Automotive Industry Action Group Cc Ql -9 Special Process: Heat Treat System Assessment 3° EditionCcal-9 Special Process: Heat Treat System Assessment Version 3, lesued 1012011 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 quality, 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, department managers, and program managers plan, direct and coordinate the association's activities, under the direction of the executive director. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies. They conduct research and develop, publish, and provide training on standards, conventions, standard business practices, white papers, and guidelines in the areas of automatic identification, CAD/CAM, EDI/electronic commerce, continuous quality improvement, health focus, materials and project management, occupational health & safety, returnable containers and packaging systems, ‘ransportation/customs and truck & heavy equipment. [ aiae PuBLICATIONS | An AIAG publication reflects a consensus of those substantially concemed with iis scope and provisions. An | ‘AIAG publication Is intended as 2 guide to aid the manufacture, the consumer, and the public. The existence of | ‘an AIAG publication doos notin any respect preclude anyone from manufacturing, marketing, purchasing. or | Using products, processes, or procedures not conforming tothe publication CAUTIONARY NOTICE AIAG publications are subject to periodic review and users are cautioned to obtain the latest editions. (MAINTENANCE PROCEDURE Recognizing that tis AIAG publication may not cover all circumstances, AIAG has established e maintenance procedure. Please referto the Maintenance Request Form atthe back f this document fo submit a request Published by: ‘Automotive Industry Action Group 126200 Lahser Road, Suite 200 ‘Southffeld, Michigan 48033 (248) 358-3570 + Fax: (248) 358-3253 Phor APPROVAL STATUS The AIAG Quality Steering Committee and designated stakeholders approved this document for publication in October 2011 AIAG COPYRIGHT AND TRADEMARK NOTICE: ‘The Automotive Industry Action Group copyrights the contents ofall published materials unless otherwise indicated. Copyright isnot claimed as fo any part of an original work propared by a U.S. or state goverment officer or employee as part of tie person's official {lties, Al rights are preserved by AIAG, and contont may not be altered or dsseminated, published, or transfered in part of such Content. The information's not toe sad in part or whole fo anyone within your organization orto another company. Copyright lnfringement is 2 violation of federal law subject fo cnminal and civil penaltes. AIAG and the Automotive Industry Action Group are rogistered service marks ofthe Automotive Industry Acton Group. (© 2011 Automotive Industry Action Group ISBN #9 781 60534 2368caQl-9 | ‘Special Process: Heat Treat System Assessment Verson 3. issued 1072011AIAG 2 te Special Process: Heat Treat System Assessment The cata for poak perfomance Version 8, Issued 10/2011 FOREWORD Automotive Industry Action Group (ALAG) 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 are 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 (CQI-9 Chairperson) ~ TRW Automotive, Inc. Dean Higdon ~ Acument Global Technologies North America, Pete Batche ~ Akebono Brake Corporation, North America Stefan Bruder ~ Bodycote Warmebehandlung GmbH Madhu Chatterjee — Bodycote Thermal Processing, North America Rick Howell —Chrysler Group LLC, North America Darrell Rydzewski — Controls Service, Inc. Virender Choudhri ~ Delphi Corporation Stephen Toltesi ~ Eaton Corporation Suranjeeta Dhar ~ Ford Motor Company Peter Schiefer— Ford Motor Company, Germany 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cal-9 | ene CHANGES TO Cal-9 3°° EDITION The Special Process: Heat Treat System Assessmént, 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 | suppliers, heat treat suppliers, and calibration companies that service the heat trejt industry. Below is a summary of the important changes in this 3° edition. |. | Three new Process Tables have been add + Low Pressure Carburizing | 5 ere ‘© Jon (Plasma) Nitriding | The format and layout of the Process Tables have been improved to facilitate the heat treat system assessment. | References to AMS 2750D have been renfoved and replaced with AIAG CQI-9 specific requirements, 4, Frequency for SAT and Instrument Calibrption have been changed. The requirement in the 3" Edition allows the heat treater to choose ohe of the two following options: Option 1 Quarterly SAT (Probe Method A or B) oF Monthly SAT (Comparative Method), and Quarterly Control Instrument Calibration (single-point or multi-point calibration). | Option 2: Quarterly SAT (Method A only) and Semi-Annual Control Instrument Calibration (multi-point c@libration; I-point calibration not allowed with semi- annual frequency). | 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 ‘palpont calibration is allowed) ‘+ Semi-annual (multi-point calibration method; single-point calibration is not allowed) 6. Frequency for checking the quench oil codling 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 + 15 "C (+ 25°F), 8 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 oxygen probe controllér (carbon controller) shall control the carbon potential +/-0.05%, | 11. Question 3.12 was modified. This question addresses the proper height ofthe workload on a continuous belt furnace. |AIAG 2m gals Special Process: Heat Treat System Assessment The cata for peak performance Version 3, Issued 10/2011 TABLE OF CONTENTS ABOUT AIAG... FOREWORD ‘TABLE OF CONTENTS. INTRODUCTION... GeneRaL = PROCESS APPROACH, Heat TREAT SYSTEM ASSESSMENT GOALS... ASSESSMENT PROCESS ASSESSOR QUALIFICATIONS. ‘OTHER REQUIREMENTS 1 SCOPE... 1.1 Genera LZ APPUCATION 1.3 REFERENCE. 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE .. 3 SPECIAL PROCESS: HEAT TREAT ASSESSMENT ... 3.1 THenmocourtes : a rir z 3.2 INSTRUMENTATION eee eee eee ae 45 3.3 Syste AccuRACY TEST (SAT). 3.4 TEMPERATURE UNIFORMITY SURVEYS (TUS) 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 .. PROCESS TABLE D: INDUCTION HEAT TREATING .. PROCESS TABLE E: ANNEALING / NORMALIZING / STRESS-RELIEVING .. PROCESS TABLE F: LOW PRESSURE CARBURIZING. 83 PROCESS TABLE G: SINTER HARDENING... PROCESS TABLE H: ION NITRIDING GLOSSARY.ey | AIAG 2m Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 Te catalyst for peak performanceAIAG. cats Tio cata or ask performance Version 3, lasued 10/201 INTRODUCTION 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. In the HTSA, the word “shall” indicates a requirement for purposes of the self assessment. Failure to meet the requirements results in an assessment that is either “Not Satisfactory” or “Needs Immediate Action”. ‘The word “should” indicates a recommendation. Where the term “such as” is used, any suggestions given are for guidance only. Process Approach The HTSA supports the automotive process approach as described 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-specific requirements, defines the fundamental requirements for heat treat management systems. ‘The HTSA is 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,ome AIAG» Special Process: Heat Treat System Assessmient Version 3. Issued 10/2011 Tho catayet fr pack pertomarce Use of CQI-9, HTSA, and Process Tabk 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 | | AAssessor(s) shall have the following specific experfence to conduct the HEAT TREAT SYSTEM ASSESSMENT: | 1, Bean experienced quality management system (QMS) internal auditor (for example, ISO/TS 16949, ISO 9001) | Assessor shall possess heat treating knowledge. Evidence shall include a minimum of 5 ‘years experience in heat treating of a combination of formal metallurgical education and heat treating experience totaling a ininimum of S years. 3. Assessor shall possess i be familiar with the application of automotive quality core tools including statistical process control, measurement systems analysis, part approval, failure mode and effects analysis, 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 requirements 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 anly 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 TS16949 or Iso 9001 requirements for process control and inspection records. |AIAG 2a cals ‘Special Process: Heat Treat System Assessment The cata for peak perforce Varsion 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 andior service are processed throughout the automotive supply chain. 1.2 Application All requirements of the HTSA are generic and are intended to be applicable to all organizations performing the heat treat operations addressed in this document, regardless of type, size, and product. Eight Process Tables have been developed and the appropriate table(s) is to be referenced during the assessment. The Process Tables are specific to heat treat processes 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) . Ferritie-Nitrocarburizing (Gas o Salt) Process Table C= Aluminum . Aluminum Heat Treating Process Table D —Ferrous . Induction Heat Treating Process Table E - Annealing, Normalizing, and Stress-Relieving ‘© Conformance to CQI-9 is required for all organizations that perform annealing, normalizing, or stress-relieving to achieve desired final characteristics of the part. Process Table F — Low Pressure Carburizingcate AIAG a Special Process: Heat Treat System Ascereaont Version 3, Issued 1072011 Tho cata for peak poformance T 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. 7 | ‘These Process Tables contain requirements for: 1, Process and Test Equipment Pyrometry Process Monitor Frequencies In-Process/Final Test Frequencies ‘Quenchant and Solution Test Frequenties The Process Tables specify the tolerances of process parameters and the frequencies for checking process control parameters and parts. The requirements and guidance 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 eRe reo acy SCC tg ISO/TS16949 ‘Quality management systems International Organization for ee a Standardization ISO/IEC 17025 General Requirements forthe International Organization for competence of testing and Standardization libration laboratories _| _ _ 1SO 9001 | Quality management systems International Organization for ___| requirements Standardization TEC 60584-1 ‘Thermocouples Referencé Tables | Intemational Electrotechnical | Commission _ [ASTM E230 | Standard Specification andl | American Standards of Testing and Temperature-Electromotiye (EMF) | Methods for Standardized Thermogouples -10-AIAG = cats To cata for peak performance Version 3, Issued 10/2011 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE 1 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 Assesstnent, 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 each “Not Satisfactory” item and determine corrective action, including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. “Needs Immediate Action” requires immediate containment of suspect product. Address each “Needs Immediate Action” item and determine corrective action(s), including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. Assessments shall be conducted annually unless otherwise specified by the customer.cal-9 ‘Special Process: Heat Treat System Assessment Varson 3 sued 102011AIAG» gate Special Process: Heat Treat System Assessment ‘Tho cata for paak perfomance Version 3, Issued 10/2011 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: EQUIPMEN INSTRUCTIONS FOR COMPLETING THE JOB AUDIT. SECTION 4: JOB AUDIT FORM. -13-“14 caQl-9 | Version 3 Issued 1072011 Special Process: Heat Treat System Ascoremont Instructions for completing the Ci AIAG Tho catayst for peak pertomance 1. Facility Name: Name of the facility bein ‘One form shall be used for each facility. 7] locations in the same general area. If there) Metallurgist) or different management syst separate facilities. | Address: The street address ofthe facility’ additional information, Phone Number: The phone number of th If there is no common phone number for t Manager or Quality Manager shall be used, Fax Number: The fax number of the facil hourly, associated with the heat treat ope Captive Heat Treater (Y/N): Enter “Y” i company. Enter “N” if the company does Commercial Heat Treater (¥/N): Enter “ ‘companies other than their own company. ater “N components for other companies. Date of Assessment: Enter the date(s) of tl assessed. 1 facility may have several buildings or physical isa separate management team (Quality Manager and -m, then these locations shall be considered as being assessed; P.O. Box numbers may be given as facility. ie facility, the phone number of the Operations ity. Number of Heat Treat Employees at tal Facility: The number of employees, salaried and ion at this facility. this facility heat treats components for their own jot heat treat any components for their own company. facility heat treats components for if this facility does not heat treat any ¢ assessment. An alphanumeric format shall be used to avoid confusion with different numeric formats Example: May 3 —4, 2011 Date of Previous Assessment: List the dat System Assessment of this facility process(es) performed at this facility. This that shall be used during the assessment. P Heat Treat System Assessment Current Quality Certification(s): The he e.g,, ISO/TS 16949, ISO 9001. Certificatio certifications. If customer quality cettifica customer shall also be given. ‘Type(s) of Thermal Processing at this Facii of the previous CQI-9 Special Process: Heat Treat + Place a checkmark to designate all thermal information determines the appropriate Process Table cesses not listed on the cover sheet are not part of the } t treater shall list their current quality certifications, is may be from 3rd party sources or customer quality jon is given, then the year of the last assessment by the 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 implemer tation of the corresponding corrective action(s). ‘The date of the re-assessment shall be given here, and the appropriate Question(s) from Sections | —4, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), Satisfactory Findings” shall be modified as has been observed. Also, the “Number of Not ‘appropriate. Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the principal participants from the heat treater’s organizationAIAG 2m cals ‘Special Process: Heat Treat System Assessment ‘Tho cata or peak partormanco Version 3, issued 10/2011 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. “1S.“16 cal-9 Special Process: Heat Treat System Assessmi Version 3. tssued 10/2011 Cover Sheet Form The catays for peek performance [Special Process: Heat Treat System Assessment Fearne [scree fescue [Romar a reat eat Eayene ate Fak ra Cape) Heat Tear area oa Tae Deo asseaa at aly TTS dais Resoeeoeeion aes Loonies Pica ot at Seoeaey Baa [ante o Far Praga the Doo Ra [pete ot Thermal Processing a recess Table A= Ferrous [carrey [csentra [csron Reston ute Haraerns |Guenen Temper Preiptaton ardonrg Prosess Tobie 8 - Porous Forni Nerang ae or Sa [Process Table C-Atominom [Rune Heat Treanor [duction Hes Treat Process Tobie omster [Seses Rete [Process Table [cw Pressure Coma [reasee Tobie Process Tobie on NarAIAG 2a cals ‘Special Process: Heat Treat System Assessment Tha cata for pak perfomance Version 3, issued 1072011 Instructions for completing Sections 1-3 Sections | - 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 1 In the “Requirements and Guidance” column, the word “shall” indicates a requirement and the term “such as” indicates that any suggestions given are for guidance only. NOTE 2: ‘The “Requirements and Guidance” column will indicate to the assessor when the Process Tables are pertinent to the questions. When the Process Tables are pertinent to the 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 in the “N/A” Assessment column, Ifthe observed | evidence is in compliance to the question, the assessor shall note the evidence in the “Objective Evidence” column and place a check mark in the “Satisfactory” column. Ifthe 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, NOTE 4: Where nonconforming product is identified in the assessment of a given question the assessor shall place a check mark in the “Needs Immediate Action” (NIA) column, NIA requires immediate containment of suspect productThe cata for peak performance ity & Quality Planning Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 cal-9 uid Ruren 9 Kmqistodsoy jusuoBeueyl- + WOHseS ‘oxen || pra cane ‘urna pur muses onrone juauissassy wloysAg yal] WOH :559901g jr2edS Section 1: Management Responsi “18cal-9 Special Process: Heat Treat System Assessment Version 3 Issued 10/2011 ‘The cata for pk performance wey svep2un sn sounpna eamslao quowssessy woyshg yeas yeoH{ :ss0201g 1eIo0ds -19-‘The catalyst for peak performance jt Special Process: Heat Treat System Assess: Version 3, Issued 10/2011 CcaQl-9 ees cmay| OEE | coxsences [vn sae mela urn poe souninbon ease jwourssessy wioysAg Weer] Teo} -ss0901g fer20dgcal-9 Special Process: Heat Treat System Assessment Version 3 Issued 10/2011 Tho cata fo pak periomance wore | foremies | goiennes [vn ‘mpna aaWeo suena pur suowssnbon equ onsen coo r yuoulssessy wayefg yeas] yeaH :sse001g jersedg 21‘The cata for pook porfomanca nant Special Process: Heat Treat System Assess: Version 3, Issued 10/2011 cal-9 “ppd possiost 0 sno ou separ] *|coeeooadeo 0d vy set | sense | Pesce | esos || wees eelenesreerenE won Jompvina Speen onsen quowssassy waysXs 1891] 13H :Ss9901g 1e120ds,caQl-9 ‘Special Process: Heat Treat System Assessment Version 3, fssued 1072011 ‘Tho cata or oak patomance wn sana sto WoUlssossy wo}s4g Weel] eH :ss900%4 [eIDedg, 2The catalyst for peak performance AIAG Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 cal-9 uo cananuoutoMpen &pe exes pie posse Ys ee oes srueuan eae oto pe es sua poy scpnd poe nap ae rou kms ronan] Zensen enum yn feng Be arene uma egies» eee CTS | nocemme [vn] emma wietao ay www | queussassy tiershg 1e013 ea} :sse0014 jejoods. 24caQl-9 Version 3 Issued 10/2011 28. in passa Bone — Special Process: Heat Treat System Assessment won | omens E ‘osenes [yn pump nselao even pur swounnebos wasn emcee 1 OWISSossy Wwoysfg yealy yeO}{ :ss090Ng [8120s AIAG Tho catatst fo paak perfomanceTho catalyst for peak perborarce Section 2: Floor and Material Handling Responsibility et Special Process: Heat Treat System Assess: Version 3. Issued 10/2011 caQl-9 (suodsay Bupuey ‘econo [ym] ssumpva asian 990 9 nner vonsine quoussossy wershg weal] YEOH Zs8000%g (IDOI -26-cal-9 Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 he cays forpoak portrmanco sonora eieeo semana perewusinony a ‘Waulssossy Wa}SKG yeas] yeoH !ss090%4 [eedS -27-‘The catalyst for peak patommance ess AIAG.» Special Process: Heat Treat System Assi Version 3, Issued 10/2011 cal-9 880 (1800) | | expanjtte Base Mota! | Conve) rr | > 650° (1200) 1 | Expendable Base Metal Expendable Base Metal Non-expendable Base Monitor/Record/Load Sensing (4) Monitor/Record/Load Sensing (4) Temperature Uniformity Surveys, $ 650°C (1200°F) | Mae SAT and Load Sensing = 980°C (1800°F) | 180 (2,3) ' | Thermocouples (5) 7 | n “Temperature Uniformity Surveys, Non-expendable Base | SaT'and Load Sensing > 900% 1800) | 9023) cole ‘Thermocouples (5) _ _ dl Includes Load Sensing Thermocouples used as « Control Thermocouple. 2. | When a non-expendable base metal thermcouple is used above 980°C (1800°F), the maximum total number of uses is 90 uses which shalll include any previous or subsequent temperature readings taken with the subject thermocouple, 3. | Inthe absence of documentation of the muinber of uses for non-expendable base metal hermocouple used for TUS and SAT, ther the thermocouples shall be replaced after 6 months. Expendable base metal thermocouples for oad sensing, are allowed more than one use if thermocouple shows no visual degradation, Documentation is required to show compliance 5. Notexpendable base metal thermocouples for load sensing, are allowed more than one use if thermocouple shows no visual degradation, Documentation is required to show compliance. AdeAIAG 2m ae ‘Special Process: Heat Treat System Assessment ‘The catalyst fer pookperormance Version 3, Issued 10/2011 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. Intemal sources providing calibrations shall do so in accordance with the intent of ISO/IECI7025 or other national equivalent. Records shall be kept of training and qualifications for internal personnel performing calibrations. 3.2.1.3 Calibration frequencies and accuracies are specified in the applicable Process Tables and in the Instrumentation Table 3.2.1. A grace period of 2 weeks is allowed for all calibrations, 3.2.14 The temperature for each control zone shall be recorded by a recording instrument. 32141 Recorder shall be operating during the entire time that product is in the furnace and print intervals/sample rates shall not exceed five (5) minutes for analog recorders and two (2) ‘minutes for digital recorders. Process record shall be legible. 3.2.2. Readability and Resolution: The following represent minimally acceptable requirements: 3.2.2.1 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 oven 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 increment + 250°F maximum per inch of chart paper * 10°F maximum per chart line inerement 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. 55cal-9 Special Process: Heat Treat System Assess: Version 3. lssued 10/2011 3.2.4 Calibration: Calibration of control, moni the manufacturer's instructions; however calibratic 3.24.1, For the calibration of control, monitori ‘operation and running at typical operatin, (parallel reading of thermocouple inp temperature shall remain within processit 3.2.4.2 For each channel or group of channels in us required. AIAG Tho catayt for poak portance ing, and recording instruments shall be performed to may be performed as described in 3.2.4.1 ig or recording instruments on furnaces that are in temperatures, a single point calibration is acceptable For furnaces with a load in process, the furnace i tolerance. that can be altered or adjusted, a calibration shall be 3.2.4.3, Calibration Frequency ofthe control, mopitoring, and recording instruments shall be one of the ‘wo options listed below: 3243.1 Option 1: Quarterly (single: po definitions) 2 Option 2: the frequency squat ‘employed for the instrumer Calibration Records: Calibration status anc A calibration label shall be affixed to the i control, monitoring or recording instrum shall include: or multi-point calibration; see Glossary for y rly per Probe wc ‘A (per 3.3.4.1) AND the multi-point calibration is t calibration results shall be reported as follows. strumentation device, or in the case of panel mounted intation, on the device or as near as practical to the device(s) to indicate its (their) most rept successful calibration, The label(s) at a minimum Date the calibration was performed, Due date of the next calibration. Technician who performed the calit Serial number of instrument Instrumentation calibration results or certificate shall include the follo Furnace or unit identification numl Make, model and serial number of controlling devices). Method of calibration. Ambient temperature and humidity Required accuracy. Initial and final values at each cali value will equal the initial value). Initial and corrected offset/bias val offset/bias value will equal the inti Statement of acceptance Any limitations or restrictions of th Date the calibration was perform Due date of next calibration, Technician who performed the cali ration (initials are acceptable), II be documented. The instrument calibration report ng information er instrument calibrated (not applicable to PLC Standard or test instrument used during calibration, ration point (if'no adjustment is made then the final 1s (if no adjustment is made then the corrected I value). ie calibration. ration.AIAG» cars ‘Special Process: Heat Treat System Assessment ‘Thocatast er peck perfomance Version 3. issued 10/2011 © Signature of the technician who performed the calibration. * Calibration company if not performed in-house. + Sign-off by 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. -47-‘uoneigye9 juiod-nynux pue uorrexqije9 1u10d-op au Jo suonruyjop 105 Kawsso}8 99g * -€°£ 99S) V pompayy sod KtsopENb pautsoyrad st LVS at) pur (uonezqieo rurod-nynut) prepuers Around © ype paresgyyeo st uauMnsuT axp req papiaoid pamoyfe st uoTHeIqTeD jenUATE-MIAg “] “8h | We ‘swwewngsu| ] ueusinbe Bussooad Spanos veuou eg ound pe Loesobse: so Buiowon amenduer oa Suneeouc.pemun | (oy) 902% © pmo wo | Gornowes e soos 1 sonououn a ours Supe 1 ovepues 801 Bs GDI 880% | hepuooeg wo lala yo voewored “eee ncn sess sen sree} ——} — + Buipeas04s00# epueis 10 (4o6°0 #) Ded'0 F | paepuers Aewud a ‘Raepuooes | —| ___ soj0s8 sory | dupe. %s100* nou epueig 2 (4oh'0 ¥) 9060°0 plepuRIS souEIa}9q 98 Aud preps | prepuers euogen covenos | putues we pepues euud cr powury | 3.0s1¥01SiNied | WoreAnbo wD ISIN oe atojoniownz | eouaey Coren} Per eas Ret ie} oy CeNEry Pea Cen a} Pee ie) nat adAL POET PET) SINAWAAINOTA NOLLVUAITVD LNGWAALSNI ~ PTE ATA L <= ovIV 150208 pa cosaA Juauissassy wajsks jeals 12a} :SS820/¢ [219905 6109AIAG» cats Special Process: Heat Treat System Assessment Tho cata fo posk perfomance Version 3, Issued 10/2011 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 confor ‘Thermocouple Table 3.1.3 coupled with a test instrument meeting the req Table 3.2.1 ing to the requirements of ments of Instrumentation 3.3.3. A new SAT shall be performed after any maintenance that could affect the SAT accuracy, e.g., the replacement of the lead wire, control thermocouple, or the replacement of the control instrument. 3.3.4 The SAT shall be performed while the furnace is operating at a typical operating temperature using either the Probe Method (Section 3.3.4.1 or Section 3.3.4.2) or the Comparative Method (Section 33.43). 3.3.4.1 Probe Method 334.11 Probe Method A is a check between the uncorrected reading of the control temperature system (control instrument, leadwire, and thermocouple) and the corrected reading of a test temperature system (test instrument and test thermocouple). See Illustration 3.4.1 33.4.1.2 The tip (measuring junction) of the test thermocouple shall be no further than 50 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 sufficient time to achieve equilibrium between the test thermocouple and the control thermocouple. 33.414 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.cal-9 ata or peak petormanco Example of Probe Method "A' over-Temp Thermocouple Gente ‘hermocouple N\, J = Over-Temp Protection Part or Raw Material / | | { (6) Test Instrument Test Furnace ‘Thermocouple Furnace Wall Work Zone Lead EXAMPLE OF ACCEPTABLE SYSTEM ACCURACY TEST (SAT) PROBE METHOD - A ou od i ates Coed ou 4 TRUE TEST iced cer pe ec cd Psa bei ch oh att ea cae Cia a co er a eee goo°c | gorse | 08°C (ies) | (1655) | (107) +0.1° 901.1°C AAC (40.2°F) (1654.2°F) (22°F) |AIAG 2m cats Tho cats for peak perfomance Version 3, lseued 10/2011 3.3.4.2 Probe Method B: 33.421 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 (test instrument and test thermocouple). See Illustration 3.4.2 33.422 The tip (measuring junction) of the test thermocouple shall be no further than 50 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. 33.423 After insertion of the test thermocouple sufficient time shall be allowed to achieve equilibrium between the test thermocouple and the control thermocouple under test. 33.424 The uncorrected reading of the control thermocouple connected to a test instrument shall be recorded at the highest point in its temperature cycle. Immediately following, the test instrument shall be connected to the test thermocouple. The corrected reading of the test ‘temperature system shall be recorded at the highest point in its temperature cycle. 33.425 If the calculated SAT difference between the uncorrected reading of the control temperature thermocouple indicated on the test instrument and the corrected reading of the test temperature system (test instrument and test thermocouple) exceeds +5°C (410°F) the control temperature thermocouple shall be replaced and any other appropriate corrective actions shall be taken before commencing with additional thermal processing. All actions taken shall be documented, 33.4.2.6 SAT frequency shall be quarterlycal-9 Sper ree: eat Tet System Aces AIAG 2a sys or pook perfomance Example of Probe Method)"B" over-tomp Shemocouple Controt Thermocouple N\, co Control instrument . - oversemp F Protection ra | Part or Raw | Natori Tet Furnace Thermocouple Furnace Wall Work Zone — TK {B) Test \ Instrument Lead Wire (A) Test Instrument EXAMPLE OF ACCEPTABLE SYSTEM ACCURACY PEST (SAT) PROBE METHOD - B Soa as = Teer be ae Se aw Lor ee te ; fo ee eect ca Sr 3 a 90°C gorse | -0.5°C 40.1°C 901.1°C (1652°F) (1655) | _(C-1.0°F) (40.2°F) (1654.2°F) ert Ce [ Note: Test insiument A and Test insirumgnt B are ypicaly@ same test instruméAIAG = cats Special Process: Heat Treat System Assessment Tio cats or peak perfomance Version 3 issued 10/2011 3.3.4.3 Comparative Method: 33.431 ‘The Comparative Method is a comparison between the uncorrected reading of the control temperature system (control instrument, leadwire and thermocouple) and the uncorrected reading of any other permanently installed monitoring system (instrument, leadwire and thermocouple) in the same work zone, such as an over temperature control system. See Ilustration 3.4.3 33.432 The temperature difference (delta) between the control system (control instrument, leadwire and thermocouple) reading and the reading of any other permanently installed monitoring system, at the time of the most recent conforming instrument calibration test, shall be established (¢.g., the control temperature system indicates 600°C and the over temperature control system indicates 605°C; the delta between these two devices is +5°C).. 33.433 This established delta shall not differ by more than +/-1°C (or +/-2°F) when checked at a typical operating temperature. It is strongly recommended that the comparative check be performed at or near the original comparison test temperature. See example below for calculation of delta, 3343.4 If both devices have their respective thermocouples in the same protection tube they shall be of a different type (e.g., Type K with Type N, Type R with Type S). This is to prevent false readings due to similar degradation rate 3343.5 Corrective actions shall be taken to correct a failed SAT before commencing with additional thermal processing. A new delta shall be established after any maintenance that could affect the SAT accuracy, e.g., the replacement of the lead wire, thermocouple, control instrument, or calibration adjustment for either the control temperature device or temperature monitoring system. Actions taken shall be documented, 3343.6 See Table 3.1.3, SAT Comparative Method for the resident thermocouple replacement schedule. 3.3.43.7 SAT frequency shall be monthly.cats AIAG a Version 3 Isued 10/2011 Tho cat Example of Comparative Method over-temp Thermocouple coptrot Thpemocoupe NX i Over-Temp Protection Part or Raw Material Chart Recorder Furnace Rebident Work Zone Coen Thermocouple Furnace Wall ‘Thermocouple Monitor Note 1: It is recommencied that the comparative check be performed at or near the initial temperature at the time of instrument calibration (See A & B temperature in example below). Note 2: Resident thermocouple and over-temp thermocouple may be the same thermocouple PTABLE SYSTEM ACCURACY TEST (SAT) COMPARATIVE METHOD EXAMPLE OF ACC er See eee , peo aie ee cr fry Peter ee Pe Berd ce i rit cs ica fe nay ki ced va) (8) @ ) enc 600°C 605°C +5°c | 606°C 610°C (in12"F) (2) | OF) (1123°F) (1130°F) Deviation from the initial delta = E~D-CAIAG 2m cats Special Process: Heat Treat System Assessment Tho cata fo ask perfomance Version 3, fseued 10/2041 3.3.5 System Accuracy Test Records shall include the following: Identification of the thermocouple being tested Identification of the test thermocouple Identification of the test instrument Date and time of day of the test Observed control instrument reading Observed test instrument reading Test thermocouple and test instrument correction factors Corrected test instrument reading Calculated system accuracy test difference Indication of test acceptance or failure Identification of technician performing the test Extemal calibration company if applicable Sign-off by responsible person in the heat treat organization56. = AIAG 2m Versign 3, Issued 10/2011 Tho catalyst fr pak pertrmarce TABLE 3.3.1 - SYSTEM ACCURACY TEST REQUIREMENTS Geass Tr aro) ed Pao Oi aes TYPE FREQUENCY Peake) Types 8, Rand S Quarterly ‘Noble Metal Probe Method Typos K,N, J and E | | OP'Base nota Comparative Types B, R and S Morithy 10°C (2 20°F) Method Noble Meta 23) Types K,N, J and | | sae teat | 1. Maximum value of the Calculated SAT difference (see 3.3.4.1.3 and 3.3.4.2.5). Maximum deviation from initial delta (see|3.3.4.3.2) 3, Total offset/bias assigned to the correctign of a SAT error shall not exceed 2.0°C (4.0°F). This permissible offseUbias is separate from offset/bias assignable to a Calibration error or TUS.AIAG 2m cars Tho cata for paak perfomance Version 3, Issued 10/2011 3.4 Temperature Uniformity Surveys (TUS) 3.4.1 General TUS Requirements: Temperature uniformity characteristics, qualified work zones, and operating temperature ranges of furnaces or ovens are validated by performing a TUS. ‘The TUS shall be performed in accordance with the appropriate Process Table and the requirements of this section. 3.4.1.1 Any furnace modification or repair that could alter the temperature uniformity characteristics of the furnace shall result in a temperature uniformity survey being performed prior to the furnace system being used for processing. See “Furnace Modifications” and “Furnace Repairs” in the Glossary for further guidance, 3.4.1.2 All furnace modifications or repairs shall be documented and include the determination made by the responsible authority within the organization as to whether these modifications or repairs could alter the temperature uniformity characteristics of the furnace. 3.4.1.3 TUS Test Temperatures: If the operating temperature range of the qualified work zone is equal to ot less than 170°C (305°F) then only one temperature within the operating temperature range is required to be tested. If the operating temperature range of the qualified work zone is greater than 170°C (05°F) then the minimum and maximum temperatures of the operating temperature range shall be tested. For aluminum heat treating, a tighter temperature range is given in Process Table C, C24 3.4.14 TUS Furnace Parameters: When performing any temperature uniformity survey the furnace system parameters during the test shall replicate the furnace system parameters during normal production. If atmospheres used during production present safety risks or could affect the accuracy of test thermocouples during a TUS an atmosphere of air or inert gas may be used. ‘The TUS may be performed with an empty furnace. If the furnace is empty then the thermocouples shall be attached to a fixture to insure required test locations are securely held. If the TUS is performed with a loaded furnace the load shall replicate typical operations and the thermocouples shall be attached to or buried in the load. 3.4.1.5 Use of Heat Sinks: If the TUS is performed without a load the TUS test thermocouples may be attached to or inserted into heat sinks, however the heat sink shall represent the typical section size of the heat treated product. In addition, the heat sink shall possess similar heat transfer characteristics of the ‘material that is typically processed in the furnace under test. 3.4.1.6 Furnace Vacuum Level during TUS: The furnace vacuum shall be run at the lowest set point employed in normal production but need not be less than I micron Hg (1 x 10 Torr, or 1.3 x 10 millibar) when performing a TUS 3.4.2 Continuous and Semi-Continuous Furnaces“58 cate AIAG = Special Process: Heat Treat System Assessment Version 3, issued 10/2011 | Tho cata for poak portornarce tT 3.4.2, TUS Methods: Continuous and semi-cqntinuous furnaces shall be surveyed so that the volume defined as the qualified work zone is tested. os sensors shall be arranged either three dimensionally (Volumetric Method) or in a plane (Plane Meth 3.4.2.2 Number and Location of TUS Thermogouples 2.2.1Volumetrie Method: Shall be used with continuous pusher furnaces. See Table 3.4.1 for number of TUS thermocouples. See Figute 3.4.1 for the location of the TUS thermocouples. 3.4.2.2.2Plane Method: Shall be used for continuous furnaces where the product is continuously moving through the furnace, e.g., belt fijmaces. See Table 3.4.2 for number of thermocouples, Refer to table 3.4.2 forthe location of the|TUS thermocouples. 3.4.3, TUS Data Collection: | 3.4.3,1 TUS test thermocouples shall be traversed through the furnace at a traverse speed typically used in production and representing all test locations ak required in Table 3.4.1 and Figure 3.4.1 or Table 3.4.2 3 appropriate. | | 3.4.3,2 Data collection shall begin when the TUS test thermocouples are loaded into the furnace. All temperature data generated by the TUS test thermocouples shall be recorded automatically at least every thirty seconds. The process record for furngce zone temperature shall be compared to the TUS data {o ensure compliance to TUS requirements, Manual data collection is not allowed. TUS data collected shall clearly show the soak périod achieved so that the responsible Quality Assurance organization can determine compliance with interhal process specifications defining suitable soak time, 3.4.4 Furnaces Other Than Continuous or S¢mi-Continuous 3.4.4.1 Number of TUS Thermocouples: The required number of TUS thermocouples shall be in accordance with the TUS Test Thermocouple Table 3.4.1 3.44.2 Location of TUS Thermocouples: See Figure 34.1 forthe typical location of thermocouples in rectangular and cylindrical shaped furnaces. For furnace work zone volumes greater than 8.5mm (3008), the thermocouple locations shall be similar fo the example in Figure 3.4.1 and the additional thermocouples shal be located to best represent the qualified work zone. 3.44.3 TUS Data Collection: Data collection shall begin when the TUS thermocouples are loaded into the furnace. All temperature data generated by thd TUS thermocouples and recorded on the process record for furnace zone temperature shall be recorded automatically at a frequency of at least one set of readings every two minutes for the duration of the survey. Manual data collection is not allowed. | The process record fr farce zone temperature hal be compared to the TUS daa fo ensure compliance to TUS requirements. 3.4.4.3.1When the furnace temperature) control achieves set point temperature, displaying a normal control cycling around set point, and the TUS test thermocouples have stabilized, then the TUS data collection shall continue for an additional thirty minutes minimum.AIAG = cats Special Process: Heat Treat System Assessment ‘Tho cata for ask paroemance Version 2 issued 10/2011 3.4.5. Alternative TUS Testing Methods: Design characteristics of certain furmaces may prevent the traversing or insertion of TUS test thermocouples through or into the furnace work zone(s). In such instances it is incumbent upon the Heat Treater to develop acceptable alternative methods to provide objective evidence that temperature uniformity characteristics of the thermal processing equipment meet the requirements of the applicable Process Tables and satisfy the intent of this document. ‘The alternative approach taken shall be reviewed and approved by the customer, 3.4.5.1 Property Surveys: In the event an acceptable alternative TUS testing method cannot be developed employing traversing or insertion of TUS test thermocouples through or into the furnace work zone(s), property surveys shall be accepted as objective evidence of thermal processing capabilities. Initial property surveys of the selected product shall analyze those characteristics that are sensitive to variations in process temperatures and shall establish baseline data against which monthly product property trends shall be performed. If possible the selected product is processed frequently. The normal process size range shall be represented in the selected product. When a two-step process is under review, the second step can be run on the samples independent from the remainder of the lot. If the furnace qualified operating temperature range is equal to or less than 170°C (305°F), the highest and lowest operating temperatures shall be represented by the product property survey. If the furnace qualified operating temperature range is greater than 170°C (305°F), the product property surveys shall include an intermediate temperature in addition to the highest and lowest operating temperatures. At least five product property surveys shall be performed at each survey temperature. Samples for product, property surveys shall be taken from the extremes and center of the load. Monthly property survey trends shall include selected characteristics of heat-treated product analyzed by an appropriate statistical technique. Trends shall be examined monthly with defined control limits. Processing will be halted if any property trend exhibits a shift beyond assigned control limits until the cause of the shift is corrected 3.4.6 Permissible TUS Test Thermocouple Failures: The permissible TUS test thermocouple failure rate is defined below: [When using 3 to 9 thermocouples 0 failures are permitted | When using 10 to 16 thermocouples [71 failure is permitted When using greater than 16 thermocouples | Less than or equal to 10% _ failures A temporary condition such as a short or loose connection where normal temperature readout is restored shall not be considered a failed TUS test thermocouple. No comer position failures of a TUS test thermocouple are allowed. 3.4.7. TUS Pass/Fail Requirements: 3.4.7.1 A temperature uniformity survey shall be acceptable if all previous requirements are met including the following: -59--60- caQl-9 Spacial Process: Heat Treat System Assess Version 3 ssuod 10/2011 All readings of all TUS thermocoupl temperature tolerance requirements s| soak period and the upper temperature The time required achieving recovery, exceed the time limit specified in an} minimum required time. ‘The organization's internal process Internal process specification shall de! 3.4.7.2 Reaction to TUS Failures: Ifthe tempe limits in the applicable Process Table, the cause ; The ep shal not De wsed for don pee has been performed successfully. 3.4.7.2.1 If the correction takes t and if the Qualified Operating Temperatt not required, but the adjustment shall Operating Temperature Range exceeds temperatures of the operating temperature’ 348 TUS Instrumentation: meeting the requirements of Table 3.2.1 ~ Inst thermocouples meeting the requirements of Table Compensation for known deviations in the test ins ‘mathematical corrections. 3.4.9 report: TUS Report: The items listed below shall Furmace identification name or number. Method of TUS. Survey test temperature(s). TUS thermocouple quantity and location i dimensional space, or detailed description TUS thermocouple calibration report to ing Survey test instrument calibration report t cach adjustable channel or input. Corrected readings of all TUS thermocouy identified as corrected or uncorrected. Any limitations or restrictions of the TUS, ‘Testing company identification (iff not The data collection period or soak period Survey test instrument identification num AIAG» The cata for peek pertarnance rt s and control thermocouples are within the respective jown in the applicable Process Table during the defined tolerance was not execeded at any time, stabilization or recurrent temperature pattern did not applicable process specifications. TUS is run for the specification defining suitable soak time was met. fine suitable soak time at temperature requirements. ture uniformity tolerance is not within the established the deviation shall be determined and documented, ssing until the cause has been corrected and the TUS form of adjusting (offsetting) the control instrument, ire Range does not exceed 170°C (305°F) a resurvey is jot exceed the limits of 2°C or 4°F. If the Qualified 170°C (30S°F) then the minimum and maximum range shall be resurveyed. ‘TUS’s shall be performed using independent test instrumentation iment Calibration Requirements and independent test 1.3 ~ Thermocouples. {rumentation shall be made by electronic or be included in the temperature uniformity survey jentification including a detailed diagram in three or photographs) of any load, rack or set-up. Jude correction factors, include calibration data and correction factors for les at each survey temperature. Readings shall be aay in-house). Name & Signature of the technician perfotming the TUS. ‘Survey start / stop time and start / stop date. 's applicable shall be identified. er.AIAG cals Tho cata or paak perfomance Version 3, issued 1072015 ‘* Control instrument tuning parameters, ¢.g., PID values Documentation of any furnace survey thermocouple catastrophic failures. Time and temperature profile data for all TUS thermocouples and control thermocouples for all zones tested. Control thermocouple data shall be generated by the associated process recorder or process data acquisition system, ‘* Indications of test pass or test fail status. © Summary of final plus and minus readings at each test temperature. © Sign-off by responsible person in the heat treat organization. iecas | AIAG. Special Process: Heat Treat System Assessnient | | Table 3.4.1 - TUS Test Thermocouple (VOLUMETRIC METHOD) | | me 2 af) | 0.410 8.5m? |___ Workspace Volume | <0.1m*(3t®) | 3 to 300K) Number of Thermocouples 5 9 Note 1. For furmace volumes greater than 8.5m? (3001), add at a minimum one | thermocouple foreach additiojal 3m’ (105 #), For example, for a 17.50 m’ | (620 ft) furnace, 12 thermocouples shall be used at a minimum. | Note 2, Total offset/bias assigned to the correction of a skewed TUS shall not exceed | 2.0°C (4,0°F). This permissible offset’bias is separate from offset/bias | __assignable to a Calibration or SAT error. j p o fee ey O 5° | O j | | | | O Represents thermocouple locations Figure 3.4.1 - TUS Test Thermocouple Locations -62-AIAG = cals re cata for peak pertormance Version 3 ssued 10/2011 ‘Table 3.4.2 - Number and Loe: (PLANE MI Thermocouples ‘£300 mm (1 ft.) > 300 mm (1 ft.) (eer Ree see Note 1 _see Note 2 [<0.75 m (2.5 ft) 7 3 5 0.75 mto 1.5 m (2.5 ft—5 ft) 3 7 [1.5m to 2.4m (6ft-8 ft) 3 a = ‘Add one thermocouple | > 24m (8 ft) for each 0.6 m (2 ft.) of 8 | | Ee _ additional width [ Note 1: Two TUS thermocouple locations shall be within 50 mm (2 inches) of the work zone comers. One TUS thermocouple location shall be at the center. Additional TUS thermocouples shall be uniformly distributed throughout a plane perpendicular to the conveyance direction, Note 2: Four TUS thermocouple locations shall be within 50 mm (2 inches) of the work zone cotners and the remainder shall be at the center and symmetrically distributed about the center of a plane perpendicular to the conveyance direction -63-cal-9 ‘Special Process: Heat Treat System Assessm Version 3, Issued 10/2011 jent To cata for poak performance Instructions for completing the Job Audi ‘The organization is to complete a minimum of on should be done preferably on a part identified for heat treat part job audit during each assessment. This ne of the customers requiring compliance to this document, More part job audits may be done if tinke permits, Preferably, safety or critical parts should be audited. This may not be easily determined with identify the end customer (auto manufacturer, tier performed at the end of the heat treat system asse The job audit is not the only or main focus of the Responsibility and Quality Planning, Floor and M equally if not even more important. The job audit sufficient t0 use as a basis to complete the other The job audit is a compliance type audit/review of processing, including heat treat equipment and pr toners, especially if the fastener manufacturer does not ne, etc.). It is recommended that the job audit be ment. (TSA. The other three sections on Management terial Handling Responsibility, and Equipment are i one part, one heat process, and one furnace is not (tions of the complete HTSA. 'a specific part and its related paperwork and Jcessing records for that job from the beginning receipt of a part through processing in the heat treat operation and inspection to packaging. Parts shall be taken from the shipping area at the dock or the end of th heat treat operation. If an automotive manufacturer's part ig not available or identifiable, then parts from other customers requiring compliance with this document shall be used for the assessment, The part or fot checked shall represent a major he carburizing and tempering, induction hardening fa it treat operation such as quench and tempering, steel, solution treating and aging of aluminum, ete. In subsequent heat treat system assessments, different parts and heat treat processes shall be checked. The specific heat treat processing parameters (appl ies to 4.7 in the Job Audit) that are required in the job audit shall be added to the job audit form. This cai) be done by reviewing the customer specification(s), the Control Plan, the FMEA, and the floor work/j proper production records/compliancelinspection. System Assessment for the actual jobyheat treat pr furnace records for the actual time frame/shift etc border. Each processing step shall be reviewed for ‘These steps can be compared to those in the Heat Treat ss being reviewed for compliance. The heat treat and ‘that the job was processed shall also be checked. The actual furnace equipment and instrumentation certification shall be verified as being in compliance to the appropriate equipment requirements in the equipi For specific heat treat parameters that are propriet supplier may enter the controlling document numt ‘The parameters shall be available to the auditor f be documented in the Job Audit. -64- jent section. hry (applies to 4.7 in the Job Audit), the heat treat her, €£., control plan or process sheet, on the Job Audit. review but proprietary information is not required tocal-9 ‘Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 Section 4: Job Audit Form The cat frpoak petarmence 5 ra on ov ke sv vy ev ou neu zw. “sap payjenb fq pasoyed “2p ‘suet eh ro zu ypenues en] by eTSTEST vin | (@2upa3 exoao) 7 qwowsmnbsy | #uosseno vSiH fed) see] uoRpuo3 fenioy | YORU 22U9%8I88 | ayo 0 27 ‘#vonsend ie. ssea} uoRpue9 renoy | ee vet | usou.0ouoisno | paises ‘upny gor - y uoRDeg 65STE TOPURS p VORSSRS| TTRGIETS 16 Fousnbon aT Tho catalyst for peak perfomance poueA=eI] Tyr weusnGex| Fay t Toneoyoeds| t Sas p wORDSyeS| t Tae 16 tenbany | poTEN I] TerLeuenrGou| — Ear Toe SaTS| TITUS p VOWS] Teen 16 atenbo FT PoueA =I] (er wewenbos| Toy 5 3 car g sz ov § 2 uy usone sa uf power aaa g yeu Siepusied ier ioveueied 3 se ayoods 0, 0 ¢ vows 5 we ‘S8EL S88001d 01 22) LpESN| é Wz (238 ‘oioyssoune ‘amesedue} 4 et ‘satun 200) uoneoyioads| 3 st sooo 0 opel edodoute| Ly =z i | teovepaa enpe) | SITE uoueinbes [¥vonse0 vain ae sealed] Cenpatstenen | voteweuroen couDiao4) S| UonsenD vony aor #vonsenD gs 90m 12.8019 (aous) aon a He ois tS Oss Oss -66-caQl-9 Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 Tho cata for pak perfomance TORETETT or _| sy ‘oued e209 up payes Aeyeincoe voazognoo uogeoyoads BuussroB oui 20a] Eby or r epazioue fou zu owuoped oom seis evoappe a] zy or Te Yo rh ‘244. urpawouinoop jou 2100 zu) zh pewoyed evovendoedars oem] bby aor oF zu ove. we tz zz up postie| ¥ dere exor014 eucordce a.m] __ 6 = seimnarauodeay ISTE] ym | (eouepns 2280) | oye eee ruawounbow | vonsano vSiH oe oe ea s8eq} woRRUCS enya | ewerul 10 warns |" pare eet cma 19 (cous) aorTho catalyst for pook perfomance cal-9 Special Process: Heat Treat System Assessment Version 3. Issued 10/2011 wz TR] OEP 82 ‘odors sive otf oe Cz | coeyueprcvedon sued ow sina| oy 1 [ooo ag Oo Trem STEREO Pa tu0d ton 0) sued pawl | ez Seuunteypatenoed syed oe|_aty ean ez suewosnoe:supered en] ivy “Siuemainbsy Bulbeped| Finegan qweweinbey | # uoRsEND YSLH voyguourong eovsiopu| , uauembne | avons v vensenoaprycor | uonseno 1519010 (6048) aor -68-AIAG a gate Special Process: Heat Treat System Assessment Tho cata for peak perfomance Version 3, issued 10/2011 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 .. 70 PROCESS TABLE D: INDUCTION HEAT TREATING PROCESS TABLE E: ANNEALING / NORMALIZING / STRESS-RELIEVING .. PROCESS TABLE F: LOW PRESSURE CARBURIZING. PROCESS TABLE G: SINTER HARDENING. PROCESS TABLE H: ION NITRIDING wn GLossary. -69-cal-9 Special Process: Heat Treat System Assessment Version 3. issued 1022011 NEUTRAL HARDENING / AUSTE! The estas for pook performance IPERING / MARTEMPERING / PROCESS TABLE A: vayausree / CARBON CORRECTION / TEMPERING / PRECIPITATION Hi IRDENING - AGING ee ‘the cstomer ray hve sdtonl requirements inspecton ten pres request, When peering te ob ad the aur sal ety at ate [contain oe costes oguren |coniquos funace reguencies are pero vor rer or pets YPichever i more freguent. lex Comat to requirement NOK ‘Cees not conply we recukomert (Exp noncompince in Relat HTSA Question #) Na Regament nt apscsbie a] REIT agnosie ‘usta a ‘PROGESS i TEST EGUPENT REGOREMENTS [rea Ts] 2} [pt aoces. oem entaanon asters stalnaf empresa narra Sa RRS aS a SS EGGS TS ASOT TT CT TST NTO OTT TT TIS [1a [separ tract an grb Bou eaund sane br rea NToRSNe) Tia]| a3 [rae weigh acon ale voted gare and ciemdamnaly aa mn maa) aa [Bewtaries,szaayaen apecension acon Renan wahaes GASSES Od SENT Jnvaraces sale clerated aus sa rar Rel] _32 _ [verfestonefeatbatonctsncromes, so carbo] IR cortsion steers Sain Oaladaalororo we TAT] 92 [vette ot carton of 3g aayarn wiz fs ard on hs ab pafored won ta zn wall aa abe contol ha ata rary ng peor rigor alban) or santana (aban clon GW Jaen coaton atone) Tre] he sae eta eee a a STORE wR ATU FT OPTS aT 2 esses Athan 120 sandr esac apeved sands TATa] 2 [Fs eriesig rors sae verted path Cobre aor ani] aa Restrepo cee parr Gans an washer SIGS TST VOSTRO we (ah GaTSU TST SRE 22 [Estes mmaty per ransacies errs arnrere 7 See Ait] 35 [cara kona boca toa ST Tae aE Ea Ra a TRE TOA TAT RE IT TORT BS OTS VOR TO BT TTT ee a [epee nomen hres shee 14 (e-25 Tenge uno hacer anes laces abtbe 1 2°7) TEE] a5 econ rmratzet tr aonirg posers ob arkoied wn 710 1 TEP slp reno snus setangpremetrs urastpra stb coteos wn scares ising toe etc Int ose Irorcontnaous umacs, hi regutement opp the Quid Wor Zone Tis] 35 fReozaetorperire orem an pect areng acces tal be cowcea win “LB (1 TF oe set ore aseudosesy crac wearing ore. Funace presale cnveledB sok irc sg te ve [eee ite tre ate) BET [So are pr ab TERI SOT FOS TET IOS OO STR TANTRICAIAG = cais Special Process: Heat Treat System Assessment Tho cata or peak perfomance Version 3 Issued 10/2011 PROCESS TABLE A -Carburizing / Carbonitriding / Carbon Restoration / Neutral Hardening / Austempering / Martempering ! ‘Tempering / Precipitation Hardenin [fa eauiaiensghie blow are sora customer specie regan Aging frm eso estonia niprion eg, gt genie. When pening eerie onan tenes shal ety eaten |coninuous tunace equenles are pe lot werk erderor as specie. whichever more feguen jok Complies to requleent [NOK Doe nl comply to requement (Expl noncomplance ‘elated MTSA Question #) IKA:Requement at appeabie ex NoK Ta Hones samaromewatre ones name pcre sro [ron atserirain [2s ansa)soty tee feet penta Soran he a Cd ETT lcs ratarsans [semes bw eye roe tomer [ctr ramadan [semea erst ever? may Te TAS RSIS COUT lnsr shows Arm fener? nave) Ate Jmere(tactper [eames sor [retype a SST SE SS ST SERIO = aie Prinses TEE] tt raat STS GOT 214 [oaesjorowartanzabn onto prs shoe : iis [esa ea wae] 14 — lean ni races Pras — 22 [lenge [Garona rsnang we [Canam marge fisnatevey amos or” leon afevery2 mo or fens sa ger” fostre setzer seme is cyte ren ey Tea eT Fearn iy wea Sack ron De agen Stra [sora opesson haan yer st = [separ nl“12. cals AIAG 2m ‘Special Process: Heat Treat System Assessment Version 3. Issued 1012011 ‘The cats or pook portormance PROCESS TABLE A - Carburizing Carbonitriding / Ca}bon Restoration / Neutral Hardening / Austempering / Martempering / ‘Tempering / Pecipitation Hardening - Aging [Armaan ave bw a sorte CiTome nee aU Inspection testing, eater fequencies ete When perfoming he Jo aut the auto shal very eater Ihe customer may have adationa require \Cominuous wnat equencis are pert work ter or28 specie whichever is more equent 10x Comptes requirement Iox: Goes netconpyn autor (Exi oncomptanc nen SACRO) a Raa Taegan oa TIT SS STRAT TT PaaRTaSaT ae [Poors arene ea reser 2 [cn [Femina a A ar area aaa a feces eee tarts ot bese pnts fewer es oo ah Rad =r STE 212 [feraumon any br nner ung ferent octet re on 7) [wonacescrnal Tent Ts. ane | a ee a ry Hi] Tr — fae sat ascent paiverhree fe TT a para Bag] a TTT ail Barr RT ANS STR TEST al eran et unase Fomees. Sy] 77 — ee ee a A ae =m cea ae ia z ata ae su Eee iparemanr = Ss} Hs ates in eee al sai ET] Fo a ae a Si eueaenee ou oar ae fear ean TES] ro See 3h fraeteacinaaram va — fap cama ast] i it Rasa : —— : Esters is ee a oo (era Tem Bar : asbeeaue medians)cal-9 ‘The cata or poakportrmance Version 3, Issued 10/2011 PROCESS TABLE B: NITRIDING (GAS) AND FERRITIC- NITROBARBURIZING (GAS OR SALT) RT TE TT cnn nv. cn ret We pth esha ty cosimows rc res ert oon or ied worm at 2 com asap ere cots WR TSA eon) 7 TSA _CategoryProcers Steps ae ROCESS he aT eae GURNEE prmern 2) [Sara tema oyeetnssnawenmcas canes | See | SE a TTT IT RTT RS TS TT — raison a ee : | a ST ES TS AT TS TE ST SST TET = 5 a jexreTe SEP enc cS Fa TE TT SET RTT STR TRIS TE er 1 fore enter hat 1966 | 2 een | recone Fs, nn ri in rt oe | sae] 5 so a a aN a ST ROT TTT74. caQl-9 ‘Special Process: Heat Treat System Assessment Versign 3, Issued 10/2011 AIAG» Te catalyst for peak performance, ‘PROCESS TABLE B - Niriding (Gas) and Ferrtic-Ntrocarburizing (Gas or Salt) Pea Ge RS RE RE [me cstema my hve aoa eee etn tg, ab Nueces, When parting fob aut eto a ye er {ontrnmto te enone [erence equi nel or odo pete bree ate lx compte ogee (rox ote compo nautnert ipa oacanpoc ats MTSAhectonf) fitment af PROCES NONTORREDUOIEES ae Feo TT ATT EE TET SRST TI te formes ony Fe Leesa [Sapeea e SE a RT ETT > Emr aaae Sra ric erate ym ana ma oa EE] i fe aT ETT caapaacial ar, tare] SaasAIAG Te cata or pk poomance cal-9 ‘Special Process: Heat Treat System Assessment Version 3, lssued 10/2011 PROCESS TABLE B -Nitriding (Gas) and Ferritc-Nitrocarburizing (Gas or Salt) RS EE - sworn, cin rng Ve i ha el ty nnn tags tk opti wi Speen en ee ip emp bee hu) en ~ ma corey om 7 ne T= — Taner ; jor eee = — ca 5 = a sax ea eet — =} ee 5 ato ae ee —— er =r = = : ber} i = aan 5 Lee Lar ar “15.cava AIAG 2» Version 3, Issued 1072011 The catalyst fr peak performance PROCESS TABLE C: ALUMINUM fear TREATMENT [RT aR Ten Bee aT To TSP cme ae onan npston eng. atone, en Ptmig hee aud heer vty et tr [commuove furnace reuensie ae perl work re) f= seced,whichever ie mere eget loc. compe torent Nox Des nt congo reguremert (Spin ponsompance inal MTSA Question) Ina“ Reqrerent tsps Ta Raa cr TSA uestons b ROSES ROTI RaaRBATRGOREIENS Er aS a Te SR PSS ST RT TT RTT SE aS RTS TE ST RETA TST ET fiscetiad omaaea iS foros aa 2 eT FE | SF Ras pas ER ps SESS SS SS IT ST TRIS TTT eR Taras SCART BeOS Ta cH WHET AT TTT TT TST oT TS SIRT CEE | ST CTS Sa RSET ATTRIB TRG GT WH SAT Ea] SER TER RT TORT TOS RS AT ST HFSS [tenure tera etre elton an agg paces sa 6 89-1) [erosive Une okracety area rans fae 1 25) Issn sda engeteerargan shat as ceo Ie pay fg of be Osa Yl Zoe fesee tn (Efe me teneetoe nesses Theta nr pete ee Continuus Fumsces ts equement apes tp the nid Work Zoe. qs} TRESS SOTURN Sl be Srier wInT SOE TA ae wae [Seca aatre acrarg ronal, Purana ol bcos we res Sage Bt st les bore For Coins Fursces tha equrmet apes the Guia Work Zone 7] 5 ra Bn PESTS apa ba aT WRT TST AY a SL TST Fecrunes cry pretce Punorenstsre bm cole th sank nes tr athe ower rece as ror CntinucusFutraces, the requrermt spies pe Guia ok Zone GT] ST a RRS HIB SN aN AS SOT TOAST ATT TT RITEAIAG 2a The cata or peak perommance cal-9 ‘Special Process: Heat Treat System Assessment Version 3 sued 10/2011 PROCESS TABLE C - Aluminum Heat Treating loc compete requremare ouvert (Ei noncomplarce Relate HTSA Question #) [iT aR aT GN STS OE SR [crim ona ects... Pcton Wri trance te. When para sb te os ty et te [cortmous mace equncie Prt wok reo spied Weve ere Reet. Tarra Tas aa rae eS Romer pemary ere cona reranens [Staeciorney oe a omen eee oace esa [S28 i oat [stale ove sree enowatre | = — = eeeancie Exams Eamonn pase en agence bres ae [auch dey ume ra be tsson Pane Pate lueaareter new z se Sir] 7a paceman Ger a trae en 7 Rm Se oe TP fe ene es — = = = aca lo arcal-9 Special Process: Heat Treat System Assessment Versgn 3. ssued 102011 T PROCESS TABLE D: INDUCTION heat TREATING preaeea yea a score veer pct eg rr gnc, epee ah es yt |x. conpestoeasrent oe wy met ren oop Rae HA Gotan) I Renarenm tei a ROSES FEST URIS RESINS TT} a a SS SS a RT a SET SELBY VIR STG IT DTV [pe ssstateAStW ema IsOamers SSprird 9 covered aoe SE TT ORS TT TE TN AT TTT ST BE ae ia ora Dabs ST ES a Ran NRTA RI] = IS sc anne Hal dT BeSGRT A SAR earn ay Samoa aa FN [Se sencnak procs pro sotueiaoncir is fet eas ze TER aT RT RT [asemnrsae Sere Sa TR TOT TRA TTT | pantry B08 | { Br Ta aro FRET TaT BIAS TH ET a 12 RESTS ARE OTT _ |G GAT wR RATES REET TTT Bie (emt oo 2 SS ar [xe et eta ots a REIT 5 oF 72 fr tan ea Hepes calc pono aan Tavera eT 248 [ese tee rae, cure era TI RTE TT RT as fo eae oot ee ‘The cata or pook prformancaAIAG» ‘Tho cata or oak portomanco cal-9 ‘Special Process: Heat Treat System Assessment Varsion 3, Issued 102011 PROCESS TABLE D - Induction Heat Treating lox. - comptes to requirement Inox Dove net comp to requrerert (Explain noncompane in Rest TSA Question) [ve Requremmt at peso [RTrerenens gen Blow ae Sub anae GRSPRTE TTT |e cuter may ave atonal equieents ©. nspection testing great Haquences, te. When petrming he Job a the ur shal ety ea freer contrntn toe canter reuse Tent [Raed TSR gay race See ‘Guaston os a oo astaaatp waa panaanTn meme ars ST a8 luc ee ana er post et cnarge,eaupenepor sab ar [artdow rarer ae) or ee eo { astataarp wea peRENTA we me ATER BT fr rv ana ner pot arg. enue et sso ak [ution marten ae) ae SRSA SSeS AA ST TST pr ares pa patina rege event ep ion am |sntsonmaneton ac) Bd [set a RoR oR AERTS A TRS TS "pe werch ark wan ou mentees hearer BIE ‘Sommer St |Smeeod sla [STS COREE SETS TS GE BS SSSA fre anno tremor settee Pe eatenert BIE ae Bs ea [Spee sas Son at aE ENN T PA SEE Fea STOTT me TS [Rast Preven Sob OH Bs a Washer fescertereaereeet a reerauet saibn (UT ena lepers sonatas be some onbet hereraue).-80- caQl-9 Special Process: Heat Treat System Assessment Versign 3 Issued 10/2011 Tho catalyst for peak performance PROCESS TABLE E: ANNEALING / NORMALIZING / STRESS- RELIEVING [A re S law a abana COROT HCE [seston may me ana mder,nete g |coningous umacereuances ar pera (werk ode os specedw fox comptes o requirement regan, When perorming the Jb aut te actor sal vary eat rater heer roe reguet Iergooe carter esos) Tnair pcan Jnox- dons not come equrement (Explain nancomplancen "elated HSA Question =) Je Racuirenert not apc r L ao aaa TS ganas Bape 7 PROCES FEST ESP PEORIRTS i as ETT] 3] RRS ncaa He SS ee ST ST nS SITS a a ETE] ST a TT BET GY OTT TATE ea} 3 FS aS SS ST ST Irnssa ssi oe clones Sminiy narninom Tt pase ren sss coring coan Sexy ESS RRS SEAT ST EE ORI TE BS TER OTE ETE [SE tan craig SR WT OT GOTT BE TOT FOOTWEAR TH SBS [se meant cstontesy sixes a a GRE Fa TET VERTED ITT ERO ESN RTS TC asin ring cote tety ESTAR A TSE o TSE PSH [ioreamnace Decay nediochen rire amncon [srsnd avi ar rancactur rourenerty awed ei) Ol ved aoa ae wl Tengen ee Pa PRET SET] 32 Sa we STS SS HTS SENT ELE SS a TSR Ta TRA RT RTT RT GTC HE COSTS STL TTS SE patrtang tpeatres snl bei 180 rain sal 19S 1.30) Fecedecinowenet serra rons [ve Fe Comme Fursovs. the ourener peso be fais Wer Ze rea win TC sh 17) oa po os roy ji ocean sores sng ot elowe Were a eleAIAG 2a care Special Process: Heat Treat System Assessment Tho cata for pack peromance Version 3 Issued 10/2011 PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving [eae GR Dla SRDS ORT TRC TT |cntrmnato tha custonar'sequrererse [continuous mace reqvences ar pelt (no eer or a seca, whchever re eget jok comptes to requrerant Ino Does not compl to reautement (Explain noncompliance n‘RlatsdHTSA Question #) fra Requremes: nt appeals [rm customs may have acitona eguremens «9 Inspection testing, eae requencs, ete. When perfrmgthelob sl, the stor shal very heat Wester = ee ea Jecongwen son fs tom fancr’ re) Jeena et pr Bz] Ta pamper [SSS al ee sR Rea SATS CT 214 fmesonoee forsee uhm rivgen metara ojseos ay eta'te a [sirsicymortred darned gna eey rs me 214 |fiosmtere ate fee en 3 Iovate? . fiom eee cette ty Ite te so 4 2] aaa aE 7 = Eo] 8 Tae RPT 7 214 [esematy cate onsen nl fea 2% [pcetne arbor fy argent fst ec e ST wT en 2) Pesaro teas state Jay nara [cosa “Blecata AIAG 2a Special Process: Heat Treat System Assessment ‘Version 3. Issued 10/2011 ‘The cata o poak perfomance PROCESS TABLE E - Annedling / Normalizing / Stress-Relieving (aa a To we DART sts lv cstamer may hte aon qamerts¢.9.specton testing. ru faaences, cc. When promig theo aud, he str sal very heat rater [cscmtngto me castoners eure |cortueushnsce eqn ae pert wor rr or 8 seced, wher ore lox. compte omauieent Inox: ees net comp wo ruramant Sxl noncorpancen "alts TA Quaston#) Inns nage st stcaie ea Ree Ear] a — fare TBS 218 roan a fers chor stove toe Inererons nace ar} Sa Ta Ta] eee a a Ter Tpacn tana | TET] Fant rete Se [Saeraear Pare Toate erp a laa eau fensernse [Proen npeateAIAG_a ‘The catalyst or peak pertamance PROCESS TABLE F: LOW PRESSURE CARBURIZING cal-9 Special Process: Heat Treat System Assessment Version 3 ssued 10/2011 [aver gran Baw ae BBO TTPO TOS | customer may hove ado requramits, Inept tring, get Haque, a. Vian prong th bathe auctor sha vey es eer | cnterming to the cstomer regan lox. compas to requrement nox: Bes ne comp to rgurement (Exp noncomplincein "alts HTEA Qutston#) [NA Requrement at apron am Raa TE ‘ategoryP roan Sens a a SEI TSRTRRT FT) ST Pes ataxic nae ol a pea TIERS SE FE) eT ~ FS | 31 RS rae wT AT WIR ow Sa FR SF a aT TT TSS OO ST a SBC COTE a ITO YT FSTST TIO TTS TTT TS FE | SE a IT RTT Bi OR EIT ST ETOH TSE FT) aa ia aa ree TESTI i late ASTM stars ISO sc aa oproedvde FE | ES i ag Pra sal ted per be OS ETE FIT] 33 Rear ype nT CE pet guar OD ash TB TST Bs TT ATTA [re-cwrea amy pu maruasu'tmeurenets a tenn, 5 ES SSRI Ce EADS STRATA Ft | 32 [Terese cabal Praca at Ser Seen ST FES] SRR Se SRT Ta RT Te CS TST SATS TEN po STOTT [renee oy aoe trey sntepaig uns le. 19 0°20 Tsp 3 Ge wire Tr ae ar gt Hoos al te crea win 5 SCOT TOF AS DOTS frosty eons cca prance. Fuse angus shat soleus tanh es stro cr france an eb soe Je pr Trace aosser sooty of hyscenbo on. Corda erg SAGAS SPURS SSS oars ie 3A sere et oe sata nal he apt naa et ese i eb anc om try ocean. Corr eS ir opt ce TOOT TSA mane ue 2 acs rts ees) Communes eoarg uth ogrot aera en eco homers ene’ ccna) ay ta oro senor [Se aT RT ICI SB TRISTE TST GAOT TT TT Jim seer -reonaarertaton sn ay JF aN RPT ic wan ft Pal SEIT HOTT SONICS84 cal-9 ‘Special Process: Heat Treat System Assessment Versio 3, fssued 10/2011 PROCESS TABLE AIAG» The catalyst for peek performance, Low Pressure Carburizing Fa ara pre aw a Raat To oer HE [sar ay ae ster tert og agente lox compe toreuenent Iv done ot apy requrment(Eepa onconptinc Raed KTBA Queso #) fins orem nt apace reutncies ee. Whan prorat the aux sha sy a eter GaegeryPrces Bape ee [Sea SSSR eT [ear [Say essa ca [Rea aT TE stan mats ary se FTE GRTOT RTE Ta ROTTS Freer a aT Riera TT ETE aT TST TREE RT a aaa Tae Sa TT = Ba ear ae Zit fw esr ay tr boon aching an rg 7 [iCPROCESSPWAL TEST 7 : Mas ie eee Fir] 37 eens ra caesar eronsh Pev es Treanor ee Fas] a aa ET Sat a ae ll FEE Ea a RT are a are Te 5, aT Bia fame an = eat Ceara Gam TT ay _ Sa Ta 3} for sien. Sh RRM Seema raaey carga) fra sere ati aT TE Fre oes OTF aoe foosroon ormettenpetrs).AIAG The cata for peak performance PROCESS TABLE G: SINTER HARDENING cal-9 ‘Special Process: Heat Treat System Assessment Version 3 ssued 10/2011 RAE TR NT RT RT [be comer my have ston eqaramens.nepeeton es, rtrraquecs, i, When paige bt te eos vey Set est ening fe cnt norm [comtinsostunace eueni a pelt (nr or rat pte wichrer mor age STOTT tip earn pee aan FSR a HHH FA) ATS SFT funaom sate ema ssa as ara esac sn marg rs se eects cer oy wae Pal OOTP BE ATE [spe STeine cd ER TT GERNOT BS TIT IETS TTT AST SE ST [resp ee TB SRT GY De RS GS STRETTON FO SS TT [sitann cabo Thouen ts easn nang arcu ars a ease rad nh ida ale a TIN SE SAO ST DPR SEN TT [nse aunans Sosa apres ia SETHORTIO ATS TRA TTT TAS TI ATT [ES RR TT RRS TOOT WE TTT BE ET RTS TTT RTT RTT [seperate ntay murs at tc shin 9 Aro 0) Tene vy ee rans lito oe erst aor aE] Tages ay ES TT DCSE TET RS FST |oame caso ana av 2 pees omega 00 a7 aon conan neva en ns ops shal lew snteme sane: cnr Ire Commun Face, he mqurent apples he Gud Wer 2a -85-cals eee eat ee eel AIAG Version 3. Issued 10/2011 Tho cata for pook performance, PROCESS TABLE G -Sinter Hardening RR TTT ES TE TT rh cet myn biol pect esa, ee gens, Wen peering jo hr hl wyatt ioe kent cnnneteenrn oonne Ree EA upon = Same pea ner | me oma Eaccttting raoeom nto [stiencrt” [evssporacprsntar ato | : ey eeetn anna fexcommey mene) [eran snenonaiasouse fis sedes eosurong fntecseg , | [rent Encuesta nort Fectafeean [Rast % femeerrcncwoonerwcmeamene | P*AIAG 2 as Special Process: Heat Treat System Assessment ‘Tho cata or pak porormarce Version 3, issued 10/2011 ‘PROCESS TABLE G - inter Hardening a [Pastore tn int ebemet 9 nspeston tg rt genc a, Whe cong bth tsa ey he ee ening lentnucstunace ques pelt nr oer ora pled, cheer mer agen loc. conps rguteman Ino Gwe not cont easton epi nncomplace Rind KTSAGuton #) egestas nF | AT aor Bape 212 Feseeatrecvtr aca oe GR ERTS RSC GTON TS ST [eons esnatorcimecen ae)” peoane fear fzrcoenoiey mers fertacnerarpeoe frame Jane semen Pair Fae a frsnsoaassasaie fsnspnsi oie [mersmaytnspet ervey mr cpet [vere rary Even or ramp [sone [sree ET] a a RT RT a oad TE TTT AT aS TE aT TER Bry TE STATE TTR aT ae [sn rap : arr ST AST TST ar TTT 2 Pepe [Seaman SR} a Saar |re tomate echo} hoettcte 78 [mura seaeetn [ecmioore : = RS ier = aa ar a I lamar + ais sear aorcal-9 Special Process: Heat Treat System Assess! Version 3. Issued 1012011 PROCESS TABLE H: ION NITRIDING AIAG ‘The cata for paok prtormance fi {nema sen nara pc net |e mt sored gn tae Pema Mi fs eceyegetitinnannec hen Wer peti oh nh een ety et et cna he ‘oeen SS So a a TTT SR a vey es a mins fo sr ‘RecN ATES wer} IE SATS ET SS TS TT wf 5 Fa cl TSS ST OEE — a ETS RTTAIAG 2a cats Special Process: Heat Treat System Assessment ‘The cata! for peak performance Version 3, Issued 10/2011 GLOSSARY Glossary of Terms In the context of this document, the following definitions shall apply: Accuracy: The closeness of agreement between a measured quantity value and a true quantity value. Adjustment: Set of operations carried out on a measuring system so that it provides prescribed indications corresponding to given values of a quantity to be measured, AIAG: Automotive Industry Action Group, As Found Data: Calibration data collected prior to adjusting (see Pre Adjustment Calibration), As Left Data: Calibration data collected after any required adjustment however, these values may be the same as the As Found Data if'no adjustments were made/required (sce Post Adjustment Calibration), ASTM: American Society for Testing and Materials. Base Metal Thermocouple: Thermocouple composed primarily of base metals and their alloys. Examples of more common base metal thermocouples include E, J, K, N, and T. Bias: The intentional adjusting of a measuring device to correct for such things as; calibration error, SAT error or skewed TUS results Caleulated SAT Difference: The difference between corrected and uncorrected readings taken during an SAT as specified in Section 3.3 and Table 3.3.1 of this document. Calibration: A calibration is a comparison between the values indicated by a measuring instrument, ‘measuring system, or measuring device and the corresponding values realized by standards or field test equipment. ‘See single-point calibration and multi-point calibration for further clarificatio1 As used herein, a calibration may also include verification that specified requirements, such as tolerances, performance, or other decision criteria have been met. Calibration may also include actions to take when requirements have not been met. Capability: The total range of inherent variation in a stable process, Carbon Restoration: A heat treat atmosphere process with the proper carbon potential that will restore the surface of the steel to the proper carbon content. It is usually performed on raw material that has decarburization at the surface. This is not to be used as a re-processing process. Continuous Furnace: Any furaace where product is conveyed continuously from the charge end to the discharge end, by way of example this would include continuous belt and pusher furnaces, Control Instrument: A device that operates automatically to regulate a controlled variable. Where the variable to be controlled is the temperature of process equipment the device is typically connected to a thermocouple. The process equipment would include ovens, furnaces, quench baths, and refrigeration equipment. The device may or may not also record temperature. Control Plans: Written descriptions of the system for controlling processes for production of parts or bulk materials. Control Plans are written by organizations to address the important characteristics and engineering requirements of the process and product. Each part shall have a Control Plan, but in many cases, “family” Control Plans may apply to a number of parts produced using a common process2906 cal-9 Special Process: Version 3 Issued 10/2011 Control Thermocouple: A thermocouple connect equipment. Contral Zoni control thermocouple, control instrument and heat Bath: Thermal Controlled Temperature Liq to the desired temperature, Product is normally im} Corrected Reading: Data that has been adjusted t and/or test sensor(s) either by electronic methods or Corrected Temperature: See Corrected Reading. Corregtion Factor: The number of degrees deter the temperature reading of a thermocouple, of an in true temperature. In the context of this document a correction factor i of error/deviation will result in a correction factor of Critical Spare Parts List: A list of service parts in obtaining spare parts would result in unacceptabl Cross-Funetional Team: A team of employees thi organization. The team will typically consist of an metallurgist, and quality personnel. Customer: The recipient of the organization's or 3 Customer Requirements: This term refers to the equipment manufacturer (typically the automobile purchase order, in engineering standards, part spet Cyeling: A periodic repeated variation in a control Pattern, Deviation: In the context of this document, the dil and the true temperature. See Error. | Degradation: The gradual shift of an attribute or the device can no longer fulfill its intended purpos« commonly accelerated by their unprotected exposul applications (e.g. lack of protection tube where one} Dew Pointer: A meter especially suited for measul Dew point is used to indirectly determine the carb Digital Instrumentation: An instrument that disp| ‘measurements in a digitized form. Energy Monitor: An electronic monitor that mea induction heating coil Error: In process instrumentation, the algebraic di the measured signal. Heat Treat System Assessment That portion of the working zone ig i AIAG 2a Tho catast for paak performance to the temperature control instrument of the process ] thermal processing equipment having a separate ;puL/output device to control its temperature. ocessing equipment containing a liquid that is heated fersed in the liquid. ‘compensate for known error in the test equipment mathematical correction. Corrected data. jined from the most recent calibration that is added to strument or a combination thereof (system) to obtain the algebraic opposite of error/deviation (e.g. +2.0°C -2.0°C). itical for the operation of equipment, Extended delay delays in the heat treat option. t represent the different functions within an jperator, line supervision, process engineer, ipplier’s product or service. fequirements or specifications from the original jompany). These may be identified in the contract or ications, etc. Jed variable or process action. See Temperature ference between the uncorrected indicated temperature iperating characteristic that may lead to a point where ‘The degradation of thermocouples for example, is to atmospheres typically found in industrial process is required or a damaged protection tube, etc.). ing the dew point of carbon-bearing atmospheres. potential of the atmosphere, lays or presents the values of process variable jures and displays the actual energy delivered to the ference between the indication and the true value ofAIAG a eae The cats fo peak perfomance Version 3, lseued 10/201 Equilibrium: A state of balance. In the context of SAT testing, equilibrium is recognized when the control thermocouple and the test thermocouple have achieved the same relative constant temperature and exhibit similar cycling characteristics. Expendable Thermocouples: Thermocouple wire typically insulated with ceramic fiber cloth, glass braid, or polyvinyl materials. Most commonly provided on spools. External Offset/Bias: The intentional adjusting of a measuring device through manually entered set point changes (see bias). Field Test Instrument: A portable measurement standard that meets all the requirements of Table 2.1 and is used routinely to calibrate control, monitoring and recoding instruments found on thermal processing equipment. It is also used in the performance of SAT’s and TUS’ s. Final Value: See As-Left Data, Fluidized Bed Furnace: A furnace that contains a dynamic mixture of a gas and/or vapor and minute solid particles of such a size that the mixture resembles a fluid in motion. Product is normally immersed in the fluidized medium, Furnace: Equipment used for the thermal processing of materials and parts. Furnace Modifications: Actions taken that change the furnace from its original documented state. Examples of furnace modifications that could alter the temperature uniformity characteristics of the furnace and shall require an additional TUS would include: © Increase in the maximum qualified operating temperature © Decrease in the minimum qualified operating temperature Change in burner size, number, type or location Change in heating element number, type or location ‘Changes to airflow (baffle positions, fan speed, fan quantity, etc.) Change of refractory thickness New refractory with different thermal properties Change of vacuum furnace hot zone design or materials Change of control sensor location. Change of combustion pressure settings from original settings ‘Temperature control scheme changes (proportional vs. high-low/on-off) ‘Changes in temperature control tuning constants Work zone volume increase covering area not previously tested ‘Work zone location change covering area not previously tested ecceecccec coc Furnace Monitoring Systems: A system that monitors the operation of the furnace. Furnace Repairs: Maintenance actions that restore the furnace to its original documented condition, If repairs are not expected to impact the temperature uniformity characteristics of the furnace an additional TUS shall not be required. Examples of furnace repairs that would not require an additional TUS would include: © Replacing a bumer with an identical bumer © Replacing a heating element with an identical heating element © Refractory repair using material with identical thermal properties 91-cal-9 Special Process: Heat Treat System Assessmer Version. Issued 102011, Replacing a control thermocouy with identical components and Restoring original documented Replacing a controller with an System accuracy test failures Correction of fumace pressure Repair of furnace door seals coco ce Heat Sink: A mass of material intended to represer thermal conductivity / heat transfer characteristics o under test. Heat Treater: An organization that performs heat Restoring original documented AIAG» The catalyst for peak prtormance ile without changing its documented location Replacing heating system components (gas regulator, valve, metering device, etc.) ettings mbustion pressure settings -ontrol tuning constants ‘identical controller with the same tuning constants yntrol problem it simulated product and shall posses the highest ‘the material predominantly processed in the furnace {reating to production and/or service parts. The heat treating may be intemal or “captive” to a manufacturing organization, or a separate commercial heat treating supplier. HTSA: Heat Treat System Assessment, Initial Value: See As-Found Data, Internal Offset/Bias: ‘The intentional adjusting of means (see bias). Interpolation: Determining correction factor valu temperature and the lowest calibration temperature, IR: Infrared. Laboratory Furnace: A furnace used solely for d material specifications. measuring device through electronic or software 1 for points between the highest calibration {termining response to heat treatment as required by Load Sensors: Thermocouples that supply the temperature of the production material to control, monitoring, recording, or field test instruments. T buried in the production material or a representation Measurand: ‘The quantity intended to be measur Measuring Junction: The electrical connection ‘owisted or welded, that is immersed in the medium hot junction. Monitor: To observe or measure the status or quath so that corrections to a process or condition may bi prescribed or desired limits. Objective evidence shi Monitoring Instrument: An instrument used to m process variables for the purpose of obtaining usefi ‘examples would include analyzers, indicators, alart Monitoring Sensor: A sensor connected to a mon} e thermocouples may be attached to, inserted into or of the production material drween the two legs of a thermocouple, typically hhose temperature is to be measured. Also called the tity of something continuously or at regular intervals ‘made without delay if the quantity varies outside of II be provided to support this activity. {casure or sense the status or magnitude of one or more | information. In the context of this document 8, oF limits. toring instrument.AIAG 2m eae Special Process: Heat Treat System Assessment To cats for peak perfomance Version 3, Issued 10/2011 Multi-point Calibration: A calibration performed by sourcing (as opposed to measuring) simulated signals at multiple test points. Signals from a standard or field test instrument are sourced to a measuring instrument, measuring system, or measuring device that represent the low, mid and high points of the range of the measuring instrument, system, or device being calibrated. See Calibration. A diagram representing a typical multi-point calibration is given below. Multi-Point Calibration Control of Control Instrument ‘Thermocouple Source (input) CALIBRATION IS Calibrated Signal to DONE WITH EMPTY Control instrument FURNACE Control Instrument Noble Metal Thermocouple: A thermocouple whose elements are made of platinum or platinum- rhodium and their alloys (Types B, R, and S), Nonconforming Product: Product that does not conform to the customer requirements. Nonexpendable Thermocouples: Thermocouples with ceramic insulators over bare thermocouple wire ‘or thermocouple wires placed in a magnesium oxide mineral insulation and encased in a metal covering (MgO). Observation: The act or practice of noting and recording some fact or event, often involving the measurement of some quantity with suitable instruments. Off Set: See bias. Over-Temperature Instrumentation: Temperature instrumentation installed in a furnace to monitor and detect when a safe operating temperature is exceeded. Its purpose is to prevent fire hazards, loss of equipment and damage to materials being processed. Oxidizing Burn-Out: A process to remove any residual ammonia from the furnace. The process usually involves removing most of the carbon bearing protective atmosphere and then introducing oxygen. ‘Oxygen Probe: An in-situ measuring probe that determines the partial pressure of oxygen in carbon- bearing atmospheres. This measurement provides an indirect measurement for the carbon potential of the atmosphere. 93.-94- cal-9 Special Process: Heat Treat System Assessment Versio 3. lssued 10/2011 Pack Density: Product mass represented by a speci density may impact temperature uniformity charac Parts Heat Treatment: Heating or cooling a specif physical or mechanical properties by a source other Post-Adjustment Calibration: A comparison be or measuring system and the corresponding values adjustments have been made in an attempt to eliminy these values represents as-left data. Pre-Adjustment Calibration: A comparison betw ‘measuring system and the corresponding values rea adjustments are made. The calculated difference in Preventive Maintenance Program or PM Progral prevent faults from occurring. A sound PM prograt whereby items having a potential to adversely affec quality are documented and resolved. The frequenc} and/or the equipment manufacturer’s recommendati Primary Standard Thermocouple: A test thermos 3.1.2 fora primary standard thermocouple with cali institute for calibration. Primary Standard: A measurement standard esta Reference Standard for a quantity of the same kind Typically used for the calibration of Secondary Stat Process Record: Data collected by a recording ins process variable. This data may be in electronic or arrangement, Process Tables: Tables in the HTSA that list the r covered. These tables contain minimum requirement Produet Properties: Product characteristics affect depth, ete.) Qualified Operating Temperature Range: The t proc Process Table requirements, s material based upon temperature uniformity AIAG Tha catat for ask perfomance fic area or volume of the work zone. Changes to pack istics. ic metal or alloy in an effort to obtain specific than the raw material producer. ‘een the values indicated by a measuring instrument ealized by standards or field test equipment after ie or minimize error. The calculated difference in en the values indicated by a measuring instrument or lized by standards or field test equipment before any these values represents the as-found data. m: A maintenance program specifically intended to shall also contain elements of a predictive nature furnace temperature uniformity, efficiency and/or of PM checks is established based upon experience 8. -ouple meeting the requirements established in Table ration directly traceable to the NIST or other national lished through calibration with respect to a ind meeting the requirements of Table 3.2.1 {dard instruments or Field Test instruments. {rument to permanently document the value of lardcopy format and presented in a tabular or graphic quired process controls for the heat treat processes s. cd by heat treat (hardness, microstructure and case smperature range in which a furnace is qualified to survey test results confirming compliance with Qualified Work Zone: The defined portion of a furnace volume where carbon potential and/or temperature variation determine the final properties to the applicable Process Table temperature uniform Quenchability Check: A measure of the cooling dj inspection machine that displays the cooling curve Quench Delay: The time delay between the end o! operation. For furnace heat treating, this is the total opening until the parts are at the bottom of the quenk time from the end of the heat cycle to the start of th system). lof the part. The temperature variation shall conform ity requirement, mamics of the quench media. A quenchometer is the f the quench media. ‘the heat treat cycle and the start of the quench ime elapsed from the start of the furnace door(s) ch tank, For induction hardening systems, this is the ‘quench flow (or when the parts enter a quenchAIAG 2m gate Tho cata for pack perfomance Version 3 ssued 10/2011 Quench System: A system facilitating the rapid cooling of heat treated product. Quenching: Rapid cooling. Quenching Medium: The medium used to quench parts after heat treating, e.g. air, oil, polymer, and water. Readability: The smallest value that can be read on a scale or displayed on an instrument (least significant digit, Recipe: This term is typically used when a computer-based system sets and controls the process parameters, ¢.g., temperature, cycle time, carbon potential. The ‘recipe’ refers to the settings of the process parameters. Recording Instrument: An instrument used to collect and document in a permanent process record the value of one or more process variables. The recording instrument may be connected to a control monitoring, load or recording thermocouple. Examples of a recording instrument would include chart recorders, video graphic recorders, or data acquisition systems. Recording Thermocoup! A thermocouple that is connected to a recording instrument, Reference Standard: A measurement standard designated for the calibration of other measurement standards for quantities of the same kind and meeting the requirements of Table 3.2.1. Typically used for the calibration of Primary Standard instruments. Resident Thermocouple: A thermocouple that is not removed from its test location between system accuracy tests utilizing the Comparative Method. The resident thermocouple is read with a Field Test instrument and shall meet the requirements of Section 3.3.4.3 and Table 3.3.1. Resolution: The smallest difference between indications of a displaying device that can be meaningfially distinguished. Reprocessing: Any process that is performed on nonconforming product so that it will meet the specified requirements. Responsibility Matrix: A responsibility matrix defines the designated personnel for all key functions. This matrix includes the primary and secondary designees. Retort Furnace: A furnace that employs a retort or muffle in which the product being heat treated is contained, Salt Bath Furnace: A furnace utilizing molten salt as the heat medium, SAT Difference Calculations: See Calculated SAT Difference. Secondary Standard: A measurement standard established through calibration with respect to a Primary Standard for a quantity of the same kind and meeting the requirements of Table 3.2.1. Typically used for the calibration of Field Test instruments, Secondary Standard Thermocouple: A test thermocouple meeting the requirements established in Table 3.1.2 for a secondary standard thermocouple with calibration directly traceable to the NIST or other national institute for calibration. Semi-Continuous Furnace: A furnace where product is conveyed at regular time intervals from the charge end to the discharge end. By way of example this would include pusher type furnaces. Shop Traveler: A document usually created in the receiving department for each batch or lot of parts received. The document defines the process routing of the parts.-96- cal-9 Special Process: Heat Treat System fe Version 3, Issued 10/2011 Signature Monitor: An electronic monitor used t plots the energy unit, ¢.g., voltage or kilowatt, vs. ti Sign-off: An initial, name, or other suitable indicat reviewed and approved Single-point Calibration: A calibration performe: single fest point. signal representing a typical operat ‘measured simultaneously by the measuring instrum standard or field test instrument. See Calibration. A) calibration is given below Control Thermocouple Test Instrument Measure t/c signal at control input terminals Soak Time: The total time elapsed during a single! at the completion of the process cycle. Soak Period: The span of time during which all 7 thermocouples and the associated furnace tempera established in the applicable Process Table. By definition, none of the thermocouples can resid the soak period ‘The soak period begins as soon as all thermocoupl the applicable Process Table and concludes at the | | | The catayst or paok ptomanco ‘monitor induction heat treating systems. The monitor e or distance. ion confirming that an event was observed and/or by measuring (as opposed to sourcing) a signal at a ing temperature or other typical process variable is int, measuring system, or measuring device, and a ‘diagram representing a typical single-point 1-Point Calibration of Control Instrument CAN BE PERFORMED WITH LOADED FURNACE. Method ensures Control Instrument is interpreting voltage signal correctly. Method has been successfully used in USA over 30 years Control Instrument ‘uninterrupted, continuous soak period that concludes iperature Uniformity Survey (TUS) test ire thermocouples are within the TUS tolerance values outside of these established tolerance values during, is are within the TUS tolerance values established in ompletion of the process cycle or when any thermocouple falls below the lower tolerance level applicable Process Table. | wr exceeds the upper tolerance level established in theAIAG 2a cals Special Process: Heat Treat System Assessment The cata for peak performance Version 3, Issued 10/2011 Characteristics: Product characteristics or manufacturing process parameters that can affect safety or compliance with regulations, fit, functions, performance, or subsequent processing of product Refer to customer-specific requirements, Stabilization: In the context of TUS testing, the condition wherein all control thermocouples and TUS test thermocouples are within the allowable TUS tolerance span as indicated in the appropriate Process Table and the controllers are cycling and/or maintaining the set temperature in each zone. In addition, for unloaded furnaces, no TUS test thermocouple may exhibit a continuous upward or downward temperature trend, For loaded furnaces some TUS thermocouples may exhibit a slow rise in temperature toward the set temperature, Provided this rise in temperature does not continue beyond the set temperature this rise in temperature of TUS thermocouples towards the set temperature meets the requirements for stabilization. System Accuracy Test (SAT): An on-site, in-situ comparison of temperature values generated by a control thermocouple against those temperature values generated by a system accuracy test thermocouple or other permanently installed thermocouple in the same furnace zone in accordance with the requirements and methods established in Section 3.3. System Accuracy Test (SAT) Thermocouple: A thermocouple used in the performance of system accuracy testing and meeting the requirements of Table 3.1.3. ‘Temperature Controller: The instrument used to control the temperature within a furnace zone. ‘Temperature Pattern: A periodic repeated temperature variation within the thermal processing equipment. See Cycling. ‘Temperature Uniformity: The temperature variation within the qualified furnace work zone in relationship to set point temperature. For retort furnaces where a thermocouple in the retort is used to control temperature, the temperature variation is with respect to the thermocouple in the retort and not to the furnace set temperature. ‘Temperature Uniformity Survey (TUS) Thermocouple: A thermocouple used in the performance of temperature uniformity survey testing and meeting the requirements of Table 3.1.3, ‘Temper Delay: The time delay form when the parts exit the quench tank to the time when the parts are placed in the tempering furnace. ‘Thermal Processing: Any process in which product is subjected to controlled temperatures for the purpose of altering structural and/or mechanical characteristics impacting the final properties or condition of the product. Thermocouple: A sensor used for measuring temperature consisting of two dissimilar metals which produce an electromotive force (EMF) roughly proportional to the temperature difference between their hot and cold junction ends. 3 (Three) Gas Analyzer: An instrument that measures carbon monoxide, carbon dioxide, and methane in carbon-bearing atmospheres. This measurement provided an indirect measurement of the carbon potential of the atmosphere, -o1-98 cal-9 ‘Special Process: Heat Treat System Assessme! Version 3 ssued 1072011 ‘Three-Valve Fail-Safe Vent (for ammonia lines): ammonia from inadvertently entering the furnace du valves are arranged in such a way that, when the am that might leak past the valve is vented to the atmo: AIAG Tho catalyst for pesk perbmanice An arrangement of three valves that prevents ‘ng carburizing or neutral hardening operations. The inonia line to the furnace is shut off, any ammonia yhere and thus prevented from entering the furnace. ‘Traceable (or Traceabi ): The ability to relate calibration to NIST or equivalent agencies in count ‘Trap Points: Areas in containers (baskets, fixtures| inadvertently trap parts, allowing the potential for p "gure 2- Valves | and Zave closed revert amnmnora flaw to furnace Jrvaive 2 nadvertery leaks. ermoria is vented (Valve 3) tothe fanosehere .casurement results through an unbroken chain of jes outside the United States. shipping boxes, etc.) or any equipment that may sto be mixed between batches. Uncorrected Reading: Data that has not been adjusted to compensate for known error in the test equipment and/or test sensor(s). Uncorrected data. Use (of a thermocouple): One cycle of heating an thermocouple a “use” would be one cycle of heating than the normal control cycling around the set point cooling a thermocouple. For an SAT test and cooling the thermocouple in an amount greater temperature. For a TUS test sensor a “use” would be one eyele of heating and cooling the thermocouple in an amount greater than the normal cycling of the furnace temperature uniformity. For Load Sensing Verification: Providing of objective evidence that Work Instructions: Instructions that describe wor inspections, heat treat operations, process parametet synonymous with the term “job instructions”. ‘Zone: A defined portion of a furnace volume whet hermocouples a “use ‘one furnace load cycle. given item fulfils specified requirements. conducted in one function in a company, e.g., setup, tolerances, etc. The term “work instructions” is product is processed.AIAG = cats Special Process: Heat Treat System Assessment he cata for peak portarmance Version 3 Issued 10/2011 | MAINTENANCE REQUEST FORM Name of Submitter: a Date: Company: Company Addres: Phone: Fax: E-mail: MAINTENANCE REQUEST Page Number of Change: Document Currently Reads: Recommended Changes/Should Read: Reason for Change (Use additional sheets if necessary): Signature of Submitter: DISPOSITION (AIAG USE ONLY) Manager's Recommendation: Comments: PES ee ee Ra ee en eee cen ent ‘Automotive Industry Action Group + 26200 Lahser Road + Suite 200 + Southfield, Mi 48033, Telephone: (248) 358-3570 + eMail: Quality@aiag.org Web: www.aiag.org -99-ERRATA SHEET FOR CQI-9 Spe Process: Heat Treat System Assessment, 3°° EDITION 1) Figure 3.4.1 -- The 12 thermocouple locations in the cylindrical furnace is changed to 9 thermocouple locations as shown below. = >, oD oo —S\ ° ) © Represents thermocouple locations 2) Cover Sheet Form — typographical error on CD © The Header on the top right side should read, Version 3, Issued 10/2011. © Process Table G is listed twice and should read, * Process Table G — Sinter Hardening + Process Table H — lon Nitriding ‘© Directions for correction typographical error on CD: + When using the CD the first time, save the file to your computer * From the Cover Sheet, click on Page Layout tab, click the arrow in the bottom right corner of the Page Setup group to display the Page Setup dialog box * Click on Header/Footer tab and select the Custom Header button * Change to Version 3, Issued 10/2011, click OK. = Locate cell C- 40, change Process Table G to Process Table H 3) Process Table E — Annealing / Normalizing Stress Relieving - E4.1 changed as shown below. AIAG Errata Sheet for COI-9 3" Edition Issued January 2012 www aiag.org4) Process Table G ~ Sinter Hardening; G3.1, The Process Monitor Frequencies for Atmosphere Generation was corrected as shown below (red circles). [one of the three options is required. [Mentor prmary temperature 2.14 |eontat instruments). |wth sign-of ev lorocesses undef 2 1) Record temperature 2x por [shi and ater any change. [if set per imts jn 62.5) |(f set per mits in G2.5) [satiety the sign requirement \2) Continuously record ltomgerature and sign-off 2x per [shif.and ater any change. PROCESS TABLE A ~ Carburizing / Carbonitriding / Carbon Restoration / Neutral Hardening / ing/Tempering/Precipitation Hardening — Aging cr ‘Ad.1 | 1.4 [Miorostrcture shal be checked at @ minimum [Daly per fumace uniess [Daly per fumace unless 2.15 |magrifcation of 100 and, 400x or above 400x. |specited by customar to be |specited by customer to be IMicrostrictural Weual references shall be available. checked with greater checked wth greater lrequency, 09. each batch. frequency, eg., each batch, PROCESS TABLE B ~ Nitriding (Gas) and Fefritic-Nitrocarburizing (Gas or Salt) Microstructure shall be checked at a minimum Joaly per fumace unless 2.18 |rmagnifieation of 100« and, 400x er above 40x |specifed by customer tobe |specttad by customer to be Microstructural vsualreerences shall be avaiable. [checked with greater (checked wth greater Irequency, @9., each batch, |fequency, eg. each batch, PROCESS TABLE G ~ Sinter Hardening [Daiy per tumace uniess [Dally per fumace unless 2.15. |ragnifcation of 100x and, 400x or above 400%. specified by customer to be |specifed by customer to be IMicrostrictural sual references shallbe avalabie. [checked with greater (checked wih greater lrequency, ¢.g.. each batch, [requency, eg. each batch, 6) Process Table D - 4.2 typographical érror changed as shown below. F part al startup, end of production run, and 1 part per 8 Inours minimum, and 1 part pre and 1 part post tool Jchange, equipment repair, station alarm (shutdown, |mattuncton, etc) 2% AIG Errata Sheet for CAI-9 3 Ecition Issued January 2012 www.aiag.org ee Mine a