessment oases sous ano suena ue susie HBLISSOSSY UIDISKS yeaIy Tea} 28592019 [eIDedS Tho catalyst or pk performance AlA\ CRPPH HHO HEHE KKH H RHE KERER RRR HHH RRR RE RHEE -35-deen wate poems) ere ‘The catayst or peak perermanecs aay ofp oo ae tase pam sbopno ei oy emrcle abueg Busou | resin pavxdae ooh woo goes 60 | am ogee og ney ud eno rap ond i pomrrane = ous 05 pare tag soma secone used yd odoat emp orpoweu yf MWere Poauoog en a} FFE SVIUL LVIH NOMONGN WO ee saoy| SERS | kopennes |ym| ——— sowpna enna svening sue swaunben vows ou juowssassy weyshg year) Teo} :S59001g JeIDeds 9 Special Process: Heat Treat System Assessment Version 3, lasued 10/2011 cal. 36+37- -9 cal Special Process: Heat Treat System Assessment Version 3 ssued £0/2011 preyed oo as sy og yee enn at oe wonsy | Wosents | joesenes souspno pur sme von repeat spoey| en ome wauissassy WioysAg 1291] 189} :ss90014 [eIaads, The cates r peak perfomance 3 OREO RH EERE RR ERR RRR R RRR RRRoa AIAG2a Special Process: Heat Treat System Assessment i Version 3, Issued 10/201 Tio cata or pool parkwmaren 38 e € e @ «e€ « « & © « e e «& e « e e « e e * «e * e «e e e * * e * e e e e © se e « & e e s2 = » = = = = - * = cy = = = 2 = = = = = = - = = = = = 2 = = = = = = = = = » = = = - = 2 AIAG hal Special Process: Heat Treat System Assessment Te cata for pk perormancs Version 3 ssued 10/2011 3.1 Thermocouples 3.1.1 Application of Thermocouples: Thermocouples shall be selected as appropriate for their intended use. Where a process is to be controlled, consideration shall be given to variables that can have an impact upon thermocouple performance such as, but not limited to, atmosphere, temperature, electrical interference, ete, Guidelines established for recommended temperature ranges or upper temperature limits for thermocouples in publications such as ASTM E230, IEC 60584-1, or other national standards or by the thermocouple manufacturer should be adhered to. 3.1.1.1 All thermocouples shall Ete With Tables 3.1.1, 3.1.2, 3.1.3, 3.14 and 3.1.5 requirements, rarmeacnehes 3.1.1.2 Extension wire shall not wiki hrs plugs, connectors and terminal strips may be used, 3.1.2 Calibration of mb Thermocot les ipl be calibrated traceable to the National Institute of Standards and Technology (NISTY or dcher tiational institute of calibration, such as PTB (Germany). grace period of 2 weeks is allowed forall calibrations. 3.1.2.1 Thermocouples shall be calibrated iilthe prior to first use, Calibration temperature inte 3.1.2, 3.1.3, and 3.1.4 for appropriate thermacot petature range in which they will be employed and shall, pot exceed 150°C or 250°F. Refer to Tables 3.1.1, le cAlibration and replacement requirements. 3.1.2.2 Calibration certificates shall include the following detail: the actual test temperature reading, the nominal test temperature, the conesponding correction factor for each calibration temperature test point, the provider of the calibration data, and the calibration method used, 3.1.2.3 The interpolation of correction factor values between calibration test points is allowed. No ‘determinations shall be made conceming values either above the highest calibration temperature or below the lowest calibration temperature. 3.1.24 External sources providing calibrations shall be accredited to ISO/IEC17025 or other national equivalent. Internal sources providing calibrations shall do so in accordance with the intent of ISOMECI7025 or other national equivalent. Records shall be kept of training and qualifications for internal personnel performing calibrations 3.1.2.5 Thermocouples may be individually calibrated or made from calibrated rolls provided that both ends of the roll are sampled and the accuracy requirements established in Tables 3.1.1, 3.1.2, 3.1.3, and 3.1.4 are satisfied. 3.1.3 Reuse of Thermocouples: The date that any thermocouple is placed in service shall be documented. Requirements are indicated within 3.1 and Table 3.1.5. 3.1.3.1 A “use” for thermocouples is defined as one cycle of heating and cooling of the thermocouple {see glossary). See Table 3.1.5 for maximum number of uses of a thermocouple. 39.:e HAAAAARARARAHSRARARRAARRARARHAARRHARARHAABSHEARH See gate AIAG 2 Special Process; Heat Treat System Assessment Version 3 Issued 10/2011 Tho cata for peak petrmanns 3.1.3.2 Damaged expendable or non-expendable base metal SAT and TUS thermocouples shall not be reused. 3.1.3.3 For reuse of Type K and Type E test thermocouples, the depth of insertion shall be equal to, or ‘greater than, the depth of insertion of any previous use.AIAG 2a cas The cats for pase performanco Version 3 issued 10/2011 Table 3.1.1 Calibration and Replacement Requirements for Thermocouples Used for Control, ‘Monitoring and Recording. react oN Cena CN OU] Dati Bea aw ON ‘ACCURACY ie Ut} Base Metal Types | 2 760°C (1400°F) | Calibrate before first use. | Primary or | = 1.1°C ( 2.0°F) (KINALE) E : | diy | Carta pofors nrsrOse. 211°C (£ 2.0°F) | Base Metal Types | < 760°C (1 | B A NIStUSe:) | primary or | pene 4 Replace-every Two Vea | COMA or place Annually (2,3,5), | Secondary | or JE =O) Standard. | £ 0.4% 1 (2:38) Standard Primary or | 4 4.1°C (&2.0°F) Noble Metal Types Secondary | or = 760° (14003) Callbete boot use | (BRS) | Reglace EvetyTwo Years | Sronnd! Some I leas) _| TT Non-Expendable 2. Thermocouples shall be replaced whenever needed, e.g. failed SAT, or damaged thermocouple; however, thermocouples shall be replaced minimally as stated above. 3. Base metal thermocouples shall not be recalibrated, Nobel metal thermocouples Type B, R, and may be recalibrated in lieu of replacement, Does not apply to Load Sensing Thermocouples. See Tables 3.1.4 and 3.1.5 41 @ . 2 2 » » » » » » 2 2 = » » = = 2 J a a 2 » 1 a 2 2 2s a » @ @ 2 2 @ @ 2 a 2 @ @ 2 2 2 2co AIAG 2» ‘Special Process: Heat Treat System Assessment Version 3, ssued 10/2011 ‘The cata! or peak paren ‘Table 3.1.2 ~ Calibration and Replacement Requirements for Thermocouples Used for Primary and Secondary Standards weay tons) center acta [aver [spect sean Tetons | foal CIC timay | seecernen ee atone | } 10.1% whichever ‘secondary type Tost 08,07 2 Bota@ttyem | Peary £06 (1.08) wom, [Rew ewe eagies oom, | igi | ie . sty erences’ |pem, | minima is greater | 1 A primary standard thermocouple together with a primary standard instrument shall be used to calibrate secondary standard thermocouples, 2. Use is limited 0 the calibration of temperature uniformity, system accuracy, controlling. recording, monitoring, and load thermocouples. 3. A Type R or $ noble metal thermocouple calibrated against a NIST (or equivalent) reference standard, No error permitted. 4, Base metal thermocouples shall not be recalibrated. 42. 6 e * « e 6 6 s @ @ e & e e e 6 « e « « € e 6 « « e € Co « e e « e « « e e e e € e e Ja » 2 cals AIAG aetna Te cats for poe peromnarce Version 9, Issued 10/2011 Table 3.1.3 — Calibration and Replacement Requirements for Thermocouples Used for ‘Temperature Uniformity Survey (TUS) and System Accuracy Test (Sat) Mans ee nN OU id ewe Ros Sd is fect) Types, Rand | Temperature Uniformity | Before fst use. Replace or | Primary or 41.190 (82.086) or Noble Meal Suneye Recalrate every 2years. | Secondary 204% Stendard Types 8, R ane S Betore tat use. Replace or | Primary or ELGG 20D Noble Metal SAT~ Probe Meta | Revplinialeeyery 2 years, n|-Secondary 204% TOTS CS DS Mbens 1 # TypesB,Ranss | SAT — Cony Geto fra 99, beige oF) [mary or £1.40 (42.07) or Noble Metal Method Racsipzate bey Tyoie.-4 | (Secondary 204% oe Riana Base Metal Temperature Unifoomay | Betore st use 'Repiate'per | Plimary or 21.190 (¢ 20°F} or Suneys Table 3.15 (1) Secondary Soa ern Standard TNUE+ face Meta, BotoelstuseRbelace por | Primary or 2 1.186 (2 20°F) or beadmbibisnshee out Table 3.1.5 (1) ‘Secondary 204% | _—Wersiar | Standard. ace Mota SAT Comparative | Before fst use Replace par | EUM=Y OF 2.0 )or Method ‘abies 11 (1) Secansar He Base metal thermocouples shall not be recalibrated. 43 VRORVVIVVIVIVIIVIVIIVVI VI VVTFVVBs BH VHSTSgous AIAG Special Process: Heat Treat System Assessment Version 3, lesued 1072041 To ata for poak promo ble 3.1.4- Calibration and Replacement Requirements for Thermocouple Used for Load Sensing Bianco) sas CNET feel) erae) (ome uel) ae ages ee AGAINST aN Kag EAS icin Types 8, Rands | Beroerretuse. Replace or | PUnety er 21.1% (2 20°F) o Noble Metat_ | Recalirate every six (6) months. | Strand £04% Before first use. Replace per Primary or Saat " | BaseMetal | Tatie 31.5 Recalbraion | Secondary. EMC 20F Or | prohibited. (1) Standard. | ISOS 1 Base metal thermocouples snl riot Be regal Brave Table 3.1.5 ~ Allowable Number of Uses for Thermecouples in Specific Applications aay Deu Mua TEMPERATURE PERMITTED USES Temperature Uniformity Surveys / Expendable Base Metal | 47 < 980°C (1800°F) 16 Expendable Base Motel | omperature Uniformity Surveys! |, aaoec (1g00%r) 1 Expendable Base Metal | Control (1) all 1 Expendable Base Metal | Monitor/Record/Load Sensing (4) | > 650°C (1200°F) 1 Expendable Base Metal | Monitor/Record/Load Sensing (4) < 650°C (1200°F) 30 "Famperature Uniformity Surveys, Non-expendable 838° | Sa and Load Sensing +< 980°C (1800°F) 180 (2,3) Metal Thermocouples (6) Temperature Uniformity Surveys, Non-expendable Base SAT and Load Sensing > 980°C (1800°F) 90 (2,3) Metal ‘Thermocouples (5) | 1 Includes Load Sensing Thermocouples used as a Control Thermocouple, 2, When a non-expendable base metal thermocouple is used above 980°C (}800°F), the maximum total number of uses is 90 uses which shall include any previous or subsequent temperature readings taken with the subject thermocouple, 3. Inthe absence of documentation of the number of uses for non-expendable base metal thermocouple used for TUS and SAT, then the thermocouples shall be replaced after 6 months 4. Expendable base metal thermocouples for load sensing, are allowed more than one use if thermocouple shows no visual degradation, Documentation is required to show compliance. Non-expendable base metal thermocouples for load sensing, are allowed more than one use if thermocouple shows no visual degradation. Documentation is required to show compliance. -44- (PARK ARAKAHRASHRARASATHHR ARH ARAARHR HARE AKReHAReRRAHA= = a a - = = = » a * 7 2 = = = a = = = = > = = mz = - = = = = = = = = =» = = = = = = = eons AIAG cats ha cataystter peak paermance Version 3, feaued 1072011 3.2 Instrumentation 3.2.1 General Instrumentation Requirements: Instrumentation shall be selected as appropriate for their intended use and shall meet or exceed the accuracy requirements indicated in Table 3.2.1 3.2.1.1 All instrumentation calibrations shall be traceable to the National Institute of Standards and ‘Technology (NIST) or national or international standard, 3.2.1.2 External sources providing calibrations shall be accredited to ISO/IEC17025 or other national equivalent. Internal sources providing calibrations shall do so in accordance with the intent of ISO/MECI7025 or other national equivalent. Records shall be kept of training and qualifications for internal personnel performing calibrations. 3.2.1.3 Calibration frequencies Jr KalQe ‘art Specitiel {nthe applicable Process Tables and in the Instrumentation Table 3.2.1. A grace period. SARs isaltow ioe all calibrations, 3.2.1.4 The temperature for each contr 201 Mol doriad S scoring instrument, 3.2.14.1 Recorder shall be operating during the entire time that product is in the fumace and print intervals/sample rates shall not sressiis (5) minutes for analog recorders and two (2) minutes for digital recorders. Processirecord shall be legible. Readability and Resoluti The follovtiny: present minimally acceptable requirements: ‘Test instruments shall be digital and have a minimum readability of 1.0°C or 1.0°F. 3.2.2.2 At least one controlling, monitoring, or recording instrument for each furnace or aven zone shall have a minimum readability of 1.0°C or 1.0°F for digital instruments or 2.0°C or 4.0°F for analog recorders, 3.2.2.3 Temperature resolution requirements for digital and/or analog furnace chart recorders shall comply with the following: © 55°C maximum per centimeter of chart paper 5 °C maximum per chart line inerement . 250°F maximum per inch of chart paper . 10°F maximum per chart line increment 3.2.3 Offsets: The use of offsets is generally discouraged, however when used, a documented procedure shall exist which at a minimum describes when their use is permitted, how to perform manual and electronic offsets, how to document the basis for the offset (calibration, SAT or TUS), how to account for the offset when performing calibrations, SAT's or TUS's and how to reintroduce any intentional offsets ‘The procedure shall also indicate who has the authority to approve the use of offsets and how this approval is documented. 3.2.3.1 Offset or bias applied to the instrumentation calibration shall not exceed 2.0°C or 4.0°F. 45.46 gale AIAG 2m Special Process: Heat Treat System Assessment Version 3, issued 1072011 Tho cata or aeak petomrce 3.2.4 Calibration: Calibration of control, monitoring, and recording instruments shall be performed to the manufacturer's instructions; however calibration may be performed as described in 3.2.4.1 3.24.1 For the calibration of control, monitoring or recording instruments on furnaces that are in operation and running at typical operating temperatures, a single point calibration is acceptable (parallel reading of thermocouple input). For furnaces with a load in process, the furnace temperature shall remain within processing tolerance. all be 3.2.4.2 For each channel or group of channels in use that can be altered or adjusted, a calibration required 3.2.4.3. Calibration Frequency of the control, monitoring, and recording instruments shall be one of the ‘two options listed below: 3243.1 Option 1: Qual ry sino) AUIS a 3.2432 Ontion2: the Use Di LOG that the SAT is performed quarterly per Probe Method A (per 3.3.4.1) AND the multi-point calibration is employed for the instriment calibration: 3.2.5 Calibration Records: Calibration statlis atid’rgstilt sifall Be reported as follows. i I 3.2.5.1 A calibration label shall be affixed to the instrumentation device, or in the case of panel mounted control, monitoring or recording instrunentition, On the device or as near as practical to the device(s) to indicate its (theit) most recent successful calibration. The label(s) at a minimum shall inelude Date the calibration was performed. Due date of the next calibration Technician who performed the calibration (initials are acceptable), Serial number of instrument 3.25.2 Instrumentation calibration results shall be documented, The instrument calibration report or certificate shall include the following information: © Fumace or unit identification number Make, model and serial number of i controlling devices), Standard or test instrument used during calibration, ‘Method of calibration, Ambient temperature and humidity Required accuracy. Initial and final values at each calibration point (if no adjustment is made then the final value will equal the initial value). Initial and corrected offetibias values (if no adjustment is made then the corrected offset/bias value will equal the initial value), Statement of acceptance Any limitations or restrictions of the calibration Date the calibration was performed. Due date of next calibration. ‘Technician who performed the calibration. trument calibrated (not applicable to PLC e é é e@ e ¢ e e e € e e e e «e e « «¢ « « « « e « «e «e « « e e «e e e . « e « «e « «e «e « e eLe SFT TTTTISTTIFITSIFIFIF SHS SFIS SHUT HOT DS BBB AIAG a cats Special Process: Heat Treat System Assessment ie cata rpek dotoxmance ‘Version 3 sued 1020" © Signature of the technician who performed the calibration. © Calibration company if not performed in-house. ‘* _Sign-offby responsible person in the heat treat organization, 3.2.6 Electronic Records: When using a system that creates electronic records the system shall create write-once, read-only electronic records that cannot be altered without detection. “ATSLSCCCSC SC SCC ECCS E CECH KCECETEC RVC RECT EEEEELE uomeiqye> ymod-ofSu4s jo suoniuyop 10} A1HSso18 99g (L'F'€°€ 99S) V PoLHIIN 49d KyoYeNb poursojsod st ut) prepureys Creu & yri parerqyEd s 1 941 1eKp Pepirosd pamojje SI woNIENqyeD jenuUE- | We svoudnbe Sssoooid wows esa reuua4g aie uuond pu uonesbaa 7 (601200) spbiniedue au Susnseau olen | (0890078 € reowewoen as | cuasseo0id oun 0a unqn pe Bupseoes Buln sea 9 Goren € Bien Baraouyn a rwounasu | peti a puepune "901 GOTH ae0S | epuoves so Aus ‘jee arena i090 S007 proves wtp azoe prepues Keung z srepoeaos ‘siosuas puepuerg Ai ‘seye0U6 8] Z8ABYORIM "juaKeANbe 10 ue Aouud pe shana 0 plalaspposie 5100 septs on prepuris aepuozes o Lonesqye> hojeegst OF Fant J0(2103) 5.500% | prRpUEIG couDsB}ey oe tet faewnd, moves | prepueis euonen, sounsjar a umexaes paves hewn organi | Na.OSII0LSIJed | WeNNBG40 ISIN oe stojonsovez | bua Coy CESIbESE CREE! Covel peu OCC A) eo ence a! dalvearwo ioe mene nisro herrea SUNAWAMINOTY NOLLVYANIVD LNAW MLSNI ~ TE ATEVL Sam YORI SHOT 102/08 panes} uoIsion a suoussony wots ow Side SVIV 6109[Pepepoeesepasasenperenepeyeespeeresagegeunes es ae AIAG 2 cals Special Process: Heat Treat System Assessment. The cata for peak perorance Version 3 asued 10/2014 3.3 System Accuracy Test (SAT) 3.3.1 The SAT shall be made in accordance with 3.3, and the System Accuracy Test Table 3.3.1 requirements. 3.3.2 The SAT shall be performed using a test thermocouple conforming to the requirements of Thermocouple Table 3.1.3 coupled with a test instrument meeting the requirements of Instrumentation Table 3.2.1. 3.3.3. A new SAT shall be performed after any maintenance that could affect the SAT accuracy, e.g., the replacement ofthe lead wite, control thermocouple, or the replacement of the control instrument 3.3.4 The SAT shall be perfobed il CellC ine Hacnee is) pulaling at a typical operating temperature using either the Probe Method ir 3.34.1 or ra 3,3.4,2) or the Comparative Method (Section | a ) 3.3.43). c 3.3.4.1 Probe Method A: 04 203: 334.11 Probe Method A iay@ jcheake a the uncorrected reading of the control temperature system (contro! instrument, Meat jive, and thermocouple) and the corrected reading of 2 test lompeature system (Let instrament and {6st thermocouple). See Ilustrtion 3.4.1 ions 334.12 The tip (measuring junction) of the test thermocouple shall be no further than $0 mm (2 inches) from the tip (measuring junction) of the control thermocouple. Existing furnaces that have physical limitations preventing compliance to the 50 mm tip-to-tip distance shall be reviewed and approved by the assessor 33.413 The temperature indication of the control instrument connected to the control thermocouple shall be within +/- 5°C (or +/- 10°F) of the corrected temperature indication of the test thermocouple on a test instrument. After insertion of the test thermocouple, allow su lime to achieve equilibrium between the test thermocouple and the control thermocouple. 3.34.14 If the calculated SAT difference exceeds 5°C (10°F) the appropriate corrective action shall be taken before commencing with additional thermal processing. Control thermocouples failing to meet the requirements shall be replaced. A new SAT shall be conducted on the replacement thermocouple. Actions taken shall be documented Note that when using Probe Method A, any electronic offset value introduced into the control instrument for the purpose of centering a TUS result shall be included in the SAT difference calculations. 334.15 SAT frequency shall be quarterly, -49-cals AIAG 2m Special Process: Heat Treat System Assessment issued 10/2011 Te cates or peak peramance Version 3 Example of Probe Method "A" Ovor-Temp Thermocouple Controi Thermocouple (A) Control instrument Over-Temp Protection Part or Raw Material Chart Recorder Furnace Furnace Wall Work Zone ‘Thérmogouple (B) Test Instrument Lead Wire AMPLE OF ACCEPTABLE SYSTEM ACCURACY TEST (SAT) PROBE METHOD - A Coty nd presses rest est conrroL ET oe Pe Ue neotts tra ert ett ee oat ty cc) artes FACTOR Seo ” (3) {0) eh 00° 901.5°C +0.1°C 901.1°C. (1682°F) (1655°F) (+0.2°F) (1654.2°F) -50- = “ e e e es e e e S & & % es % se = 2 e = % e 7 . e e es s = e «e « se * cs e « © ee * CJ caAIAG 2m cals The cata er pesk paermance Version 3 ssued 10/2011 3.3.4.2 Probe Method B: 3.3.42.1 ‘The Probe Method B is a comparison between the uncorrected reading of the control temperature thermocouple indicated on a test instrument and the corrected reading of a test temperature system (est instrument and test thermocouple). See Illustration 3.4.2 33.422 The tip (measuring junction) of the test thermocouple shalt be no further than SO mm (2 inches) from the tip (measuring junction) of the control thermocouple, Existing furnaces that have physical limitations preventing compliance to the 50 mm tip-to-tip distance shall be reviewed and approved by the assessor. 3.34.23 After insertion of the test thermocouple sufficient time shall be allowed to achieve equilibrium betweea-the test thermocouple and the control thermocouple under test relgegeoen 334.24 The uncorrected “reading oP the Control thermocouple connected to a test instrument shall be rooted au the GiRkest Ppt ints (eMPErature cycle. Immediately following, the test instrument shail be & the tebt thermo¢ouple. The corrected reading of the test temperature system shall be recorded atthe highest point in its temperature cycle. 334.25 If the calculated SAT difference between the uncorrected reading of the control temperature thermocouple indicated on the test dnstruiment and the corrected reading of the test temperature system (test instrument’ diidt6sC-thermocouple) exceeds =:5°C (10°F) the control ‘temperature thermocouple shall be "eplgad and any other appropriate corrective actions shall be taken before commencing with additional "thermal processing. All actions taken shall be documented 33.4.26 SAT frequency shall be quarterly “Sie 9 ? ° 9 , 9 . . » » ® ° a 2 » a » a a a a 2 a 2 a 2 a 2 a a = a a a a » a a a a J a 2 2