CQI-27 Assessment Final Pegasus 28-02-2024

CQI-27
Sspecial Process: Casting System Assessment

Version 2 Issue 3/2018
CQI-27 Special Process: Casting System Assessment
Complete Foundry Name: Pegasus Auto Parts Monterrey S.A. de C.V
Complete Address: Ave. Las Americas 72, Bodega 2, García, Nuevo León México, C.P. 66000
Phone Number: ´+52 (81) 27-13-37-50

Website: https://www.pegasus.co.jp
Date of Assessment: 1/24/2024
Date of Previous Assessment(s): Annual Assessment
Date of Re-Assessment (if necessary):
Foundry Personnel Contacted:

Name: Title: Phone: Email:
Alan Valadez Quality Manager 8115046597 avaladez@pegasusmexico.com

Agustin Hernandez Production Manager 81 2322 8955 ahernandez@pegasusmexico.com
Auditors/Assessors:
Name: Company: Phone: Email:
Takashi Kuwahara Pegasus Auto Parts Monterrey 8112274736 t_kuwahara@pegasusmexico.com

Masaki Mori Pegasus Auto Parts Monterrey 8112274736 ms_mori@pegasusmexico.com
Number of Conforming Number of Non- Number of Not Applicable

Types of Casting Processes at this Foundry: Findings Conforming Findings Findings
Process Table A
Sand Casting (Iron/Steel)
Process Table B
Centrifugal Castings
Process Table C
Centrifugal Liners
Process Table D
Investment Castings (Iron/Steel)
Process Table E
Aluminum SPM Cylinder Heads
Process Table F
Aluminum Sand Castings
Process Table G
Aluminum Metal Mold
Process Table H
76 0 14
Aluminum High Pressure Die Cast
Process Table I
Magnesium High Pressure Die Cast
Process Table J
Zinc High Pressure Die Cast
© 2018 Automotive Industry Action Group
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Special Process: Casting System Assessment
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PROCESS TABLE H - Aluminum High Pressure Die Cast
All requirements given below are subordinate to customer specific requirements.

When performing the CQI-27 Casting Assessment the auditor shall verify foundry is conforming to customer requirements; including a customer approved Control Plan defining the agreed upon inspection testing and
frequencies. *If minimum requirements are not met, provide supporting records to justify actual conditions.
What is the scope covered by this audit? The entire foundry? A specific product line? A specific part number? Other?
Describe the scope of the audit: Foundry process and one production line
Conforming /
Observations / Comments Non-
Item Category/Process Step Requirement
about Actual Condition Conforming /
Not Applicable
1.0 Casting Design and Tooling
This Table is for conventional high pressure die casting, horizontal and vertical squeeze
Casting Process PAM process is high pressure die casting. Conforming
casting, semi-solid, and similar variants of die casting.
1. Casting plant must be compliant to customer specific software requirements. Design Software by mold supplier based on drawing requirements.
H1.1 Design Software 2. Casting plant must have and maintain customer specific requirements for math data PAM used CAD softwares (Autocad and Solidworks) for mold and Conforming
transfer for the tooling and for part Drawings / Models. product
1. The design responsible party must complete an FEA (Finite Element Analysis) for the
casting. The ultimate tensile strength, yield strength, and percent elongation used in the
FEA must be over the lower limit of engineering requirement for the specified alloy for
similar applications.
2. The foundry should know the specific features of the casting where maximum Customer is responsible for design, therefore FEA is perform by
FEA Analysis - stresses exceed 50% of the Yield Strength. For purposes of this assessment, the customer. Some customers request mechanical test (compression or
H1.2 tensile) on the final product and PAM perform these mechanical tests Conforming
Part One expression "high stress" refers to any feature exceeding 50% of the Yield Strength.
3. Yield Strength as used in this discussion is the x-bar (mean value) minus 3s (three based on product drawing spec
sigma) statistical calculation from tensile bars pulled at the casting source.
4. Any high stress features identified in the FEA must be evaluated when casting
simulations are reviewed, and when establishing product audits such as wall thickness,
microstructure, hardness, x-ray, crack inspections.
5. If there are any features on the casting which would have an Extreme Load
Maximum Stress greater than 75% of the Yield Strength of the alloy, then Limit Testing
at Extreme Load conditions is appropriate. The foundry may not be responsible for this
testing, however, the foundry is responsible to provide worst-case parts for this testing.
Customer Product Engineering will define the worst-case conditions, such as internal
porosity, for Limit Testing.
FEA Analysis - 6. If there are any features on the casting which would have an Extreme Load When requested, wors case samples are perform for customer.
H1.3 Conforming
Part Two Maximum Stress greater than 75% of the Yield Strength of the alloy, Customer Product Strenght measured by compression test based on drawing specification
Engineering may restrict shipment of castings for serial production only to the extent of
what was provided for Limit Testing. This may be tighter than stated Product
Engineering acceptance criteria if the worst-case parts provided were not at the
extremes of the permissible acceptance criteria. In other words, if it was not Limit
Tested, it cannot be shipped. This is a decision to be made by customer Product
Engineering.
© 2018 Automotive Industry Action Group A2

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1. The casting plant must use solidification modeling software such as MagmaSoft,
AnyCasting, ProCast, EKK, FLOW-3D or similar software approved by the customer
Product Engineering on the casting as part of the design process for the gating and
venting system prior to tooling construction and prototype part submission. Simulation
must include both fill and solidification analysis.
2. Results must be reviewed with the Customer Product Engineering. Supplier have MagmaSoft for mold design. This software is use for
H1.4 Casting Simulation Conforming
3. At any high stress features in the FEA, the simulation should avoid hot spots, air analysis of solidification modeling.
entrapment, multiple metal fronts converging.
4. It is strongly recommended that the solidification modeling software be capable of
modeling jet cooling. It is strongly recommended that the solidification modeling
software be capable of modeling squeeze pins.
Customer is notified about how many cavities to be approved, PPAP

Single cavity dies are required. If the casting plant predicts a multi-cavity die will work,
documentation is created for each cavity
H1.5 Single Cavity the proposal must be approved by customer Product Engineering. Casting simulations Conforming
Supplier have MagmaSoft for mold design.
must support that multi-cavity would produce acceptable quality castings in all cavities.
This software is use for analysis of solidification modeling.
1. If the casting plant creates the raw casting drawing, that drawing must be approved
and released per the customer Product Engineering requirements.
2. If the casting plant creates the tolerance limits between the raw casting drawing and
any other drawing, those tolerance limits must be approved by the customer Product
Engineering.
3. Whenever possible, the X-Y-Z datum surfaces used on the machined components
should be the same X-Y-Z datum surfaces as the raw castings. This is for dimensional Casting mold drawing are defined based on product 2D drawing and 3D
H1.6 Casting Datum Conforming
control purposes and minimizing datum shifts between the casting and machined model.
surfaces (one of the causal factors related to thin-wall conditions).
4. Tooling design must allow all raw casting locators (datum surfaces) to be on one
piece of the tooling steel. This is for dimensional control purposes. Customer Product
Engineering approval is required for any deviation from this concept.
5. The raw casting datum surfaces must not be removed by any post-processing or
machining unless customer Product Engineering has approved it.

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1. The die steel must meet industry standard material specification and be specified on
the die detail drawings. Typical alloys are H11 and H13.
2. Minimum Requirement for insert materials is the NADCA Standard 207- (Latest
1. H13 alloy is used for the mold.
Edition).
2.H13 alloy is used for the insert materials.
3. When Applicable the casting plant must be able to demonstrate compliance with
3. Currently, there is no customer specific request, but it is possible to
Customer Specific Requirements for insert and cavity applications.
satisfy the request.
H1.7 Die Material 4. The holding blocks (frames) must be made from steel with control of the material Conforming
4. Currently, there is no customer specific request, but it is possible to
hardness to customer specific requirements. Typical alloys are P20, 4140, 8620.
satisfy the request.
5. With customer Product Engineering prior approval, the supplier can utilize “soft
5. Soft tools are owned by mold suppliers and simulated before making
tools” to produce prototype samples if production tooling is not available when the parts
molds. If there is no problem, we manufacture molds and prototypes.
are required. These sample castings may be used for activity such as product
validation tests, assembly builds, and machine tool runoffs. The castings must be
produced with the production intent melting and metal handling process.
1. After trial casting, if there is no problem in the dimensions of the

1. Minimum requirement: Die steel must be heat treated in accordance with NADCA
product, heat treatment is carried out according to NADCA Standard 207
Standard 207- (Latest Edition).
H1.8 Die Heat Treatment or similar in country of use. Conforming
2. When applicable the casting plant must be able to show compliance for the final
2. If required, compliance of hardness metallurgical properties is request
hardness metallurgical properties and impact toughness.
to mold supplier
When applicable, the die design may be specified in whole or in part by the customer. Die design is create based on customer drawing and inspected by full
H1.9 Die Design Approval Conforming
For example, high wear features, such as sealing grooves, should be built as inserts. dimensional report.
1. Overflows should be located where simulations show the last places to fill.
2. All dies should be vented to atmosphere unless the application includes vacuum 1. It is placed at the last place shown.
H1.10 Die Vents assisted venting. 2. Gas and air vent from the vented. Conforming
3. All dies must have at least one chill vent unless customer Product Engineering 3. There is at least one chill vent for each cavity.
waives this requirement.
1. The casting plant must be able to demonstrate the die sealing surface check on the
1. Supplier perform die sealing surface check. PAM makes fitting
production press.
H1.11 Die Sealing Surface Validation checked when recieved mold Conforming
2. A spotting press must be used to audit the warm die sealing surface unless customer
2. Spotting press is perform by mold supplier
Product Engineering waives this requirement. Spotting press can be out-sourced.
1. Minimum distance established from part edge to cavity insert with design review and
1. It is approved by the casting plant.
H1.12 Parting Line Shut Off Distance approval by the casting plant. Conforming
2. Established using softool tools.
2. Distances established based on industry standards or documented supplier practice.

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Not Applicable
Dies may be water cooled, oil cooled, or both, with regulated temperature and flow
Dies can adjust temperature and flow rate with water cooling, oil cooling,
H1.13 Internal Die Cooling Circuit Design rates. The die must be designed with sufficient internal cooling circuits. These circuits Conforming
both. Designed using internal cooling circuit.
must be confirmed with simulation software, and approved by the customer.
1. Check-sheet verification to account for potential issues outside of the standard

Preventative Maintenance scope of work.
2. Verification prior to releasing the die to production. 1. Have a check sheet
Die Inspection (Such as End of run 3. Internal mold water lines must be checked for water flow rate when the mold is new 2. Use water flow analysis
H1.14 Conforming
Inspection) and during maintenance unless customer Product Engineering waives this requirement. 3. Check it when mold maintenance and receive new mold. Cooling
A qualitative inspection for flow is unacceptable. A quantitative measure of the flow rate system is control by flow pressure
is required. The intent is to maintain the tooling with the flow rate used in the design
simulations.
1. Confirmation of de-calcification of the water flow line.

1. Yes
2. Water and hot oil plumbing flow checks.
2. Yes
3. Thermocouple function check.
Pre- Release Checklist Elements 3. Yes
H1.15 4. Ejector pin function check. Conforming
Tool Room 4. Yes
5. Core Condition.
5. Yes
6. Other Items ( Hydraulic Connections, Air line Connections, Vacuum valve Actuator
6. Yes
Cylinders, Limit Switches).
1. The life of the die is tracked based on number of cycles.

2. There is an itemized list of regular maintenance items completed at pre-defined
1. Mold life tracked by number of shots
frequencies.
2. Maintenance Plan established
H1.16 Tooling Maintenance 3. Checksheet to track completion of regular maintenance. Conforming
3. Maintenance Plan records
4. Abrasive systems (such as shot blast and hand grinding) not permitted for cleaning
4. Non-abrasive systems implemented (Solvent washing)
tooling. Non-abrasive systems (such as dry ice, high pressure water blast, solvent
washing and ultrasonic) are required.
1. Replacement inserts (new steel), where there is a customer specific requirement, a

PPAP approval may be required. Customer specific requirements may require a 1. In case of mold change, new PPAP is developed, notification is send
process change request submission with possible production trial run requirements. to customer.
2. All tooling repair (welding, grinding, machining, insert replacement) requires 2. In case of tooling repair, inspection is performed with first pieces prior
H1.17 Tool Changes Conforming
dimensional verification (internal approval) prior to re-instituting the tool for production to use mold again for mass production.
volumes. 3. When tooling is corrected, PPAP documentation or any customer
3. The supplier complies with all customer requirements related to which PPAP requirement is developed
requirements are needed when tooling is corrected.

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Not Applicable
1. All castings produced must be identified with customer branding requirements,
casting plant logo (as applicable), casting part number, cavity number, and cast date in
1. Casting produced identified based on customer requirements (cavity,
designated locations per customer requirements.
part number identification, date month and year)
H1.18 Casting Traceability 2. In some applications, traceability to both casting machine and/or Conforming
2. Since it is managed by travel sheet, WIP plate and lot number,
measured process parameters specific to the casting may be required. Identification
traceability is no problem.
must be accurate and readily visible on non-machined surfaces, and must not interfere
with parting lines, appearance, function, processing or assembly.
1. Gage and fixture plan must be reviewed and approved by customer. (May include in-
line gage equipment for 100% check of critical dimensions as identified on part
specification and/or part drawing).
1. Gages and fixture are provided for 100% check of critical
2. All features on fixtures and gages which measure a dimensional aspect of the part
characteristics. Gages reported on PPAP documentation.
must be built within +/- 5-micron accuracy. This is the dimensional accuracy of the
2. Fixtures and gauges with tolerances based on drawing, gauges
fixture and gage; not the dimensional accuracy of the part. Customer approval is
reported on PPAP process for customer approval.
required for any other accuracy such as 10% or less of part working tolerance.
3. Gauges made of hard tool test material
3. All surfaces of fixtures and gages which touch the part must be made from hard tool
H1.19 Fixtures and Gages 4. Built with replaceable tips Conforming
steel unless customer Product Engineering approves other materials.
5. hydraulic/pneumatic clampling implemented
4. The tips of all clamps on fixtures and gages must be built with replaceable tips unless
6. Gage R&R performed during every PPAP
customer Product Engineering approves a different design.
7- All gauges are verified perioducally in house (once per year).
5. Production fixtures must use hydraulic or pneumatic clamping during the machining
operations. Manual clamping is not allowed.
6. Variable gages must pass Gage R&R per AIAG or similar standard.
7. All fixtures and gages must be certified periodically either by in-house if capable or by
third party.
2.0 Cast Machines
1. A start up checklist must be used to confirm that all water, oil, and air lines are 1. Based on before working inspection table we are conducting
hooked up as designed. inspection before working.
H2.1 Start-Up Conforming
2. Error proofed or color coded lines are required. 2. It is color-coding the entry and exit of cooling water.
3. A checklist must be confirmed for every setup. 3. Each machine has a checklist

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1. Startup sequence must account for cycles used to warm up the mold.
2. Auto scrap or manual method is used to segregate warm up parts as scrap.
1. We consider set up shot is a 16st.
3. Cycle time must be measured for each casting cycle to account for cycle
2. Using auto acrap
interruptions, should they occur.
3. Confirm is performed automatically every shot.
4. Auto scrap or manual method is used to separate parts after restarting from
H2.2 Startup and Downtime Recovery 4. Using auto acrap Conforming
interrupted cycles.
5. QC person conducts product inspection once every 2 hours and every
5. The foundry must correlate the number of start-up cycles with the finish machined /
lot. In addition, all products are inspected in the finishing line before
thoroughly inspected part quality. The number of parts to scrap is not based on the first
shipping.
good part, it is based on the last bad part. There can be some overlap of good and bad
as the die heats up. Must assure that none of the bad parts are shipped.
1. The die cast machine size must be determined using projected area/shot force
1. Use internal calculation formulas to determine the size of die casting
calculations, preferably by using North American Die Casting Association (NADCA) PQ²
machine.
software or other similar calculation methods.
2. Shot Speeds and Pressures based on Flow Analysis software, similar
2. Shot Speeds and Pressures must be determined by using Flow Analysis Software.
H2.3 Machine Selection products parameters and final inspection results. Conforming
3. Verification that the machine's shot end has the capability to fill the die in the required
3. Confirmed with final inspection results (Dimensional, appearance and
time must be verified with NADCA PQ² software or similar calculations.
mechanical test)
4. For machine tonnages over 1800T, ABAQUS software or similar software is strongly
4.N/A
recommended for analyzing die / machine distortion.
1. Shot force =650 kgf average, clamping force = 350T (Die casting
1. The shot force must be less than the clamping force.
machine 350T)
2. Preferred metal pressures are over 10,000 psi = 700 kg/cm2 = 700 bar = 68.5 MPa.
2. Preferred metal pressures standards = 69.9MPa～80.9MPa (Die
H2.4 Shot Force 3. To meet Conforming
casting machine 350T)
common Product Engineering requirements for material properties, internal porosity,
3. It depends on product shape, PAM manage small parts (100 gr
and leakage, the pressure is usually about 80 MPa.
product wight average), pressure is around 100-120 kgf
1. Machine must have real time shot monitoring capability for shot speeds, positions,
pressures, cycle time, slow shot velocity, fast shot velocity, intensification pressure,
biscuit length, slow shot distance, intensification rise time. 1. All functions are included in the die casting machine.
2. The cast machine real time shot monitoring must be programmed with the 2. Everything is checked automatically by the machine, and an alarm
H2.5 Shot Profile Control extractor/robot control or create an alarm when key parameters are beyond control sounds when an error occurs. Conforming
limits. 3. The actual value graph can be confirmed on the monitor.
3. It is recommended that the entire shot curve be monitored, not just discrete points. 4. Automatic sorting by DC machine.
4. The intent is for castings which are outside shot profile control limits to be reliably
separated and scrapped.
Low Inertia Shot End/Shot 9 stages of speed change are possible.also and It has deceleration
H2.6 Machines with a low inertia shot end or shot deceleration are recommended.
Deceleration function. Conforming

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H2.7 Automatic Tie Bar Machines with automatic tie bar adjustment are preferred. Can adjust the tie bar automatically. Conforming
1. The critical slow shot should be calculated using the percentage that minimizes wave
formation and air during injection of the metal. Casting source should be able to show
1. Percentage fill is 50% average
H2.8 Fill Percentage justification for using the percent fill that they picked. Conforming
2. Percentage fill is 50% average
2. The fill percentage in the shot sleeve must be at least 50% unless customer Product
Engineering approves a lower percentage.
1. Die cavity surface temperature must be audited with target values and tolerances.
2. Infrared cameras, lasers, or touch probes can be used. 1. Die cavity audit when initial trials for part number
3. Thermocouples in the molds are recommended. The temperature should be 2. Laser thermometer
H2.9 Die Temperature Control Conforming
continuously displayed. There should be an alarm to indicate when the temperature is 3. Not implemented
out of range. Automatic temperature adjustment is preferred. 4. Yes, every mold has a cooling system
4. Die water flow should be maintained while the die is hot.
1. Plunger lubrication should have controls to avoid excessive plunger lubrication.

1. The application amount can be adjusted automatically. Also can
2. Plunger tip lubricants must be dispensed onto the plunger tip outside of the shot
adjusted it manually.
H2.10 Plunger (Shot Tip) Lube sleeve. Dispensing plunger tip lubricants inside the shot sleeve is not allowed unless Conforming
customer Product Engineering waives this requirement. Vertical squeeze casting must
2. Lubricant is dispensed outside the shot sleeve from the pipe.
minimize the usage of spray mist lubricants inside the shot sleeve.
H2.11 Plunger (Shot Tips) Shot tips should be water or oil cooled. Use Oil Chem Trend PL-513 Conforming
1. Manual spraying is allowed. Auto spray systems are preferred.

2. Auto spray heads must be programmable or dedicated to the die. Spray heads
1. Auto Spray installed in all die casting machines.
requiring operator adjustment of flexible tubing are not allowed. Any copper tubing
2. Regarding spray position, confirm each time before production, based
must be securely clamped such that the spray pattern is fixed. Confirmation of spray
on spray position standard. Spray coating amount can be changed by
pattern must be visually observed as part of die set-up, or other opportunity prior to the
H2.12 Die Spray program change. Conforming
start of production.
3. When an abnormality occurs, the alarm of the die-casting machine
3. If a central die spray system is used; it is preferred that the system pressures be
and the pat lamp light up.
controlled, and alarmed with panel lights or other alarms if out-of-control conditions
4. Sprayer condition is checked during set up.
exist.
4. It is preferred that there be a physical audit for the actual spray quantity per cycle.
Die spray fluids must be formulated and controlled. Control method is pre-control chart. Die spray can be recycled using a Mixing pumping unit with
H2.13 Die Lube Ratio recovery&die casting lublicant machine (1/100). Ultrasonic measuring Conforming
Measurement instrument is a refractometer or equivalent.
instrument is used for concentration measurement.

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1. In order to meet porosity specifications, it is critical for the die cavity to be totally dry
when the shot is made.
This must be taken into account when designing the die, the holding block (frame) and
selecting the spraying method.
2. It is recommended to sample new dies with manual spray only. Assure the die is 1. After applying the die spray, air blow is done automatically. There is
completely dry. Inspections for porosity in the castings can be compared with the also a pipe dedicated to air blow.
H2.14 Air Blow-Off simulation modeling. After a baseline is established with manual spray, it is Conforming
recommended to sample the dies with the auto sprayer (if an auto sprayer is intended 2. Use an automatic spray device after trials and establish pattern for
to be used in production) followed by a manual blow off. Compare with the baseline. mass production.
There should be no deterioration in the porosity results. If the results are as good as
the baseline, then sample the die with fully automatic spray and blow off. Compare with
the baseline. The intent is to assure that the automation is actually getting the die
cavity totally dry.
1. Each shot is cooling during conveyor transportation (10 minutes of

1. Each part may be cooled with water or air. cooling until get to press)
2. Extraction tools must be designed to utilize the biscuit or gating for clamping without 2. All products are extracted using biscuits by robot arm without make
touching the final casting product. contact to mold.
H2.15 Extraction Conforming
3. Automatic extraction is preferred. 3. All machine is automatic extraction.
4. Automatic extractors must be programmed to scrap castings when parameters, such 4. When it falls out of range, it will be programmed to scrap castings
as metal temperature, biscuit size, are out of range. automatically.
1. Each casting must be confirmed for proper position in the die before trimming. The
1. After extracting the product, check the presence and position of all
preferred method to confirm proper part position in the trim die is a sensor.
H2.16 Trimming products with sensors. Conforming
2. To avoid mechanical distortion of parts, stroke control and energy absorption
2. Machine have stroke control and absorption system.
methods should be used.

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3.0 Start-Up Procedures
1. Flow meters are required on each mold water / oil lines unless customer Product
1. N/A, general flow meter for complete cooling system
Engineering waives this requirement.
2. has color on pipings so that it can be connected accurately.
2. Water, air, oil lines must be hooked up as designed. Error proofed or color coded
H3.1 Die Heat or Cooling 3. Use the formula to calculate the flow rate of the spray, every part Conforming
lines are required.
number has spray pattern
3. If external cooling is utilized, spray flow rates and location must be planned and
measured.
Confirm that the oil temperature is set at the specified temperature prior to the start of Check the oil temperature with the monitor of the die-casting machine
H3.2 Hot Oil Verification Conforming
production. Recorded by a checklist. and fill it in the casting work daily report every day.
H3.3 Die Pre-Heat Temperature Confirm that the die cavity temperature is set correctly with the specific die. Routine for start up is set on PAM-QS-D-006 regulated by initial shots Conforming
H3.4 Shot Parameter Verification Confirm that the shot end hydraulic controls are set correctly with the specific die. Parameters confirm on Die Casting Daily Report Conforming
H3.5 Die Spray System Verification Confirm that the sprayer controls are set correctly with the specific die. Parameters confirm on Die Casting Daily Report Conforming
The machine must alarm for either operator or automated scrapping based on cycle If an error occurs, it will automatically scrap and a warning lamp and an
H3.6 Scrap Standard Number of Pieces count from start-up. An accounting system for scrap parts after machine cycle alarm will sound. Accounting systems are introduced for all die casting Conforming
interruptions must be in place. machines.

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4.0 Metal Control
Incoming/Returned Material Raw /Returned materials must be stored without mixing them in marked storage areas
H4.1 It is classified by type and stored Conforming
Storage by type.
Primary metal may be required for some applications based on customer specific
H4.2 Source of Material We work base on aluminum material request by customar Conforming
requirements.
1. Chemistry must be controlled at each key point in the process (melting, holding, and
pouring).
2. It is required to use ASTM E716 disk book molds (or approved equivalent) for
chemistry samples.
3. There must be a spectrometer on site for chemistry control. Industry Standards, such
as ASTM E1251, must be followed for sampling, verification, standardization and 1. It is controlled for each process.
calibration. 2. Use an approved equivalent.
4. The Spectrometer must have certified Master Calibration Standards which cover the 3. Spectrometer is used for chemical management. ASTM E1251 used
range of each chemistry element being controlled. Sufficient Calibration Masters must for reference.
be on site in order to audit each element being controlled in direct comparison with a 4. The calibration is performed with Calibration Master SAM-C002 once
Calibration Master. per month minimum
H4.3 Metal Chemistry 5. A procedure must be posted near the spectrometer which clearly defines the 5. Permissible tolerance range already set up in spectrometer by each Conforming
permissible tolerance range of the Master calibration Standards. aluminum alloy
6. Manage it based on JIS standards (H5302) or Alloy patent limits
6. There must be control limits for all key elements of the material grade. 7. Limits established based on standards, sample is machined before
make test.
7. The Sludge Factor must be measured and controlled below 2.0, preferably below 1.8. 8. Alloy manage based on standard limits
SF = %Fe + 2X %Mn + 3X %Cr. The Iron (Fe), Manganese (Mn), and Chromium (Cr) 9. Alloy manage based on standard limits
specification limits for raw material suppliers must take into account the maximum
permissible Sludge Factor. Be aware that the temperature of holders should not be
turned down low when there is no production. The lower the temperature, the faster the
rate of Sludge formation.
8. The Iron:Manganese ratio must be calculated and controlled. The recommended
Iron:Manganese ratio target is 2:1.
9. Recommend 0.10% maximum Lead (Pb).

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Hypereutectic Silicon Alloys such as 390 and ADC14 must meet the following
requirements unless customer Product Engineering approves other limits. 1. N/A, PAM not use Hypereutectic Silicon Alloys
1. The silicon particle size in the castings must be below 50 microns. 2. N/A, PAM not use Hypereutectic Silicon Alloys
H4.4 Hypereutectic Alloys Not Applicable
2. Phosphorus must be greater than 0.005. 3. N/A, PAM not use Hypereutectic Silicon Alloys
3. Iron must be less than 0.80. 4. N/A, PAM not use Hypereutectic Silicon Alloys
4. The depth of the surface Silicon Depletion zone must be measured and controlled.
For any elements with customer specified mandatory limits, these limits must be At this moment not customer specified mandatory limits, limts based on
H4.5 Chemistry Conforming
reduced by the tolerance permitted on the Master calibration Standards. standards such as JIS H5302
The most frequent grain refinement additive is Titanium Boron.

H4.6 Grain Refinement N/A, PAM not make modifications on any chemical Not Applicable
1. Grain refinement may be required by customer Product Engineering.
The most frequent silicon modification element is Strontium.

1. N/A, PAM not make modifications on any chemical
H4.7 Silicon Modification 1. Silicon modification may be required by customer Product Engineering. Not Applicable
2. N/A, PAM not make modifications on any chemical
2. A common target is 150 ppm.
1. Unless customer Product Engineering waives this requirement, all metal must be
rotary degassed (cleaned) at least once before casting.
2. Degassing in a central melter and autoladle transferring to cast machine holders is
unacceptable. These autoladle transfer processes will not be Approved.
3. Degassing must be in a transfer ladle or in a holder at the cast machine. The design
of the degassing unit must have a baffle plate.
4. The use of cast machines with integral melter/holders is strongly discouraged. It is
1. Degassing is carried out once every 12 hours.
often difficult to meet requirements for metal cleanliness and degassing. A minimum
2. Degassing is perform on the individual furnace of each DC machine
requirement is a baffled chamber with a rotary degassing unit running continuously.
3. Degassing is put in the conveying ladle.
H4.8 Degassing Conforming
4. N/A, cleaning routine is perform on daily basis
5. After rotary degassing, a vacuum gas sample must be taken in order to determine
the specific gravity. Calculate specific gravity of sample using weight in air vs. weight in
water method. The specific gravity difference must be within 0.10 of the theoretical
maximum based on the chemistry of the alloy and a maximum of -27 inches of Mercury
vacuum pressure. For many alloys, the theoretical maximum is around 2.70.
6. Vacuum gas sample testing is required for each batch degassing cycle unless
customer Product Engineering approves other process controls. Vacuum gas sample
testing is preferred every two hours for continuous degassing units unless customer
Product Engineering approves other process controls.

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Molten metal from the melting furnaces may be tapped directly to go to the cast line, or
Each DC machine has an individual melting furnace, and holding
H4.9 Metal Transfer it may be transferred to intermediate holders. If intermediate holders are used, they Conforming
furnace, therefore no transportation is applicable
must have heat.
The temperature of metal being delivered to a cast machine holding furnace must be Melted material temperature is monitor permanently by thermocouple
checked. The temperature of metal being delivered must be within internally specified sensor and verified externally with a thermometer, check once per
H4.10 Metal Transfer Conforming
control limits such that the cast machine holding furnace stays in specification. month. When the set value is exceeded, the machine automatically
adjusts the temperature.
1. Metal at the cast machine must be in holders. Holders must have heat.
1. Each DC machine has a holding furnace that maintain proper metal
2. The temperature output must be readable by the machine operator. If the metal
temperature.
temperature in the holding furnace falls outside of the specified range, an alarm must
Holding Metal Treatment and 2. When the metal temperature falls outside the range, the abnormal
H4.11 be established to indicate an out of tolerance condition. Conforming
Temperature Control lamp lights up. Metal temperature can be visual check on Furnace
3. Holding furnaces at the cast machines must be capable of controlling metal
display
temperature at the metal extraction point to within +/- 5°C, unless the customer agrees
3. It can be controlled within +/- 5 ° C.
to a wider range.
Load of raw materials or scrap is input into the Fusion Furnace, holding
Charging raw materials or scrap into the auto pouring holders or ladles and running
H4.12 Metal Quality furnace composition is reviewed on spectrometer and mechanical test of Conforming
production out of them at the same time is prohibited.
final product.
Alloying into the auto pouring holders or ladles is allowed, but must be minimized in
H4.13 Alloying Pegasus not alloying into the auto pouring holders or ladles N/A
order to prevent defects such as inclusions.
5.0 Cast In Place Inserts
1. The customer Product Engineering must approve the source for cast in place inserts.
2. The insert source must implement Full Compliance with the applicable template
1. N/A to PAM, not use cast in place inserts.
H5.1 Insert Source Process Table before PPAP. For example, a ductile iron bearing cap in a bedplate, the Not Applicable
casting source must implement Full Compliance with the Ductile Iron Casting Process
Table before PPAP.
1. Cast-in-place inserts must be pre-heated immediately prior to pouring metal into the
die. 1. N/A to PAM, not use cast in place inserts.
H5.2 Insert Process Control 2. The cast-in-place inserts must be completely dry. The volatiles content on the inserts 2. N/A to PAM, not use cast in place inserts. Not Applicable
must be audited, measured, and recorded. 3. N/A to PAM, not use cast in place inserts.
3. The cast-in-place inserts must be properly stored (maintained clean and dry).

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1. There must be a regular audit to section the castings to inspect the bonding of the
cast in place insert with the aluminum. Audit results must be documented.
H5.3 Insert Audit 2. Machined castings must be dye penetrant audited to inspect for cracks (or contact Not Applicable
separation) around the inserts unless customer Product Engineering approves an
alternative method. Audit results must be documented.
6.0 Pouring/Casting Operation
1. Ladles must be made of, or coated with, an insulating material.

2. Time from metal extraction to casting shot must be minimized and controlled.
1. Coating with insulating material (Chem Trend TOP-211)
3. Automatic pouring of molten metal into the shot sleeve is required. Manual pouring is
2. The time from the metal extraction to the casting shot is kept to a
not allowed.
minimum and controlled by the machine.
4. Pouring height into the shot sleeve must be minimized.
3. Automatic injection of molten metal into the shot sleeve is possible.
5. Ladles must be free of residual "skull" material (aluminum film known to contain high
4. Adjustment is made so that aluminum does not spill from shot sleeve.
H6.1 Pouring Ladle Control concentration of oxides) before entering the dip well. Visual inspection criteria should be Conforming
5. Daily visual inspection included on DC Checklist PAM-FORM-PE-001
defined and posted in the work area.
6. Yes, there is a dam in the laddle, and laddle make an inclination at the
6. Auto pour ladle design must have a dam (hole in the back) to hold back the dross.
time to take melted aluminum
Back tilt the ladle such that the ladle fills through the hole submerged beneath the
7. Laddle is keep 5 second jut over holding furnace in order to maintain it
surface of the metal.
hot.
7. Metal ladles must be positioned where heat from the melt surface can keep the ladle
hot when it is "parked" at the home position.
When pressure pour dosing furnaces are used, an inert gas or dry air may be used to
H6.2 Dosing Furnace pressurize the chamber. If air is used, the dew point must be less than -40ºC, preferably N/A, dousing furnace not apply to PAM N/A
below -80ºC.
Launders from dosing furnaces must be designed and maintained such that metal does
H6.3 Launders N/A, dousing furnace not apply to PAM N/A
not buildup in them.

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1. Unless customer Product Engineering waives this requirement, there must be a low
frequency audit to measure the oxide content of the metal going into the molds using
Porous Disk Filter Analysis (PoDFA). PoDFA can be outsourced. Future metal 1. N/A, chemical composition of metal is inspected on daily basis
H6.4 Oxide Control cleanliness requirements may be based on PoDFA. Audit frequency to be agreed upon 2. skimming once every hour. Conforming
with customer Product Engineering; frequency may be zero. 3. N/A, current customers not request K-mold audits
2. Dip wells must be frequently skimmed to minimize the dross accumulation.
3. Some customers may require K-mold audits after cleaning of melters and holders.
Equipment computer programs or mechanical limits for pouring and cycle times must be
Password is necessary to change program. People without authority can
H6.5 Machine Settings protected from non-authorized changes so that only authorized personnel can change Conforming
not change.
the program or settings.
Cast machine must have real time closed loop monitoring which is either tied into the It has a loop monitoring in real time and generates an alarm when the
H6.6 Control Limits extractor/robot control or creates an alarm when key parameters are beyond control main parameter exceeds the control limit. Conforming
limits. Castings that are outside the control limits must be marked and later scraped. Castings outside control limits are automatically scraped.
Heat treating must be before machining and may be in-house or outsourced. Heat
H6.7 Heat Treatment treating must be in compliance with CQI-9: Special Process: Heat Treat System Heat treatment performed to all molds before machining based on CQI-9 Conforming
Assessment (HTSA), published by AIAG.
1. Any liquid quench must have automatic temperature control and agitation. Equipment
must be capable to control quenching medium to within ± 5º C. 1. Heat treatment outsourced supplier comply
H6.8 Heat Treatment Conforming
2. The quench medium must be at least 80C unless customer Product Engineering 2. Heat treatment outsourced supplier comply
approves a lower temperature limit.
H6.9 Heat Treatment Cold water not to be introduced to the quench tank while parts are being quenched. Cold water is not introduced Conforming
H6.10 Heat Treatment The delay from solution heat treat into a quenchant must not exceed 30 seconds. Delay not exceed 30 seconds Conforming

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7.0 Inspection and Testing
Pegasus have capacity to ver inspection requirements form customer
Retained Material or Cleanliness Equipment must be available onsite to properly administer retained material inspection with equipment such as CMM, UTM, Spectrometer, calipers,
H7.1 Conforming
Requirement per customer requirements. micrometers, etc. Inspection records are keep based on customer retain
requirements. (Reference to PAM-FORM-C-055-01).
1. As a minimum, the casting plant shall have a programmable Coordinate Measuring

Machine (CMM) on site. The CMM must be run in an automatic mode. Where possible,
the application of point cloud/laser scanning inspection technology is preferred. When
used in combination with point cloud scanning technology, the CMM is considered the
“gage of record” for dimensional measurements because of precision associated with
1. CMM is used for measurement of products. All measurements are
the points measured.
make based on customer request (manual and automatic is possible).
Dimensional Inspection - 2. The casting plant shall maintain a CMM hit point map/drawing showing all CMM hit
H7.2 2. There is a critical point in drawings, measurements are perform based Conforming
Part One points that are agreed upon between the casting plant and the customer. (Point Cloud
on customer method when applicable.
Inspection/laser scanning can be used in place of CMM inspection if agreed upon with
3. Raw casting is dimensioned.
customer Product Engineering).
3. The raw casting datums must be included in all CMM hitpoint programs. The intent is
to be able to dimensionally check the casting at any stage of manufacture in order to
know if the raw casting was To Print. This expressly includes being able to check a
finish machined component to determine if the raw casting was To Print.
4. The CMM program must include checking the flatness of each individual raw casting
datum surface if the datum pad is intended to be a flat surface. Preferably less than
0.250mm.
5. Point cloud/laser scanning inspection must use the part-design datum construction to
4. CMM programs include all checkings based on drawing requirements,
align the measurement data. Unless otherwise specified by the customer, "best-fit" data
if flatness is a requirement, we include in inspection.
alignment is not allowed.
5. cloud/laser scanning inspection is design based on drawing
6. The casting plant is responsible for comparing the scan with the 3D Math Model. In
position/dimensions required, datum on drawing are used for reference
all cases the Point Cloud/laser scan must be aligned to the math model using the X-Y-Z
Dimensional Inspection - of inspection.
H7.3 raw casting datum surfaces. Results must be shared with customer Product Conforming
Part Two 6. Comparing is carry out with customer drawing and with 3D Model as
Engineering and the responsible APQP Quality Engineer.
well.
7. Scan reports must include a screen shot showing which surface features were used
7. Scan report is not used in Pegasus
to align the scan to the 3D Math Model; and what is the distance, D, of those scanned
8.- Scan report is not used in Pegasus, program is developed based on
surface features to each of the same features in the 3D Math Model. The scan report
customer drawing and evidence is send to customer for every PPAP.
must clearly state which version of the 3D Math Model was used.
8. Point Cloud/laser scanning Inspection is recommended for prototype parts and PPAP
parts as defined by the customer specific requirements. The scanning may be out-
sourced.

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There must be regular audits to section raw castings for wall thickness verification;
including any high stress features in the FEA. If the supplier is responsible for any Pegasus not perform machining at this moment, mehanical test is
H7.4 Wall Thickness Conforming
machining, there must be regular audits to section machined castings for wall thickness perform based on customer request (compression and tension test)
verification.
Supplier is responsible to acquire proper non-destructive inspection tools to evaluate for

H7.5 Internal Passages blocked passages. This may include boroscopes, endoscopes, probes, fiber optics, flow Yes, PAM have X-Ray machine for compliance Conforming
meters, or X-ray.
1. There must be on-site capability to regular audit with dye penetrant (color check) or
fluorescent penetrant inspection (FPI) entire casting or sections of castings specified by 1. N/A, PAM product not use dye penetrant or color specs
Dye Penetrant Check and
H7.6 customer; including any high stress features in the FEA. 2. N/A, internal inspections are using X-Ray, customers not request this Not Applicable
NaOH Etch Castings
2. There must be on-site capability to cut and NaOH etch castings for internal test
inspections. (NaOH is sodium hydroxide, also called caustic soda.).
1. The supplier shall have a real time fluoroscopic/X-ray unit on-site.

1. Yes, Pegasus Monterrey have X-Ray machine equipment, added to
2. There must be certified Masters at the X-ray capable of measuring the sensitivity and
PPAP per customer request.
resolution so that the system can be proven to meet customer requirements defined by
H7.7 X-ray 2. Master included with machine. Conforming
product design record.
3. N/A, X-Ray checks including per customer request
3. X-ray audits must include any high stress features in the FEA.
4. N/A, not request for PAM product applications
4. For some applications, automated defect recognition may be required.
Unless customer Product Engineering approves higher porosity levels, (1) under no
circumstances can the internal porosity exceed ASTM E505 Level 2 using the 1/8”
series of reference photos regardless of actual section size; and (2) at any features of X-ray check based on customer requirement, if not have requirement,
H7.8 Internal Porosity Conforming
the casting which would have an FEA Extreme Load Maximum Stress greater than 50% strength test is take as reference for approved parts.
of the Yield Strength of the alloy the internal porosity must not exceed ASTM E505
Level 1 using the 1/8” series of reference photos regardless of actual section size.
1. Customer must approve any salvage repair procedures. Casting repairs, such as
welding, epoxy, Devcon, and impregnation, are not permitted, unless approved by 1. In case of repair mold cavity, this is communicated to customer for
customer Product Engineering. approval.
2. If repairs are allowed, repair method and procedures must be approved by Customer 2. In case of repair mold cavity, this is communicated to customer for
H7.9 Repairs Conforming
Product Engineering. approval.
3. If straightening is allowed, a customer Product Engineering approved method is 3. In case of repair mold cavity, this is communicated to customer for
required, normally with a fixtured, automated process. Manual methods should not be approval.
used.

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8.0 Material Properties
1. The supplier shall have a metallurgical lab located on-site with capabilities to analyze
1. Pegasus Auto Parts Monterrey have a internal laboratory with three
chemistries, hardness, microstructure, area fraction porosity, dendritic arm spacing
main equipments (CMM, Universal Testing Machine and Spectrometer)
(DAS), silicon particle size, and any other features specified by customer Product
to make dimensional inspections, strength tests and quemical
H8.1 Laboratory Location Engineering. Conforming
composition tests.
2. The supplier shall have Scanning Electron Microscope (SEM) capability available.
2. Not have SEM in place, but capability available in other Pegasus
The SEM does not have to be on-site. However, the location and access to it must be
facility.
reasonable for defect analyses.
1. Material property testing must be defined per customer design records.

1. Material property testing is defined by customer (Spectrometer test)
2. Mechanical properties testing must be on site unless customer Product Engineering
2. Mechanical properties testings are performed on site
approves another location.
3.- Mechanical property testings are basically for tensile/compression
3. Mechanical property testing must include ultimate tensile strength, yield strength, and
strength, any other test for mechanical properties can be carry out based
H8.2 Material Property Testing percent elongation. Yield Strength must be measured with an extensometer attached to Conforming
on customer requirements.
the specimen unless customer Product Engineering agrees to some other method.
4.- Any retest or replacement is approved by customer Engineering.
4. If retest or replacement is necessary must be with agreement of the customer
5. Tests are always performed with prototypes and continue with regular
Product Engineering.
production when customer approved first samples.
5. Testing begins with prototypes and continues through regular production.
The casting source must prepare test bars from a location approved by customer
Product Engineering. For example, these might be cut from a casting or from a
separately cast bar. Mechanical properties are often required from test bars cut from All mechanical properties are tests with the complete sample, if
H8.3 Mechanical Property Conforming
actual castings in an area designated on the engineering drawing or in the part quality customer required with test bar, this test can be developed.
document. The test bar location in the casting will be dimensioned from casting
features.
1. Metallurgical examination is to be done by the supplier prior to any component 1. Based on customer requirement, type of material is used and internal
testing to insure microstructure meets engineering drawing specifications. test is performed with Spectrometer in order to veify chemical
2. A metallograph image analyzer is required on-site unless customer Product composition.
Engineering approves some other method of measuring features in the images. The 2. Pegasus Monterrey have this equipment to verify Area Fraction
H8.4 Microstructure Analysis image analyzer must be capable of measuring any Product Engineering requirements porosity (Vision mahine, X-Ray machine) Conforming
such as Area Fraction porosity. 3. Pegasus Monterrey have this equipment to verify Area Fraction
3. Reference photographs must be readily available at the metallograph for all porosity (Vision mahine, X-Ray machine)
microstructure requirements. 4. Pegasus Monterrey have this equipment to verify Area Fraction
4. Microstructure audits must include any high stress features in the FEA. porosity (Vision mahine, X-Ray machine), based on customer request

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1. Hardness testing is to be done on-site per ASTM E10/ISO 6506. Supplier must have
certified Master blocks on-site for auditing the calibration of the hardness tester.
2. The Tolerance range for the Master block must be posted on the hardness tester.
3. The Tolerance range for the Master must not exceed +/- 3%.
4. The customer specified range for hardness must be reduced by the tolerance
Hardness testing is not performed currently in Pegasus Auto Parts
H8.5 Hardness Testing allowed on the hardness Master block. Conforming
Monterrey. Can be add to our regular inspections if customer required.
5. Unless Product Engineering specifies otherwise, Brinell hardness test using a 500Kg
load, 10 mm diameter indenter, and 30 second dwell time.
6. Hardness to be measured at a specified location from customer Product Engineering.
7. If hardness readings are out of specification, all castings in the Lot shall be hardness
tested with any out-of-specification castings rejected.
The supplier is responsible for any residual stress testing requirements unless
Customer Product Engineering agrees that the supplier is not responsible for it. Testing Stress testings are perfomed in place with Universal Testing Machine
H8.6 Residual Stress Testing Conforming
may be outsourced. Customer Product Engineering must approve the source which (compression, strength, tensile)
conducts the testing.
The supplier is responsible for any fatigue testing requirements unless Customer
Product Engineering agrees that the supplier is not responsible for it. Testing may be
H8.7 Fatigue Testing Fatigue testing can be developed outsourced if customer required Conforming
outsourced. Customer Product Engineering must approve the source which conducts
the testing.
The casting plant shall demonstrate the corrosion rate of metal shall not exceed
Maximum rate as customer requirement. If applicable and required by the customer, the Currently corrosion is not requeried by customer. Corrosion testing can
H8.8 Corrosion Testing Conforming
corrosion test shall be salt spray (Reference ASTM B117) and humidity as customer be performed outsourced if customer required
requirement.

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Not Applicable
9.0 Leak Testing
1. Some castings may require leak testing. Leak rate specification must be defined on
the customer Product Engineering document.
2. Acceptable methods for leak testing are: air under water, sniffers, pressure decay,
mass flow.
3. Pressure decay / mass flow cannot measure Zero leakage. Zero leakage
H9.1 Leak Test Requirement applications must use air under water or helium particle counters (sniffers). N/A, PAM product not request leak test N/A
4. Pressure decay / mass flow must pass Gage R&R below 10% at the maximum leak
specification.
5. Pressure decay / mass flow cannot pass Gage R&R at very low leak rate
specifications. These very low leak rate applications must also use air under water or
sniffers.
1. Castings must be thoroughly dried before going into pressure decay / mass flow. An
in-line drier is preferred.
2. Casting cavities must be leak tested separately in order to assure there are no cross
channel leaks.
3. Pressure decay / mass flow controllers must have automatic temperature
measurement and adjustment.
4. Leak Masters must have leak rates within +/- 10% of the maximum permissible leak
rate of the part.
5. A Zero Leak Master is required for pressure decay / mass flow. A Zero Leak Master
is an Impregnated casting. Verify in water dunk that is has zero bubbles.
H9.2 Leak Test Process N/A, PAM product not request leak test N/A
6. Each day that the pressure decay / mass flow is used, the measured leak rate for
the Zero Leak Master and for the Max Leak Master must be recorded and plotted.
7. Customer maximum leak rate limits must be reduced by the observed Bias and
Variation of the measurement system (such as the +/- variation of the Zero Leak
Master).
8. A certified orifice may be used as the Leak Master and/or as the Zero Leak Master if
customer Product Engineering approves.
9. Pressure decay / mass flow test equipment must automatically stamp good parts
while the part is still in the test fixture.

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Conforming /
Not Applicable
1. The supplier shall have water dunk capability on site for determining the location of
leaks on castings as shipped to the customer AND for fully machined castings returned
from the customer.
2. Water dunk must use water temperature at least 20ºC.
H9.3 Water Dunk Capability N/A, PAM product not request leak test N/A
3. 100% water dunk, zero bubbles, is common for components with a Zero Leak
requirement. Typical water dunk parameters are 5 bar air pressure, minimum 15
seconds without a bubble. Air pressure and minimum time must be approved by
customer Product Engineering.
1. Impregnation is not allowed unless expressly approved by customer Product

Engineering. Approval must be documented per Customer specific policy, such as on
the part print.
2. Customer Product Engineering must approve the sealant (resin) to be used.
H9.4 Impregnation N/A. Not have customer request N/A
3. Customer Product Engineering must approve the impregnation source which would
perform the impregnation.
4. Impregnation must be in full compliance with any customer specific Statement Of
Requirements for Impregnation of Castings.
1. Some castings may require flow testing. Flow rate specification must be defined on
the customer Product Engineering document.
2. Flow testing must use automated air flow equipment. Using round balls or probes is
H9.5 Flow Testing N/A. Not have customer request N/A
not acceptable unless approved by customer Product Engineering.
3. Flow test equipment must automatically stamp good parts while the part is still in the
test fixture.
1. Error-proofing is required before final packaging if similar looking part numbers are in
production in the same facility. 1. Error proofing implemented for packing
H9.6 Error-Proofing Conforming
2. Scheduling production of similar looking part numbers on different production shifts is 2. Understand it
not error-proofing.

ISBN#: 978 1 60534 388 4

CQI-27 Assessment Final Pegasus 28-02-2024

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CQI-27

Sspecial Process: Casting System Assessment

Phone Number: ´+52 (81) 27-13-37-50

Foundry Personnel Contacted:

Alan Valadez Quality Manager 8115046597 avaladez@pegasusmexico.com

Takashi Kuwahara Pegasus Auto Parts Monterrey 8112274736 t_kuwahara@pegasusmexico.com

Number of Conforming Number of Non- Number of Not Applicable

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

© 2018 Automotive Industry Action Group A2

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

Customer is notified about how many cavities to be approved, PPAP

© 2018 Automotive Industry Action Group A3

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

1. After trial casting, if there is no problem in the dimensions of the

© 2018 Automotive Industry Action Group A4

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

1. Check-sheet verification to account for potential issues outside of the standard

1. Confirmation of de-calcification of the water flow line.

1. The life of the die is tracked based on number of cycles.

1. Replacement inserts (new steel), where there is a customer specific requirement, a

© 2018 Automotive Industry Action Group A5

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

2.0 Cast Machines

© 2018 Automotive Industry Action Group A6

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

© 2018 Automotive Industry Action Group A7

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

1. Plunger lubrication should have controls to avoid excessive plunger lubrication.

1. Manual spraying is allowed. Auto spray systems are preferred.

© 2018 Automotive Industry Action Group A8

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

1. Each shot is cooling during conveyor transportation (10 minutes of

© 2018 Automotive Industry Action Group A9

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

© 2018 Automotive Industry Action Group A10

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

© 2018 Automotive Industry Action Group A11

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

The most frequent grain refinement additive is Titanium Boron.

The most frequent silicon modification element is Strontium.

© 2018 Automotive Industry Action Group A12

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

5.0 Cast In Place Inserts

© 2018 Automotive Industry Action Group A13

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

6.0 Pouring/Casting Operation

1. Ladles must be made of, or coated with, an insulating material.

© 2018 Automotive Industry Action Group A14

PROCESS TABLE H - Aluminum High Pressure Die Cast

All requirements given below are subordinate to customer specific requirements.

© 2018 Automotive Industry Action Group A15