1. Scope

  • This audit is intended for use for internal audits at MSM. The criteria found within is largely based on Nadcap's audit checklist AC7110 with changes and modifications.

2. General Information

  • 2.1 Instructions for the Auditor:
    In completing this audit, auditors must respond with a Yes, No, or N/A to address each requirement. For any No response, the auditor must initiate an NCR. Yes responses indicate adequate compliance. N/A may only be used for items that do not apply to the system at all. If an opportunity for improvement or observation is noted, that response may be indicated. This response shall be considered the same as a Yes with notes for potential improvement for upcoming audits.
    Note: guidance attached to any question may contain required information.

  • Processes performed at the facility (check appropriate boxes)

  • Supplement A- Metallographic Evaluation of Qualification Welds – Additional requirements for

  • Supplement B – Bend Test Evaluation of Qualification Welds – Additional requirements for

3. Welder Qualification

  • Welder Qualification Specifications
    Supplement B – Bend Test Evaluation of Qualification Welds – Additional requirements for

  • Identify which are applicable:

  • AMS–STD–1595

  • MIL–STD–1595

  • AWS D17.1

  • EN 287–X

  • ISO 24394

  • ISO 9606-X

  • Other (Please Identify)

  • Welder / Welding Operator Qualification Procedure
    Does the supplier have a documented welder / welding operator qualification procedure?

  • Procedure Number / Revision:

  • Vision Requirements
    Do qualification documents include objective evidence that the welder(s) / welding operator(s) have satisfied the specified vision examination requirements?

  • Test Specimen Preparation
    Is test specimen configuration and joint preparation documented?

  • 3.5 Process Qualification
    Do test welds made with a given welding process, qualify only that welding process?

  • 3.5.1 Processes Performed
    Identify the processes performed below:

  • Oxyfuel Welding (OFW)

  • Shielded Metal Arc Welding (SMAW, MMA)

  • Submerged Arc Welding (SAW)

  • Gas Tungsten Arc Welding (GTAW, TIG)

  • Gas Metal Arc Welding (GMAW, MIG, MAG)

  • Flux Cored Arc Welding (FCAW)

  • Plasma Arc Welding (PAW)

  • Electron Beam Welding (EBW)

  • Laser Beam Welding (LBW)

  • Specified Alloy Group
    Are the alloy groups specified in the qualification document?
    Identify which of the following material / alloy groups are used:

  • Carbon and Low Alloy Steels

  • Alloy Steels

  • Stainless Steels

  • Precipitation Hardening Stainless Steels

  • Nickel and Nickel base Alloys

  • Precipitation Hardening Nickel base Alloys

  • Aluminum and Aluminum base Alloys

  • Magnesium base Alloys

  • Titanium and Titanium base Alloys

  • Cobalt base Alloys

  • Other

  • Other Welding Conditions
    Are other welding conditions identified on qualification documents, as specified by contract?
    (See handbook for guidance)

  • Thickness Range Requirements
    Do the test welds only qualify for the range of thickness as defined in the qualification specification being used? (E.g. For AWS D17.1 standard qualifications this range would be 0.67t to 4t)

  • Verification of Test Weld Conditions
    During welding, does quality control, or other responsible authority, at the welder’s facility validate the appropriate test weld conditions such as, but not limited to, welder identification, filler materials, shielding gasses, base metal group, base metal forms (sheet, plate, tube, etc.) test weld thickness, test weld positions, or other requirements as specified in 3.1?

  • 3.10 Inspection Capabilities List testing facility for Visual Inspection, Radiographic Inspection, Bend Testing, Penetrant Inspection / MPI, Metallographic Examination, Ultrasonic, Leak or Proof Testing:

  • Approval for Metallographic Evaluation of Welds (Captive Lab)
    When metallographic assessment of Qualification welds is performed by the Supplier’s captive laboratory, is Supplement A included in the audit?
    (Note that NA is only an option when approval for metallographic assessment of welds is not required or metallographic assessment is not being performed by the Supplier’s captive laboratory)
    (See AC7110/12S for unique Customer requirements)

  • Approval for Bend Test Evaluation of Welds (Captive Lab)
    When bend test assessment of Qualification welds is performed by the Supplier’s captive laboratory, is Supplement B included in the audit?
    (Note that NA is only an option when approval for bend testing of welds is not required or bend testing is not being performed by the Supplier’s captive laboratory)
    (See AC7110/12S for unique Customer requirements)

  • Approval for Visual Weld Inspector (Captive Lab)
    When Visual Weld Inspection of Qualification welds is performed by the Supplier’s designated Inspector has the requirement for the qualification of the visual weld inspector been met?
    (Note that NA is only an option when visual weld inspection is not being performed by the Suppliers’ visual weld inspector)
    (See AC7110/12S for unique Customer requirements)

  • Approval for Metallographic Evaluation of Welds (Independent Lab)
    Is the Independent Laboratory performing metallographic testing of Qualification welds approved in accordance with customer requirements?
    (Note that NA is only an option when an Independent Laboratory is not used or there are no customer approval requirements)
    (See AC7110/12S for unique Customer requirements)
    Honeywell Specific Requirement: Within the US, Laboratories must be accredited to AC7110/13. Outside of the US, either AC7110/13 or nationally granted accreditations (via government endorsed programs) which specifically cover weld evaluations are acceptable.

  • 3.15 Approval for Bend Test Evaluation of Welds (Independent Lab)
    Is the Independent Laboratory performing bend testing of Qualification welds approved in accordance with customer requirements?
    (Note that NA is only an option when an Independent Laboratory is not used or there are no customer approval requirements)
    (See AC7110/12S for unique Customer requirements)
    Honeywell Specific Requirement: Within the US, Laboratories must be accredited to AC7110/13. Outside of the US, either AC7110/13 or nationally granted accreditations (via government endorsed programs) which specifically cover weld evaluations are acceptable.

  • Approval for Visual Weld Inspection (Independent Lab)
    Is the Independent Laboratory performing Visual Weld Inspection approved in accordance with customer requirements?
    (Note that NA is only an option when an Independent Laboratory is not used or there are no customer approval requirements)
    (See AC7110/12S for unique Customer requirements)

  • Data Flowdown
    Is there a procedure to ensure that the following information is recorded and submitted to the test facility? As a minimum:

  • a) Welder / Welding Operator Name?

  • b)Welder / Welding Operator ID?

  • c) WPS/Weld Schedule?

  • d) Base Metal Forms?

  • e) Base Metal Group?

  • f) Welding Process?

  • g) Energy (ie amperage, type, beam power, current) / For GTAW / TIG current and polarity (ie AC, DCEN, DCEP)?

  • h) Weld Type and Welding Position?

  • i) Thickness (of all pieces as applicable)?

  • j) Specification and testing to be performed?

  • k) Filler material (if none, state none)?

  • Visual Inspection
    Excluding special application qualifications, is visual inspection performed using appropriate acceptance criteria and method, for all test welds in the as-welded condition?

  • Radiographic Inspection or Bend Testing
    Excluding special application qualifications, is radiographic inspection performed for all groove welds or, if allowed, bend testing as an alternate?
    (Note that the question can only be answered NA when neither radiographic or bend testing is required by the welder qualification specification being used)

  • 3.20 Metallographic Inspection or Bend Testing
    Excluding special application qualifications, is metallographic examination performed for all fillet welds, or if allowed, bend testing as an alternate?
    (Note that the question can only be answered NA when neither metallographic or bend testing is required by the welder qualification specification being used)

  • Testing Procedure
    Do test procedures and fixtures meet the requirements of the applicable specification(s) for those processes used in 3.19 and/or 3.20?
    (Note that the question can only be answered NA when none of the test methods defined in 3.19 and 3.20 are required by the welder qualification specification being used)

  • Re-Qualification
    Are welder(s) / welding operator(s) re-qualified, per specification requirements?
    (See AC7110/12S for unique Customer requirements)

  • Qualification Scope
    Do welder / welding operator qualification and re-qualification records indicate scope of qualification (thickness, position, material, etc.)?

3.24 Qualification Documents

  • 3.24.1 Test Results and Qualification Scope
    Do qualification documents show the results of the tests performed and the scope of the welder / welding operator qualification?

  • 3.24.2 Restrictions
    Do qualification documents indicate restrictions as required by the qualification specification?
    (Note that the question can only be answered NA when the specification in use does not require restrictions to be defined on the Qualification Documents)

  • 3.25 Test Record Data
    Is the qualification test record supported by results as required by the qualification specification revision in use?

  • Test Data Review
    Is there evidence that the test results have been approved by the responsible cognizant weld authority / welding coordinator?

Supplements

METALLOGRAPHIC EVALUATION OF QUALIFICATION WELDS – SUPPLEMENT A

  • If this supplement is not required / identified in the audit scope, check NA

  • Can the evaluator demonstrate the ability to properly evaluate weldments, including but not limited to the following weld characteristics in accordance with the inspection methodology and criteria required by the Engineering Authority? (Where features are not relevant to the welds being performed by the supplier, auditor to note reasons for non-applicability)

  • Offset.

  • Face Reinforcement.

  • Root Reinforcement (Drop-Thru).

  • Undercut.

  • Fillet Weld dimensions per applicable specification (e.g. leg size, leg length, throat).

  • Fillet Weld Root Fusion.

  • Surface Indications.

  • Internal Indications.

BEND TEST EVALUATION OF QUALIFICATION WELDS – SUPPLEMENT B

  • If this supplement is not required / identified in the audit scope, check NA

  • Are bend test procedures available that meet customer requirements?

  • Do personnel possess documented education/training to perform their tasks?

  • Are test fixtures and mandrels that meet specification requirements available?

  • Are bend test specimens prepared per specification requirements?

  • Are fixtures and mandrels being used for bend testing free from damage?

  • Are personnel familiar with the equipment set-up and the procedures for use?

  • Are specimens dimensionally inspected prior to test?

  • Are specimens visually inspected for surface damage prior to testing?

  • Are bend test specimens bent at the correct bend radius?

  • Are bend test specimens bent on the center of the weld?

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