AC 7101/7 REV.

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.

2.0 GENERAL INFORMATION

2.1 Laboratory

2.2 Laboratory Contact

2.3 Auditor

2.4 [ ] Initial Accreditation [ ] Re-accreditation [ ] Follow-up

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.

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infringement arising there from, is the sole responsibility of the user."

PRI invites your written comments and suggestions.

Copyright 2011 Performance Review Institute. All rights reserved.

t-frm-15 01-Jan-11
PRI AC 7101/7 Revision C -2-

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.

TABLE 1 – Preparation Codes

Audited Code Preparation Type

[ ] Z GENERAL REQUIREMENTS
(Apply to all specimen preparation sources.)
[ ] Z1 LOW STRESS GRINDING
(Test Codes O, Y)
[ ] Z2 LOW STRESS GRINDING AND POLISHING
(Test Codes O, Y)
[ ] Z3 CAST SPECIMENS
(May include as-cast surfaces)
[ ] Z4 SPECIAL PURPOSE SPECIMENS
(e.g. weld joints, tubes)

2.8 Specimen Preparation Source

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):

[ ] All Code Z specimens [ ] N: Impact

[ ] A: Room Temperature Tensile [ ] P: Fracture Toughness
[ ] B: Elevated Temperature Tensile [ ] XE: Crack Propagation
[ ] C: Stress Rupture [ ] XA: Creep

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):

[ ] Notched & Un-notched (Test Codes O, Y) [ ] P: Fracture Toughness

[ ] Un-notched only (Test Codes O, Y) [ ] XE: Crack Propagation
[ ] O: HCF [ ] XA: Creep
[ ] Y: LCF [ ] All other test requiring LSG
[ ] Others and Restrictions as noted below:
PRI AC 7101/7 Revision C -3-

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):

[ ] A: Room Temperature Tensile

[ ] B: Elevated Temperature Tensile
[ ] C: Stress Rupture
[ ] Other:

2.8.5 Code Z4 (Special Purpose Specimens) - The source is to be accredited for "Special Purposes" specimen
types (Check all that apply):

[ ] Notched & Un-notched (Test Codes O, Y, XH) [ ] P: Fracture Toughness

[ ] Un-notched only (Test Codes O, Y, XH) [ ] XE: Crack Propagation
[ ] O: HCF [ ] N: Impact
[ ] Other

Describe:

2.8.6 Describe Quality Systems responsibility (between the Specimen Preparation Source and the Mechanical
Testing Laboratory). Check all that apply:

[ ] Preparation source is part of the testing laboratory organization.

[ ] Preparation source and testing laboratory are under the same quality organization.
[ ] Preparation source is an external sub-tier to the testing laboratory (different company, facility,
and/or quality organization).
[ ] Code Z1 and Z2: Specimen preparation source.
[ ] Code Z1 and Z2: Specimen preparation sources which do not have independent quality systems.
[ ] Other

Describe:

2.8.7 Dimensional inspection control - Describe Quality Acceptance disciplines. (This may comprise several
disciplines; check all that apply and explain below):

[ ] Enforces process control

[ ] Uses Statistical Process Control (SPC)
[ ] Inspects characteristics prior to shipment
[ ] 100% (all characteristics)
[ ] 100% (selected characteristics), sample (remaining)
[ ] Sample selected characteristics
[ ] Other

Describe:
PRI AC 7101/7 Revision C -4-

3.0 PROCEDURES AND DOCUMENTS

3.1 Written Procedures

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.

4.0 PERSONNEL AND TRAINING

4.1 Verify personnel training for one test specimen type.

Test Code Function

Equipment operated

4.2 Training is documented. YES NO

5.0 FACILITIES AND EQUIPMENT

5.1 Refer to Capability Matrix. Verify equipment information. YES NO

5.2 Preventive maintenance plan is followed and maintenance operations are YES NO
documented.

6.0 BLANKING, ROUGH MACHINING, AND STRAIGHTENING

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.)

a. For sheet specimens, as-finished sheet surfaces remain intact. YES NO

b. A minimum of 0.010 inches (0.25mm) remains on rough machined surfaces for final YES NO
finishing operations.
c. Special Purpose Specimens: For testing of weld and braze joints, tubes, miniature YES NO
bars, and other material conditions which are not suitable for standard flat or
cylindrical specimens, blanking and finishing operations shall be covered by written
procedures.

Comments

6.2 Mechanical straightening of specimens prior to testing is not permitted. YES NO

7.0 SPECIMEN PREPARATION AND BASIC MACHINING

Verify using the Capability Matrix. YES NO

PRI AC 7101/7 Revision C -5-

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:

a. Distortion of specimen dimensions. YES NO

b. Physical damage (e.g. cracks, tears, scratches). YES NO
c. Residual stresses (tensile or compressive). YES NO
d. Metallurgical damage (e.g. local overheating from abusive grinding or machining). YES NO

8.0 NOTCH MACHINING (ALL Z CODES)

[ ]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:

*9.0 GRINDING (Codes Z1 and Z2)

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

[ ] Approved [ ] Currently In Process

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-

*Table 2 – Grinding Parameter Requirements

Note – This table is optional if the machine shop has documented acceptable residual stress measurements
and a specific procedure for achieving these results. Procedure shall be approved by customer. Document
procedure used.
TYPE GRIT WHEEL WHEEL WHEEL GRINDING MAX
ABRASIVE SIZE HARDNESS STRUCTURE BOND SPEED
SFPM (m/min)
STEELS: High Strength Alloys, A 46-120 G-K 6-10 V 4000 (1220)
e.g., 4340 & Corrosion Resistant Actual
WROUGHT High-Temp Alloys: A 46-120 G-J 6-10 V 3500 (1067)
Ni, Co, Fe Actual
CAST High-Temp Alloys: A 46-120 G-J 6-10 V 3500 (1067)
Ni, Co, Fe Actual
POWDER high-Temp Alloys: A 46-120 G-J 6-10 V 4000 (1220)
Ni Actual
TITANIUM Alloys A 60-120 G-K 6-10 V 4000 (1220)
Actual
ALUMINUM Alloys A 46-120 G-J 6-10 V 4000 (1200)
Actual
TITANIUM Alloys C 60-180 S-V 6-10 R 4000 (1220)
Actual
All Other Alloys A 60-180 S-V 6-10 R 6000 (1830)
Actual

Notes Type A = Aluminum C= Silicon Carbide

Abrasive Oxide
Wheel Bond V=vitrified R= resinoid
Grinding SFPM=surface
Speed feet per minute

Comments

9.3 Final grinding of smooth gage sections conforms to values as specified by customer
for:

a. LUBRICANT: Constant flow; Abrasive particles continuously removed (describe YES NO

method below).
b. SURFACE SPEED: Review customer requirements. YES NO
c. DOWN FEED per pass/revolution: YES NO

Axial (traverse)
Actual
Radial (plunge)
Actual

*10.0 FINAL POLISH - CODE Z2

10.1 Final polishing conforms to requirements specified by customer. YES NO

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).

10.1.4 Flat Bars [ ] Manual polish used for non-round bars

(List equipment manufacturer below.)

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.

10.1.9 Polishing to achieve a mirror-like finish is prohibited. YES NO

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).

180-240 Grit (P180-P280 European grit sizes) on gauge diameter

400 Grit (P800 European grit size) on gauge diameter
600 Grit (P1200 European grit size) on gauge diameter

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.

*11.0 DIMENSIONAL AND SURFACE INSPECTIONS

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-

11.3 Finished surfaces exhibit no cracks or transverse indications. YES NO

11.3.1 Describe frequency/method of verification:

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.

*12.0 PROCESS CONTROL - CODE Z1 AND Z2:

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

a. Code Z1 only YES NO

b. Code Z2 only YES NO

13.0 PACKAGING, LABELING AND HANDLING

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

PARA. NO. COMMENTS