Welding Process Fusion Welding (AC7110/5)

Information

Document No.
Audit Title
Client / Site
Conducted on
Prepared by
Location
Personnel
List the reference documents with revision used to complete this audit.

Sections 1-6: Scope, General Information, References, Material Control, Equipment, Procedure Control

1.0 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.
See also the audit criteria for Welder/ Welding Operator Qualification

2.0 General Instructions

2.1 Welding Scope
Processes performed at the facility (check appropriate boxes.
Baseline- applicable to all processes/materials/etc.
Supplement A- Process: Additional requirements for SMAW (MMA)
Supplement B - Process – Additional requirements for SAW
Supplement C - Process – Additional requirements for Automatic/Semi-Automatic processes
Supplement D - Material – Additional requirements for titanium welding
Supplement E –Foundry in-process completion / repair welding of castings – Additional requirements for
Supplement F - Filler Materials – Additional requirements for
Supplement G - Processes which use gases – Additional requirements for
Supplement H -Preheat / Interpass temperature control– Additional requirements for
Supplement I - Stress Relieve Heat Treatment (Furnace & Oven) – Additional requirements for
Supplement J - Tack Welding – Additional requirements for
Supplement K- Metallographic Evaluation of Qualification Welds – Additional requirements for
Supplement L – Bend Test Evaluation of Qualification Welds – Additional requirements for

3.0 References

Customer Specifications Are applicable customer specifications available at the facility?

4.0 Material Control

Cleaning Materials, Chemical Solvents & Etching Solutions Are cleaning materials, chemical solvents, or etching solutions as specified on part drawings or certified/qualified welding procedures/schedules?

5.0 Equipment

Equipment Capability Is there a documented procedure to ensure welding machines, fixtures, tooling and tooling material are suitable and capable of consistently producing acceptable welds?
Equipment Calibration Is there a documented procedure that defines the calibration of equipment at established intervals?
Electrode Control Is there a documented procedure that controls electrodes?

6.0 Procedure Control

6.1 Qualified Welding Schedules

Welding Schedule Established Is there a documented procedure to ensure that qualified welding procedures/schedules are established for each production weld where qualification is required by the customer/specification?
Customer Procedure Approval Is there a documented procedure that includes a provision for obtaining customer approval when the customer requires welding procedure approval?
Customer Schedule Approval Is there a documented procedure that includes a provision for obtaining customer approval when the customer requires welding schedule approval?

6.2 Deterioration of Welds

Is there a documented procedure to ensure, that when deterioration of welding is encountered, an investigation is conducted to assign the cause and implement corrective action?

6.3 Filler Material Control

Do supplier procedures specifically prohibit the use of filler material or if not is Supplement F for filler material control included in the scope of the audit?

6.4 Weld Start and Run-Off Tabs

Run-On/Run-Off Tab Usage Does the supplier have a documented procedure to control run-on/run-off tabs to assure they are the same alloy as the part being welded, or alloy specified by the design authority?
Run-On/Run-Off Tab Removal Does the supplier have a documented procedure to control run-on/run-off tab removal to prevent damage to the part?

6.5 Stress Relief

Is there a process to ensure stress relief of weldments is performed in accordance with applicable requirements? (If this is performed in-house and stress relief operations are NOT performed in a Nadcap accredited Heat Treat furnace/facility then is Supplement I used).

6.6 Heat Treatment

Is there a process to ensure heat treatment of weldments are performed in accordance with applicable requirements?

Section 7: Process Control

7.1 Cleaning

Part Cleanliness Is there a documented procedure to ensure part cleanliness prior to welding?
Surface Conditions Are parts properly cleaned to assure surfaces of the details and representative test specimens are free from contaminants such as oxides, scale, oil, dirt, ink, or other surface conditions that are detrimental to the joining process?
Cleaning Tool Control Is there a documented procedure to ensure cleaning tools, such as brushes, flap wheels, abrading tools etc. are marked with the material type they are used on in order to avoid cross contamination?
Protection of Cleaned Material Are part details protected after cleaning until welding can be performed?
Time Limits Is there a documented procedure to ensure that after cleaning, all part details are welded within specified time limits?
Handling Is there a documented procedure to ensure that after surface preparation, parts are handled and protected to prevent contamination, including a requirement to re-clean should contamination occur?
Jigs, Fixtures, and Measuring Devices Are jigs, fixtures, and measuring devices free of scale, grease, protective coatings, oxides, dust, oil, and other foreign matter detrimental to the welding process?

7.2 Instructions

Sequence of Operations Does the router list the sequence of operations that control manufacturing and inspection operations?
Detailed Operation Sheet Are there detailed operation sheets/weld schedules with parameter settings for each part number?

7.3 Qualification Test Reports

Test Reports Is there a documented procedure to ensure that parameter settings on operation sheets are traceable to qualification test reports, when required by customer specifications?
Approval for Metallographic Evaluation of Welds (Captive Lab) When metallographic assessment of Qualification welds are being assessed by the Supplier’s captive laboratory, is Supplement K 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 AC7110/5S for unique Customer requirements)
Approval for Bend Test Evaluation of Welds (Captive Lab) When bend test assessment of Qualification welds are being assessed by the Supplier’s captive laboratory, is Supplement L 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 AC7110/5S 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 AC7110/5S 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 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 AC7110/5S 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.

7.4 Multiple Pass Welds

Multiple Pass Welds Is there a documented procedure to ensure that, prior to the deposition of each pass in a multiple pass weld, the welds are free from visible contamination and defects?

7.5 Subsequent Passes (Multiple Pass Welds)

Is there a process to ensure visual defects and contaminants are removed prior to deposition of subsequent weld passes?

7.6 In-Process Corrections

Is there a documented procedure that defines and controls the requirements for in-process weld correction(s) prior to submitting the weld joint for acceptance inspection?

7.7 Rework Cycles

Is there a process in place to ensure rework cycles are tracked and recorded?

Section 8: Personnel

Welder/Welding Operators Certification Specifications Does the facility performing welder / welding operator qualifications comply with AC7110/12?
Activity Records Does the supplier maintain activity records for each welder/welding operator to justify extensions of the qualification period or does the qualification frequency comply with applicable specifications?
Inspector Training/Qualification Is there a documented procedure in place to train and qualify welding visual inspectors?
Inspector Qualifications Is there documented evidence of training and qualification of welding visual inspectors?

Sections 9 and 10: Inspection and Acceptance Criteria, Periodic Maintenance

9.0 Inspection and Acceptance Criteria

Visual Inspection Is there a documented procedure to ensure all welds are inspected by qualified visual inspectors?
Correction of Nonconformances Is there a documented procedure to ensure that weld nonconformances are corrected in accordance with applicable requirements?
Dimensional Inspection Are inspection tools to measure dimensional features available to the inspector?
Inspection Equipment Does the facility have the proper inspection equipment to inspect weld characteristics?
NDT Inspection Does the supplier have a process in place to ensure all required NDT inspections are performed? (Note that unique Prime requirements exist against this question. Refer to AC7110/5S to establish if additional requirements are mandated)
Records Is there a documented procedure that defines the record retention requirements for inspection records, including radiographic films (or digital equivalent)?
Traceability Is there a documented procedure that defines traceability requirements?

10.0 Periodic Maintenance

Preventative Maintenance Do documented procedures require preventative maintenance of welding equipment and tooling at a specified frequency?
Maintenance Records Do records indicate that maintenance is performed on welding equipment and tooling in accordance with the procedures and appropriate standards?

Section 11: Compliance #1

11.1 Job Audit #1

Customer/ Prime Contractor
Unique Work Order# or Lot#
Drawing #
Quantity
Part Name
Operation Sequence Number
Material Name
Material Specification
Thickness
Filler Material
Filler Material Specification
Gas
Welder/ Welding Operator
Welding Process
Customer Specification(s)/ Rev.
MIL/ Industry Specification/ Rev.
Class
Welding Requirements from purchase order, drawing, or specification
Pre-weld requirements- cleaning, preheat, prep, assembly on shop paper
Actual pre-weld conditions of parts observed at weld operation

11.2 Welder / Welding Operator Qualification

Is the welder / welding operator qualification complete and up to date for the work being performed?

11.3 Authorization to Weld Production Hardware

Is the supplier authorized to weld the part specified in 11.1?

11.4 Certified Welding Schedule

Have the requirements for an approved / certified welding schedule been addressed?

11.5 Use of Approved/Certified Welding Schedule

Is an approved/certified welding schedule in use?

11.6 Compliance with Customer Requirements

Does the welding schedule address all customer requirements?

11.7 Pre-Weld Preparation

Are pre-weld preparations performed as described in documented procedures and in accordance with customer requirements?

11.8 Compliance to Welding Schedule

Has the supplier demonstrated compliance to the welding schedule?

11.9 Rework

When performing rework is it in accordance with an approved documented procedure?

11.10 Verification of Welding Requirements

Is there documented evidence that all NDT and visual inspections (eg Visual, FPI, X-ray) have been performed to customer requirements?

11.11 Weld Restrictions

Are restrictions for the number of re-welds allowed and their locations identified as specified by the customer?

11.12 Process Approval

Can the supplier provide evidence of the prime customer approval for the welding process being used?

11.13 Calibration

Is equipment calibrated in accordance with established procedures?

11.14 Fixtures, Backing Materials, and Hold Down Bars

Are fixtures, backing materials, and hold down bars kept clean and free from contaminants during use? (NOTE: If weld schedule does not require the use of these devices, check YES.)

Supplements

Supplement A- SMAW

If this supplement is not required / identified in the audit scope, check NA
Low Hydrogen Electrodes Is there a documented procedure to ensure low hydrogen electrodes are procured in hermetically sealed containers?
Low Hydrogen Electrodes Is there a documented procedure to control the exposure of low hydrogen electrodes after removal from containers or ovens, suitably limited based on classification?
Electrodes Does the covered electrode have a distinguished color code, type, designation, or classification number marking?
If this supplement is not required / identified in the audit scope, check NA
Low Hydrogen Electrodes Is there a documented procedure to ensure low hydrogen electrodes are procured in hermetically sealed containers?
Low Hydrogen Electrodes Is there a documented procedure to control the exposure of low hydrogen electrodes after removal from containers or ovens, suitably limited based on classification?
Electrodes Does the covered electrode have a distinguished color code, type, designation, or classification number marking?

Supplement B- SAW

If this supplement is not required / identified in the audit scope, check NA
SAW Flux Is SAW flux stored in a clean, dry environment?
Welding Flux Containers Are welding flux containers properly identified?

Supplement C- Automatic/ Semi-automatic processes

If this supplement is not required / identified in the audit scope, check NA
Equipment Calibration Is there evidence that the welding equipment has been calibrated?
Equipment Qualification Is there a documented procedure that establishes equipment qualification requirements?
Qualification Records Are qualification records/results that meet procedure requirements available for each machine?
Welding Settings Is there a documented procedure to ensure weld settings are maintained within specified tolerances as defined in the weld schedule?
Reproducibility of Qualified Machine Settings Is there a documented procedure that ensures the reproducibility of qualified machine settings?
Requalification Is there a documented procedure to ensure that where the assigned cause is attributed to the qualified machine/schedule being unable to produce acceptable welds, the supplier stops welding and requalifies the machine/schedule in accordance with the applicable specification requirements?

Supplement D- Titanium Welding

If this supplement is not required / identified in the audit scope, check NA
Handling Is there a documented procedure to ensure parts are handled/protected in a manner to prevent contamination?
Discoloration Requirements - Inspection Is there a documented procedure to ensure welds and heat affected zone meet the discoloration requirements in the as welded condition?
Inspector Requirements Does the documented procedure include eyesight color test requirements for personnel who visually inspect welds?
Discoloration Requirements - Disposition Is there a documented procedure that defines how discolored welds/HAZ will be addressed?
Protective Atmosphere Is there a documented procedure to ensure a protective atmosphere is achieved prior to and during welding?
Post weld Inspection Is there a documented procedure to ensure that the part is visually inspected in the as-welded condition?

SUPPLEMENT E- FOUNDRY IN-PROCESS COMPLETION / REPAIR WELDING OF CASTINGS

This Supplement can be used for the following:
a) In-Process Welding of Castings at Foundries
b) In-Process Welding of Castings at sub-tiers under the control of Foundries
c) In-Process Welding of Castings at Fabricators as authorized by the Engineering Authority
If this supplement is not required / identified in the audit scope, check NA

E.1 Procedure Control

Welding Procedure Is there a documented procedure to control welding of castings?
Customer Authorizations Does the procedure restrict welding to only areas authorized by customer?
Condition of welded castings Does the procedure address heat treat condition of castings prior to welding?
E1.4.a Does the procedure prohibit welding of the following conditions, unless authorized by customer? Correcting dimensional discrepancies or modifying a sound casting for engineering purposes?
E1.4.b Does the procedure prohibit welding of the following conditions, unless authorized by customer? Correction of casting discontinuities detected during machining or subsequent operations?
E1.4.c Does the procedure prohibit welding of the following conditions, unless authorized by customer? Fabrication or assembly of castings or portions of castings?
E1.4.d Does the procedure prohibit welding of the following conditions, unless authorized by customer? Welding on target points after final heat treatment and dimensional inspection?
E1.4.e Does the procedure prohibit welding of the following conditions, unless authorized by customer? Welding of broken features back onto the casting?
E1.5 Patches / Sections / Plates When the use of patches, sections, or plates of cast and wrought material are required, is there procedural control to ensure Customer authorization is granted? (Note that NA is only an option when Patches / Sections / Plates are not used)
E1.6.1 Discontinuity Removal Does the procedure address applicable customer requirements for removal of discontinuities?
E1.6.2 Discontinuity Removal Verification Does the procedure address applicable customer requirements for verification of discontinuity removal?
E1.6.3 Pre-heat / Stress Relief Are pre-heat, pre-weld- or post-weld-stress relief, performed as required?
E1.6.4 Discontinuity Marking Is there a documented procedure that prevents welding over areas that have been identified with marker pens, unless customer authorization has been given?
Blending Does the procedure address the blending of welded and adjacent areas to ensure drawing requirements are met?
E1.8.1 Traceability of Welded Areas Does the procedure require the welded areas to remain traceable to the location on the casting until inspection is completed?
E1.8.2 Traceability of Welding Personnel and Filler Material Does the procedure require traceability of weld personnel and filler material lot number to the welded casting?
E1.8.3 Marking of Welded Castings Does the procedure control identification of welded areas and marking of welded castings in accordance with customer requirements?
Inspection Does the procedure require inspection of the welded areas to be performed after completion of all blending, using the same inspection procedures and acceptance standards required of the casting, unless otherwise specified by the customer?
E1.10.1 Vision – Color Recognition Does the procedure require that color recognition is included in vision examination when color coded wire and/or titanium alloy castings are being welded? (Note that NA is only an option when there are no color coded wires in use and /or the welder does not weld titanium castings.)
E1.10.2 Base Metal Type Is there a documented procedure that ensures that the welders are qualified using cast metal plates, or as otherwise required by the customer?

Supplement F- Filler Materials

If this supplement is not required / identified in the audit scope, check NA
Control Procedures Is there a documented filler material control system?
Purchasing Instructions Do purchasing instructions specify filler material specification, size and identification requirements? (Note that unique Prime requirements exist against this question. Refer to AC7110/5S to establish if additional requirements are mandated)
F.3.1 Filler Material Certifications Does a certificate of conformity accompany the filler material at receiving inspection verification?
F.3.1.1 Filler Material Certifications accessibility Are the chemistry certifications for filler material maintained in an accessible filing system?
F.3.2 Filler Material Compliance Does the filler material meet the specification requirements?
F3.3 Filler Material Markings Does the marking on filler material comply with the requirements of the purchase order?
F.3.4 Filler Material Release Is there positive evidence that the certificate of conformity has been reviewed and accepted prior to the material being released for use?
F.3.5 Filler Material Verification Is verification performed as required by procedure to ensure that purchase order conditions are met, including composition, identification, and size?
F.4.1 Filler Material Storage Is filler material, no longer sealed in its original container, stored in an environment that prevents detrimental contamination?
F.4.2 Filler Material Segregation Is filler material segregated in such a manner to prevent co-mingling of different sizes or filler material specification numbers?
F.4.3 Filler Material Access Is access to filler material storage area addressed procedurally?
F.4.3.1 Compliance Are filler material access procedures being followed?
F.5.1 Chemical Composition of Filler Material Is there only one specification of filler material within the welder’s or welding operator’s immediate work zone at one time?
Missing Filler Material ID If filler material identification markings are lost, missing, or destroyed, is the material scrapped?
Filler Material Cleanliness Can the cleanliness of filler material be demonstrated immediately prior to welding?
Disposal of Filler Material Is there a documented procedure describing disposal of filler material? (E.g. Stubs, shim etc)
Compliance with Disposal Procedures After welding, is unusable filler material discarded according to disposal procedures? (E.g., into non-retrievable cans, tubes, etc.)?
F.6.1 Proper Filler Material ID Is the filler material properly identified?
Filler Material Container Traceability Are filler material containers marked to provide for positive traceability to heat and/or lot number?
Filler Material Identification Is there a method that allows the welders to easily identify the filler material type?
Filler Material Requirements Are filler material requirements specified on drawings / process specifications and / or welding procedures/schedules/shop paper? (Note that unique Prime requirements exist against this question. Refer to AC7110/5S to establish if additional requirements are mandated)

Supplement G- Processes which use Gas

If this supplement is not required / identified in the audit scope, check NA
Gas Is there a documented procedure that defines the specification and certification requirements including receiving inspection verification responsibilities for the gas?
Compliance Are the gases used in compliance with the procedure?
Gas Lines Are gas lines and tubes used for the transportation of shield gas made from neoprene, PTFE, or material suitable for gas being used?
Chemistry Certifications Are the chemistry certifications or certificates of conformity for gas maintained in an accessible filing system?

Supplement H- Preheat/ Interpass Temperature Control

If this supplement is not required / identified in the audit scope, check NA
Pre/Interpass Heating Equipment Is there a documented procedure to ensure pre/interpass heating equipment is provided with a suitable means for controlling the temperature?
Temperature Controls Do temperature controllers meet customer specification tolerance requirements?
Pre-Heat and Interpass Temperatures Are pre-heat and interpass temperatures included in the qualified schedule/procedure?

Supplement I- STRESS RELIEVE HEAT TREATMENT (FURNACE & OVEN)

If this supplement is not required / identified in the audit scope, check NA
Temperature Uniformity Test / Systems Accuracy Test procedure Is there a documented procedure for temperature uniformity and system accuracy tests?
Does the procedure specify the following as a minimum: Test Frequency Test temperature(s) and range(s)? Temperature range covering all thermal operations? Placement and recording of thermocouples in accordance with specification? Period of monitoring after temperature stabilization? Calibration of test instruments traceable to a national standard certification body
Temperature Recorder When in use, does the oven (furnace) employ a continuous temperature recorder?
Test Records/Results Are test records / results that meet procedure requirements available for each furnace / oven?

Supplement J- Tack Welding

If this supplement is not required / identified in the audit scope, check NA
Fusion Tack Weld Instruction Is the tacking process performed using a written instruction?
Personnel Qualifications Is the tacking process performed by qualified personnel?
Procedure Control Is tack welding controlled by a documented procedure?
Tack Weld Control When performing tack welding are controls used to prevent stray arc, and oxidation?

Supplement K- Metallographic Evaluation of Qualification Welds

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 Leg Size. Fillet Weld Root Fusion. Surface Indications. Internal Indications.

Supplement L- Bend Test Evaluation of Qualification Welds

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?