AC7101/1 REV.F AUDIT CRITERIA Issued 1993-05 Revised 2014-06 161Thorn Hill Road Superseding AC7101/1 REV. E Warrendale, PA 15086-7527 TO BE USED ON AUDITS STARTING ON OR AFTER SEPTEMBER 14, 2014 Nadcap AUDIT CRITERIA FOR MATERIALS TESTING LABORATORIES GENERAL REQUIREMENTS FOR ALL LABORATORIES Editorial Changes made to 2.1 on May 12, 2015 K 1. SCOPE This Audit Criteria was developed by the Nadcap Materials Testing Laboratories Task Group (MTLTG) for the evaluation of testing facilities for Nadcap Materials Testing Laboratories Accreditation Program. While the criteria in this checklist may appear redundant with ISO/IEC 17025/AS9100 audit criteria, the Task Group determined that its aerospace auditors needed to assess compliance from the aerospace perspective. This Audit Criteria is applicable to all laboratories. Supplemental checklists provide additional detailed criteriaon the specific test methods. Appendix A of this document is required for all laboratories accredited to AS/EN/JISQ 9100 in lieu of ISO/IEC 17025, or AC7006. The MTL Aduit Handbook provides many details to ensure a successful auidt experience. The Handbook should be used as a companion to the Audit Criteria. The Handbook is located on www.eAuditNet.com under Resources → Documents → Public Documents → Materials Testing Laboratories → Audit Information. Written customer requirements always take precedence over Nadcap audit criteria. This section is for the use of auditors, as necessary, for notes during the audit. No NCRs will be written against section 1. PRI operating procedures provide that "This report is published by PRI to advance the state of technical, engineering, and quality sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there from, is the sole responsibility of the user." PRI values your input. To provide feedback on this document, please contact the appropriate commodity staff engineer. (Contact information is located at http://www.eauditnet.com under “Contact Us”.) Copyright 2014 Performance Review Institute. All rights reserved. t-frm-15 10-Apr-2014 PRI 1.1 AC7101/1 Revision F -2- Audit Category Initial Full Scope – Reaccreditation SV1 – Reaccreditation SV2 – Reaccreditation Add Scope Verification Internal Audit (NUCAP) 1.2 Audit Scope AC7006 AC7101/1 AC7101/2 AC7101/3 AC7101/4 AC7101/5 AC7101/6 AC7101/7 AC7101/8 AC7101/9 AC7101/11 AC7109/5 AC7110/13 1.3 OPEN / CLOSE Meeting Attendance 2. ACCREDITATION REQUIREMENTS 2.1 The laboratory demonstrates compliance to an acceptable quality system as defined in PD 1100. Nadcap Materials Testing Laboratories recognizes existing quality systems approvals in the form of ISO/IEC 17025 certifications by an ILAC Approved source (www.ilac.org). YES NO training or examinations) oYears of laboratory testing experience •Procedure Summary: A tabular summary of procedures used to perform the accredited test methods. 2.PRI AC7101/1 Revision F -3- For captive laboratories. The summary shall include the following information: oDescription of test oTest code or method oName of proficiency testing provider oReference of the last PT report (for quick retrieval of the report during audit) oDate(s) PT was performed oRequired frequency of PT oDescription of any outliers oReference of the last IRR/operators report (for quick retrieval of the report during audit) oDate(s) IRR was performed oRequired frequency of IRR/operators oDescription of any outliers oReference of the last IRR/equipment report (for quick retrieval of the report during audit) oDate(s) IRR was performed oRequired frequency of IRR/operators oDescription of any outliers YES NO . Nadcap requires assessment using AC7006 Audit Criteria Equivalent to ICO/IEC 17025. The summary shall include the following information: oDescription of test oTest code or method oIdentification of procedures used for testing oCurrent revision of procedures at time of current audit oRevision of procedures at date of last PRI audit •IRR/PT Summary: A tabular summary of IRR/PT activity which support the accredited test methods. only content) •Personnel Summary: A tabular summary of personnel which perform the accredited test methods.iaqg. Where no recognized quality systems approvals exsist. Nadcap Materials Testing Laboratories also recognizes AS/EN/JIS Q9100 certifications by registrars that are approved and listed in the IAQG Oasis database (www. Note: AS/EN/JIS Q 9100 accredited captive laboratories must also meet the requirements of Appendix A.org/oasis). The summary shall include the following information: oName and job title oTest codes oQualifications (education.2 The following summaries are complete (format not cause for NCR. if applicable. •Laboratory performed required testing in accordance with its procedures and/or customer requirements. YES NO 3. •Certifications and reports document the methods of data unit conversion. FACILITY (GENERAL) 3. YES NO 3. Auditor documentation of each “job audit” shall show assessment of all the requirements): •Laboratory received and documented customer requirements •Test requirements are accurately documented in laboratory testing documentation (routers/travelers/ other ways to communicate testing requirements to test operators). YES NO NA .5 A minimum of one Observation of Test is performed by the PRI auditor for each testing method in the scope of accreditation within the course of two audits. Test environment conditions are considered in creating test method procedures. and rounding method if not defined by.6 A minimum of three job audits were performed by the PRI auditor. YES NO 2. YES NO 3.1 Environmental conditions in the laboratory are in accordance with test technical requirements such as to facilitate correct performance of the tests and/or calibrations. Each test was performed in accordance with the applicable procedures and/or test specification.3 Cleanliness of test area minimizes contamination.PRI AC7101/1 Revision F -4- 2. YES NO 3. YES NO 2. referenced by. YES NO 2. controlled and recorded as required.5 Facility operations affecting specific testing – Procedures ensure notification of customers in the event of interruption due to power outage or equipment failure that has an effect on the test results.2 Environmental conditions are monitored.4 Employees demonstrate compliance to applicable safety program. YES NO 3.3 Procedure(s) are used to ensure Nadcap notification in accordance with OP 1107: Nadcap will be notified of any changes to the content on form number t-frm-11 “Notification of change/request for revised certification”. or different from test specification.4 Self-Audit was completed with references which will satisfy all audit criteria in all applicable checklists in the current audit scope. Job audits met requirements below (any NO answer results in a NCR for this criterion. YES NO 4.A.2 A procedure is used to control records (technical data and test reports) generated by the laboratory in compliance with customer requirements including record retention policy.4 The Q. implementation.A. training and qualification of personnel. YES NO 6.3 The Q. extension or modification of internal technical documents. traceable to each certification. applicable customer requirements and is documented.A. YES NO 5. YES NO 6. YES NO 5.A. YES NO 5. QUALITY ASSURANCE FUNCTION (Q. function participates in the management (creation. revision. function participates in the organization or planning of maintenance and calibration of test facilities and equipment. YES NO 6.7 The Q. YES NO 5. function in the laboratory has stop-work/stop-ship authority.4 Current revisions of test procedures are used.1 The Q. YES NO . QUALITY SYSTEM DOCUMENT (MANUAL) 4. YES NO 5. YES NO 4.A.5 Laboratory management assigns responsibility for the review and approval of test results. YES NO 4. YES NO 4. TRAINING AND QUALIFICATION OF PERSONNEL 6. and procedures.6 The Q. such that the laboratory could reproduce the test method or identify incorrectly tested material.) 5.A.A.2 Qualification of laboratory personnel includes documented periodic “observations of test” to assess the employee’s compliance to procedures used for Nadcap test codes. function oversees training and qualification of personnel.2 The Q.5 The Q.3 Individual training records and supporting procedures indicate participation in inter-operator comparison as defined by the laboratory.3 Records (technical data) are maintained.) of test procedures.1 Qualification and training of laboratory personnel complies with laboratory quality manual and/or procedures.1 Records are available to the customer upon request within three working days. function participates in the organization or planning of subcontractor selection and survey. YES NO 5. etc.PRI AC7101/1 Revision F -5- 4. YES NO 5. function has authority to require the implementation.A. function participates in the organization or planning of equipment definition and selection. YES NO NA 8.3 Applicable quality assurance requirements specified in the contract are transmitted to subcontractors.4 Operators are trained to recognize proper operation of the equipment. customer qualification list or at least 3 of the following: SECTION NA YES NO •Documentation and initial survey •100% inspection of product/service •Sampling inspection of product/service •Periodic on-site survey by the Q.PRI AC7101/1 Revision F -6- 6. EVALUATION. YES NO 8. APPROVAL.A.5 Procedures define methods and test specifications used to perform data unit conversions. function 7. however defined. YES NO 8.2 Procedure(s) are used for calibration of all Measuring and Test Equipment (M&TE) used for testing or producing results.2 Access to subcontractor facilities is provided to the laboratory for quality audits if requested.4 Procedures are used to ensure use of ASTM E 29 for rounding unless the method is otherwise stated in the certificate of test/test report. YES NO 8.5 Operators are trained to recognize a properly executed analysis or test.6 Procedures are used to ensure all software programs and equipment automation are validated prior to use. YES NO 8.1 Subcontractor evaluation is based on Nadcap accreditation. and does not include full traceability through the company to end-customer requirements. YES NO 6. PROCEDURE SYSTEM 8. when required. YES NO 6. YES NO 8. AND SURVEY OF SUBCONTRACTORS 7. YES NO NA NA . this pertains to how the requirements are directly communicated to the laboratory. definition of “equivalent” is documented. to distinguish between valid and invalid test data. YES NO 7. YES NO 7.3 A procedure is used to review the requirements presented to the laboratory.6 If degreed personnel “or equivalent” are required. The procedure addresses: •how the requirements are assessed •how the requirements are effectively communicated to the laboratory •how the laboratory determines if the requirements can be met Note: For captive labs. and to justify invalidating data.1 Procedures are approved by the customer. YES NO 8. ASTM. brief summary of actions taken to demonstrate the revision review was completed. For example: specific industry standard(test specification) or customer specification. or other recognized statistical review process to support the extended time interval. YES NO NA NA NA . or the individual checklist requirements for all internal and external calibrations performed on testing equipment. EN.7 Procedures are used to ensure all software programs and equipment automation are revision controlled and that the correct revision is used for testing and data analysis/compilation/reporting. YES NO 9. YES NO 8.2 Calibration: The laboratory uses a calibration schedule with frequencies in accordance with manufacturers’ recommendations.1 Calibration cycle extension: When calibration cycles are extended. YES NO 8.PRI AC7101/1 Revision F -7- 8. This schedule documents duration between calibrations (frequency) and responsibility for calibration (source).1 Calibration 9.11 Procedures are used to ensure technical revisions of standards publications (e. procedures are used in accordance with NCSL (National Conference of Standard Laboratories). YES NO 9. YES NO 8. A record of revision review is maintained which includes date of reference document revision.1. recommended Practice 1. date of laboratory incorporation.9 Procedures are sufficiently detailed so that the test can be consistently repeated.1.10 Details required to reproduce non-standard tests are documented and traceable to the test report/results. Any calibration cycle extensions are in accordance with standard methods or customer requirements.g. Appendix E. ISO and any other revision controlled documents used within test method procedures) in the laboratory’s scope of accreditation are implemented/incorporated within six months from the date the standard/document is issued.8 Procedures that are used for each test method reference the source of the requirement. EQUIPMENT CALIBRATION AND MAINTENANCE 9. YES NO 9. are documented on the calibration certificate. adjustment or repair to the equipment. YES NO 9.3 Maintenance: Procedures are used to identify equipment which is out of service. YES NO NA . • the "as found" and "as left" conditions are documented on the calibration certificate when the instrument was adjusted or repaired during the course of calibration. YES NO 9.1.1.4 Maintenance: When maintenance is performed to address a malfunction of calibrated equipment. modification. any damage. • the environmental conditions are documented on the calibration certificate where required by standard/spec/customer.2.5 Calibration: Procedures are used to address the calibration and use of “employee-owned” Measuring and Test Equipment (M&TE). • the calibration method is documented on the calibration certificate. YES NO 9.6 Calibrations not performed by the laboratory are performed by an ISO17025 accredited source or documented evaluation.2.1. procedures are used to assess the possible effect on test values.1. • the date of calibration is documented on the calibration certificate. • the calibration personnel are documented on the calibration certificate. maintenance activities to date.2 Maintenance 9. • primary standards or equipment are documented on the calibration certificate and are traceable to a national standard.3 Calibration: Procedures are used during calibration certificate review to ensure the following: •calibration certificates document the name and address of the agency performing the calibration.2.2.PRI AC7101/1 Revision F -8- 9. malfunction. •description(s) of equipment and operating range.1 Maintenance: Procedures are used to ensure planned maintenance of measuring equipment is performed to ensure proper functioning and in order to prevent contamination or deterioration.2 Maintenance: Procedures are used to ensure maintenance records identify the maintenance plan. YES NO 9.4 Calibration: Calibration status is identified for each test machine or associated laboratory equipment requiring calibration. • approved calibration suppliers are used. YES NO 9. including the precision of the instrument. YES NO 9. YES NO 11.1 Unless otherwise specified.1 The certificate of test/test report meets the requirements of the applicable specification. YES NO 10. The laboratory reports errors in testing in accordance with the time period that is required by the customer.2 Procedures are used to ensure replaced tests are recorded and crossreferenced with the original tests. ERRORS IN TESTING 12.1. if different from the address of the laboratory.3 The certificate of test/test report includes the name and address of the customer. YES NO 11.1 Unique identification is assigned to each test specimen in accordance with a procedure. REPLACEMENT TESTING AND RE-TESTING 11. YES NO 13.PRI AC7101/1 Revision F -9- 10.3 Procedures are used to ensure records of replaced tests are reviewed periodically for trends which could indicate test process deterioration. The identification is retained throughout the life of the test specimen and is traceable to the final documentation. SPECIMEN IDENTIFICATION AND TRACKING SYSTEM 10. YES NO 12.2 The certificate of test/test report includes the name and address of the laboratory. YES NO 13.2 Transfer of work outside the laboratory for sub-contracted processes is performed in accordance with procedures which ensure (1) traceability of documents/records with test articles is maintained and (2) verification that work performed was in accordance with purchase order requirements. CERTIFICATE OF TEST/CERTIFICATE OF CONFORMANCE/TEST REPORTS 13.1 Procedures are used to ensure RETESTS allowed by material or customer specification. YES NO NA NA . are performed in accordance with the material or customer specification. procedures are used to ensure a minimum of three RETESTS per NON-CONFORMING TEST-RESULT are performed and reported. YES NO 13. YES NO 11. including explanations where applicable. YES NO 11.1 Procedures are used to ensure errors in testing are assessed. and the location where the tests and/or calibrations were executed. Procedure(s) are used to respond to defined criteria for test process deterioration which requires corrective action. separate certificates of test/test reports are not issued for conforming versus nonconforming material. if not called out by the material specification. YES NO 13. e.5 The certificate of test/test report identifies the testing specification or procedure used. number). conform/non-conform) of all tests for which the material specification does not establish numerical requirements. that is. when applicable.10 - 13. YES NO 13.g. when applicable.g. AMS5662 Rev H). and all identification necessary to assure traceability of laboratory report to the material supplier/customer records (e. heat number. and condition. YES NO . at a minimum. Applicable at laboratory discretion. (Example: Inco 718. YES NO 13. etc). as “Observation”).13 The certificate of test/test report includes each page numbered "page __ of__ ". sample number. YES NO 13.O.14 The certificate of test/test report includes unique identification traceable to the laboratory identification system.g..8 The certificate of test/test report includes descriptions of the results (e. YES NO NA 13. Digital documents must have a means for recording corrections such that the original and corrected data can be observed during an audit.PRI AC7101/1 Revision F . YES NO 13.4 The certificate of test/test report includes identification of the test article and identification and issue(s)/revision(s) of the material specification(s) used for conformance disposition.12 The certificate of test/test report includes a statement that it shall not be reproduced except in full without the written approval of the laboratory. YES NO 13.15 The certificate of test/test report includes.6 The certificate of test/test report includes the numerical results of all tests and inspections performed for which the material specification establishes numerical requirements. Any nonstandard practices must be documented. P.. appropriate error corrections and revision indication. to the number of digits as defined by the controlling specification(s).11 The certificate of test/test report includes appropriate description of test specimens (quantity. YES NO 13.7 Test values on the certificate of test/test report are recorded.10 Test results for all specimens in the same set are included on the same certificate of test/test report. form. YES NO 13. lot number. YES NO 13. YES NO NA 13. Manual corrections are prohibited.9 Any unusual observations are noted on the certificate of test/test report (and identified as such. e. and the laboratory is responsible for the information it contains.1 Internal Round Robin Testing . and they shall be clearly identified as such.20 The certificate of test/test reports includes description(s) of any applicable thermal treatments performed by the laboratory. YES NO 13.16 The certificate of test/test report includes re-test values.broke in grips”. YES NO 13. If a laboratory uses computer-generated certificates with an actual or facsimile signature. YES NO 13.21 Computer generated certificates of test/test reports require either (a) an actual or facsimile signature. YES NO 14. or typed name. Customers are notified within the time period that is required by the customer. when compared against mandatory specification values). Testing protocol for PT and IRR is described in Appendix D. If the conformance requirements are written in the statement of work (rather than a specification or similar document) and revised after submission to the laboratory. Selection of proficiency test providers is described in Appendix C. Frequency requirements are given in Appendix B. signed by the laboratory's representative attesting that the laboratory is using a computerized system. YES NO 13.24 Procedures are used to address revision of certificates of test/test reports and notification of customers when errors are found. YES NO 13. and values known to be nonconforming (i. YES NO 13.19 The certificate of test/test report includes a statement of work with conformance requirements stated. YES NO 13.23 Procedures are used to ensure correct transcription of data from the original source to the certificate of test/test report.18 The certificate of test/test report is traceable to the request to perform work. the typed name on the document is an authorized employee. the system has security (password or other identity control) to ensure the name on the document represents the individual who performed the indicated function. Example of test without results: "Specimen 4A253: No Test . 14. PROFICIENCY TESTING AND INTERNAL ROUND ROBIN REQUIREMENTS Participation in proficiency testing (PT) and internal round robins (IRR) is required. YES NO 13.17 The certificate of test/test report includes documentation of all test articles provided to the laboratoryfor testing.11 - 13.22 The certificate of test/test report documents a statement of conformance when testing is performed for conformance to material specifications. Test values from replaced specimens need not be reported. Procedure(s) are used to respond to transcription errors..PRI AC7101/1 Revision F . revision to those requirements is documented in the certificate. or (b) a letter accompanying the certificate. YES NO 14.2. if applicable. YES NO 14.2 Proficiency Testing 14. YES NO 14. if required.3 Internal round robin programs are in place to compare testing personnel performing the same test/method.4 Participation in the internal round robin program meets the frequency requirements for all test codes held by the laboratory as described in AC7101/1 Appendix B. if applicable. YES NO .1.1 Statistical analysis and correlation of the data are performed and documented for both internal round robin testing and proficiency testing.2.2. (see Appendix B for frequency and requirements) YES NO NA 14.1. YES NO 14.4 Participation in the Proficiency Testing meets the frequency requirements for all test codes held by the laboratory (see Table 1 of Appendix B). (see Appendix B for frequency and requirements) YES NO NA 14.12 - 14.3 Statistical Analysis 14.3.3.1.1 The internal round robin program meets the established requirements as described in Appendix D.1. YES NO 14.PRI AC7101/1 Revision F . YES NO 14.3 The participation of the laboratory in Proficiency Testing Program(s) is documented.1 Procedures ensure participation in Proficiency Testing Program(s) YES NO 14. if required.5 Procedures are used to ensure participation in Internal Round Robin Programs and analyze the results of internal round robins against defined acceptance criteria. It is the host facility’s duty to provide a statistical evaluation of the data in the final report.2 The laboratory used a Proficiency Testing provider in accordance with Appendix C.2 Internal round robin programs are in place to compare testing equipment used for the same test/method.5 The requirements in Appendix D were followed.2 Procedure(s) are used for investigation of outliers.2.1. YES NO 14. YES NO 14.2. 5 Quality System Document: Procedures define the responsibility for review and approval of test results. AC7101/1 Revision F .2 Quality System Document: The laboratory has arrangements to ensure that its management and personnel are free from any undue internal and external commercial. Reasonable estimation shall be based on knowledge of the performance of the method and on the measurement scope and shall make use of.1.3 Estimation of Uncertainty of Measurement: When estimating the YES NO . the Estimated Uncertainty for the test shall be determined for any test whose frequency is ten times or more in a six month period. In certain cases.1 Quality System Document: If the laboratory is part of an organization performing activities other than testing and/or calibration.1.1. YES NO A. impartiality. authorization of re-testing.1. YES NO A. and to which the requirements of the appropriate AC 7101 checklist apply. the laboratory shall at least attempt to identify all the components of uncertainty and make a reasonable estimation. YES NO A.1 Estimation of Uncertainty of Measurement: A calibration laboratory. and preparation or approval of test procedures. judgment or operational integrity.2. YES NO A.2 UNCERTAINTY A.2 Estimation of Uncertainty of Measurement: For non-standard tests.2. financial.3 Quality System Document: The laboratory has policies and procedures to avoid involvement in any activities that would diminish confidence in its competence. the responsibilities of key personnel in the organization that have an involvement or influence on the testing and/or calibration activities of the laboratory shall be defined in order to identify potential conflicts of interest.2. or those tests developed by the laboratory for which there is no published method.4 Quality System Document: Written policy addressing errors in testing is established through the Quality Systems Documentation. previous experience and validation data. for example. shall have and shall apply a procedure to estimate the uncertainty of measurement for all calibrations. or a testing laboratory performing its own calibrations. the nature of the test method may preclude rigorous. In these cases.1 QUALITY SYSTEM DOCUMENT A. calculation of uncertainty of measurement.1. and shall ensure that the form of reporting of the result does not give a wrong impression of the uncertainty. metrologically and statistically valid. and other pressures and influences that may adversely affect the quality of their work. YES NO A.13 - APPENDIX A ADDITIONAL QUESTIONS FOR CAPTIVE LABORATORIES CERTIFIED TO AS/EN/JISQ 9100 IN LIEU OF ISO/IEC 17025 A. YES NO A. YES NO A.PRI A. regional.14 - uncertainty of measurement. A.8 ERRORS IN TESTING A.PRI AC7101/1 Revision F . the confirmation shall be repeated. regional. or as specified by the manufacturer of the equipment. all uncertainty components which are of importance in the given situation shall be taken into account using appropriate methods of analysis. or by reputable technical organizations.4 SELECTION OF METHODS A. YES NO A. The laboratory shall determine the extent of control based on its particular circumstances. Access to and use of areas affecting the quality of tests and/or calibrations shall be controlled.1 Procedures are used to control and secure records. which meet the needs of the customer and which are appropriate for the tests and/or calibrations it undertakes.3 Selection of Methods: The laboratory shall inform the customer when the method proposed by the customer is considered inappropriate or out of date.4. YES NO A.1 Procedures are used to control all test materials from the point of entering the laboratory through the final disposition. the standard shall be supplemented with additional details to ensure consistent application.4. YES NO A.6 RECORDS A. The laboratory shall confirm that it can properly operate standard methods before introducing the tests and calibrations.4. Laboratory-developed methods or methods adopted by the laboratory may also be used if they are appropriate for the intended use and if they are validated.5.1 The laboratory is secure from unauthorized personnel. the laboratory shall select appropriate methods that have been published either in international. or national standards.1 YES NO Selection of Methods: For sampling.3 UNAUTHORIZED PERSONNEL A. A. YES NO A. or in relevant scientific texts or journals.1 Errors in Testing: Specific responsibility (individual or title) for YES NO .7. Methods published in international. The customer shall be informed as to the method chosen.3.6.1 Test reports include where appropriate and necessary for the interpretation of the test reults.8.7 CONTROL OF TEST MATERIALS A. YES NO A. YES NO A.2 Selection of Methods: When the customer does not specify the method to be used. or national standards shall preferably be used. opinions and interpretations. When necessary.5 TEST REPORTS A. The laboratory shall ensure that it uses the latest valid edition of a standard unless it is not appropriate or possible to do so. If the standard method changes. 1 A. review and approval of documents/procedures issued to personnel. YES NO .2 YES NO Procedures are used to ensure correct versions of the test procedures are used at the time of testing and obsolete procedures/documents are unavailable for use in testing.10. YES NO Procedures are used for issue.9.PRI AC7101/1 Revision F . Personnel authorized for this activity are documented such that names and roles and responsibilities are clear.1 Applicable to non-ISO17025 calibration source: Procedures are used to ensure standards are calibrated compliant to ISO17025 and segregated and controlled to prevent use for anything other than calibration.9 CALIBRATION A. A.10 PROCEDURES A.15 - notification of affected customers is documented. change management.10. A. B. Ti. Co. Cu and Mg) within 6 Years Maximum. Al. 1 .PRI AC7101/1 Revision F B. Some checklists do not have PT/IRR requirements. Fe-Low Alloy.1 CODE TEST TYPE Proficiency Testing Frequency Date Performed AC7101/2 – Chemical Analysis Every 2 Years 1 Direct Current plasma (DCP) Every 2 Years 1 F2 Inductively Coupled Plasma (ICP) Every 2 Years 1 F3 Spark/Arc (OES) Every 2 Years F4 Glow Discharge (GD) Every 2 Years 1 F5 High Temperature Hollow Cathode Every 2 Years 1 D Wet Chemistry F Atomic Emission Spectroscopy F1 1 G Combustion or Fusion G1 Carbon Every 2 Years 1 G2 Hydrogen Every 2 Years 1 G3 Nitrogen Every 2 Years 1 G4 Oxygen Every 2 Years 1 G5 Sulfur Every 2 Years 1 S X-Ray Fluorescence (XRF) Every 2 Years 1 V Mass Spectroscopy Every 2 Years 1 W Atomic Absorption W1 Flame (AAS) Every 2 Years 1 W2 Graphite Furnace (GFAA) Every 2 Years 1 Notes for Chemistry Analysis IRR/PT Requirements Proficiency testing programs to include all applicable alloy families (Ni. Fe-High Alloy. .16 - APPENDIX B PROFICIENCY TESTING AND INTERNAL ROUND ROBIN REQUIREMENTS TABLE 1 – FREQUENCIES FOR PROFICIENCY/ROUND ROBIN TESTING PROGRAMS Note: PT and IRR requirements are listed here by checklist. 1 2 Every 2 Years . 1 2 Every 2 Years . F4 Glow Discharge (GD) Every 2 Years . 2 B. 1 2 Every 2 Years . 1 2 Every 2 Years . 1 2 Every 2 Years . 1 2 Every 2 Years . W2 Graphite Furnace (GFAA) Every 2 Years . Fe-High Alloy. Example 2: IRR could be performed with one operator and multiple equipments every two years and satisfy the requirement. Cu and Mg) within 6 Years Maximum. Spark/Arc (OES) 1 2 Every 2 Years . V Mass Spectroscopy Every 2 Years . G Combustion or Fusion G1 Carbon Every 2 Years . 1 2 Every 2 Years . 1 2 Every 2 Years . 1 2 1 2 1 2 1 2 Notes for Chemistry Analysis IRR/PT Requirements Internal Round Robin programs to include all applicable alloy families (Ni. 1 2 Every 2 Years . F5 High Temperature Hollow Cathode Every 2 Years . W Atomic Absorption W1 Flame (AAS) Every 2 Years .2 CODE TEST TYPE Internal Round Robin Frequency for Operators Date Performed Internal Round Robin Frequency for Equipment Date Performed AC7101/2 – Chemical Analysis D Wet Chemistry F Atomic Emission Spectroscopy F1 Direct Current plasma (DCP) Inductively Coupled Plasma F2 (ICP) F3 1 2 Every 2 Years . 1 2 Every 2 Years .3 CODE TEST TYPE Proficiency Testing Frequency AC7101/3 – Mechanical Testing A Room Temperature Tensile Every 2 Years B Elevated Temperature Tensile Every 2 Years C Stress Rupture Every 2 Years Creep Every 2 Years CT Compression Testing Not Required KR Curve (Resistance to Fracture) Testing Not Required XA N Impact Testing Not Required O High Cycle Fatigue Every 5 Years P Fracture Toughness Every 5 Years Low Cycle Fatigue Every 5 Years XE Y Crack Propagation/Crack Growth Testing Every 5 Years XN Bend Testing Not Required Date Performed . G4 Oxygen Every 2 Years . No IRR for equipment would be required for this example. Ti. No IRR for operators would be required for this example.17 - B. G5 1 2 Every 2 Years . 1 2 Every 2 Years . 1 2 Every 2 Years . 1 IRR shall be performed for either operators or equipment at the specified frequency. 1 2 Every 2 Years . 1 2 Every 2 Years . 1 2 Every 2 Years . Co. G2 Hydrogen Every 2 Years . G3 Nitrogen Every 2 Years . Example 1: IRR could be performed with one equipment and multiple operators every two years and satisfy the requirement. Fe-Low Alloy. 1 2 Every 2 Years . Sulfur 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Every 2 Years . S X-Ray Fluorescence (XRF) Every 2 Years .PRI AC7101/1 Revision F . Al. Suppliers are allowed to propose an IRR/PTP test plan for task group approval.If an IRR is performed for Creep. Plan may include SPC and/or Gage R&R data/analyses. Date Performed .4 CODE Internal Round Robin Frequency for Operators TEST TYPE Date Performed Internal Round Robin Frequency for Equipment Date Performed AC7101/3 – Mechanical Testing A Room Temperature Tensile Every 2 Years Every 2 Years B Elevated Temperature Tensile Every 2 Years Every 2 Years Stress Rupture Every 2 Years Every 2 Years XA C Creep Every 2 Years Every 2 Years CT Compression Testing Not Required Not Required KR Curve (Resistance to Fracture) Testing Not Required Not Required Impact Testing Not Required Not Required O High Cycle Fatigue Every 5 Years Every 5 Years P Fracture Toughness Every 5 Years Every 5 Years Y Low Cycle Fatigue Every 5 Years Every 5 Years XE Crack Propagation/Crack Growth Testing Every 5 Years Every 5 Years XN Bend Testing Not Required Not Required N Notes for Mechanical Testing IRR/PT Requirements 1. B. 2.PRI AC7101/1 Revision F . then Stress rupture IRR is not required.5 CODE TEST TYPE Proficiency Testing Frequency AC7101/4 – Metallography and Microindentation Hardness L General Metallography Grain Size Measurement Not required Every 2 Years Inclusion Rating Not Required Microindentation Hardness Every 2 Years L2 Alloy Depletion Not Required L3 Oxidation/Corrosion Layers Not Required L1 L4 Casting (Mold) Reactions Not Required L5 Microindentation (Surface-case depth) Every 2 Years L5X Microindentation (Surface) (ARP1820) Not Required L6 Nitriding Not Required L7 IGA / IGO Not Required L8 Alpha Case: Wrought L8 or L9 Every 2 years L9 Alpha Case: Castings L8 or L9 Every 2 years L10 Carburization/Decarburization LS Near-Surface Examinations Not Required Not Required XL Macro Examination Not Required Notes for Metallography and Microindentation Hardness IRR/PT Requirements – No Notes. B.18 - Notes for Mechanical Testing IRR/PT Requirements – No Notes. B.9 CODE TEST TYPE Proficiency Testing Frequency AC7101/7 – Mechanical Testing Specimen Preparation Z2 Low Stress Grinding and Polishing Every 2 Years Notes for Mechanical Testing Specimen Preparation IRR/PT Requirements – No Notes.8 CODE Internal Round Robin Frequency for Operators TEST TYPE Date Performed Internal Round Robin Frequency for Equipment Date Performed AC7101/5 – Hardness (Macro) M1 Hardness (Brinell) Every 2 Years Every 2 Years M2 Hardness (Rockwell) Every 2 Years Every 2 Years M3 Hardness (Vickers) Every 2 Years Every 2 Years Notes for Hardness IRR/PT Requirements – No Notes. AC7101/6 – Corrosion: No PT/IRR Requirements B.7 CODE TEST TYPE Proficiency Testing Frequency Date Performed AC7101/5 – Hardness (Macro) M1 Hardness (Brinell) Every 2 Years M2 Hardness (Rockwell) Every 2 Years M3 Hardness (Vickers) Every 2 Years Notes for Hardness IRR/PT Requirements – No Notes.6 CODE Internal Round Robin Frequency for Operators TEST TYPE Date Performed Internal Round Robin Frequency for Equipment Date Performed AC7101/4 – Metallography and Microindentation Hardness L General Metallography Not required Not required Grain Size Measurement Every 2 Years Not Required Not Required Inclusion Rating Every 2 Years L1 Microindentation Hardness Every 2 Years Not Required L2 Alloy Depletion Every 2 Years Not Required L3 Oxidation/Corrosion Layers Every 2 Years Not Required L4 Casting (Mold) Reactions Every 2 Years Not Required L5 Microindentation (Surface-case depth) Every 2 Years Not Required L5X Microindentation (Surface) (ARP1820) Every 2 Years Not Required L6 Nitriding Every 2 Years Not Required L7 IGA / IGO Every 2 Years Not Required L8 Alpha Case: Wrought L9 Alpha Case: Castings L8 or L9 Not Required Every 2 Years L8 or L9 Not Required Every 2 Years L10 Carburization/Decarburization Every 2 Years Not Required LS Near-Surface Examinations Every 2 Years Not Required XL Macro Examination Every 2 Years Not Required Notes for Metallography and Microindentation Hardness IRR/PT Requirements – No Notes. Date Performed .PRI AC7101/1 Revision F .19 - B. B. 4. 6.11 CODE TEST TYPE Proficiency Testing Frequency Date Performed AC7101/11 – Fastener Testing 15 Torque – Tension 31 Not Required Torque – Locking. Any of the above PT or IRR requirements. separate PT for microhardness is not required. equivalent room temperature participation is not necessary. can be met through other accredited checklists (does not apply to fatigue). * If result of a stress rupture test is to discontinue at a defined point. Only one room temperature tensile PT is required. if not fastener specific. 3.20 - B. If case depth utilized microhardness. ** If elevated temp tensile has been performed for PT or IRR (and all operators are the same). Torque-Out Not Required 40L2 Metallography – Alloy Depletion Not Required 40L3 Metallography – Oxidation / Corrosion Not Required 40L7 Metallography – IGA / IGO Not Required 40L8 Metallography –Alpha Case: Wrought Titanium Every 2 Years 40L10 Metallography – Decarburization / Carburization Not Required 40L25 Metallography – Grain Size Every 2 Years 6-M2 Hardness – Rockwell Every 2 Years 6-M3 Hardness – Vickers Every 2 Years 6-L5 Hardness – Microindentation Hardness Every 2 Years 8-P Tensile Test – Proof Load (nuts / screws) 8-A Tensile Test – Axial Tensile Every 2 Years ** 8-W Tensile Test – Wedge Tensile Every 2 Years ** 18 Tensile Test – Elevated TempTensile Every 2 Years ** 10 Stress Rupture Every 2 Years * 11 Fatigue Every 5 Years 13 Shear Strength – Double Shear Every 2 Years 5 Stress Durability – External Threads Not Required 14 Stress Durability – Internal Threads Not Required Q Corrosion – Salt Spray Not Required QF Corrosion – Copper Sulfate Not Required Not Required Notes for Fastener Testing IRR/PT Requirements 1.10 CODE Internal Round Robin Frequency for Operators TEST TYPE Date Performed Internal Round Robin Frequency for Equipment Date Performed AC7101/7 – Mechanical Testing Specimen Preparation Z2 Low Stress Grinding and Polishing Every 2 Years Every 2 Years Notes for Mechanical Testing Specimen Preparation IRR/PT Requirements – No Notes. no PT or IRR is necessary. AC7101/8 – Differential Thermal Analysis: No PT/IRR Requirements AC7101/9 – Test Specimen Response/Capability to Heat Treat: No PT/IRR Requirements AC7101/11 – Fastener Testing B. Separate participation is not required for axial or wedge. .PRI AC7101/1 Revision F . 5. See also AC7101/11 Table 1 regarding assignment of test codes 2. * If result of a stress rupture test is to discontinue at a defined point. AC7109/5 – Coating Evaluation Laboratory Practices: See AC7109/5 for PT/IRR requirements AC7110/13 – Evaluation of Welds: No PT/IRR requirements . Torque-Out Every 2 Years Not Required 40L2 Metallography – Alloy Depletion Not Required Not Required 40L3 Metallography – Oxidation / Corrosion Not Required Not Required 40L7 Metallography – IGA / IGO Not Required Not Required 40L8 Metallography –Alpha Case: Wrought Titanium Every 2 Years Not Required 40L10 Metallography – Decarburization / Carburization Not Required Not Required 40L25 Metallography – Grain Size Every 2 Years Not Required 6-M2 Hardness – Rockwell Every 2 Years Every 2 Years 6-M3 Hardness – Vickers Every 2 Years Every 2 Years 6-L5 Hardness – Microindentation Hardness Every 2 Years Every 2 Years 8-P Tensile Test – Proof Load (nuts / screws) Not Required Not Required 8-A Tensile Test – Axial Tensile Every 2 Years ** Every 2 Years ** 8-W Tensile Test – Wedge Tensile Every 2 Years ** Every 2 Years ** Tensile Test – Elevated Temp. If case depth utilized microhardness. See also AC7101/11 Table 1 regarding assignment of test codes 2.12 CODE TEST TYPE Internal Round Robin Frequency for Operators Date Performed Internal Round Robin Frequency for Equipment Date Performed AC7101/11 – Fastener Testing 15 Torque – Tension Every 2 Years Not Required 31 Torque – Locking. ** If elevated temp tensile has been performed for PT or IRR (and all operators are the same).21 - B. no PT or IRR is necessary.PRI AC7101/1 Revision F . 3. separate PT for microhardness is not required. can be met through other accredited checklists (does not apply to fatigue). Only one room temperature tensile PT is required.Tensile Every 2 Years ** Every 2 Years ** 10 Stress Rupture Every 2 Years * Every 2 Years * 11 Fatigue Every 5 Years Not Required 13 Shear Strength – Double Shear Every 2 Years Every 2 Years 18 5 Stress Durability – External Threads Not Required Not Required 14 Stress Durability – Internal Threads Not Required Not Required Q Corrosion – Salt Spray Not Required Not Required Corrosion – Copper Sulfate Not Required Not Required QF Notes for Fastener Testing IRR/PT Requirements 1. equivalent room temperature participation is not necessary 5. Any of the above PT or IRR requirements. Separate participation is not required for axial or wedge. 6. 4. if not fastener specific. Rule 6 Time process between the beginning and the end of the program shall be less than 6 Months . Option 3 Option 3 – Submit a plan to meet the intent of proficiency testing for Task Group approval. tubes or batch is recommended for the homogeneity analyses. The *Full Process Provider.PRI C. sample preparation and testing). ISO 17025.g.) Criterion 1: ISO Guide 43 or ILAC G-13 Compliance and 3rd party accreditation (such as ISO 9001. Rules for acceptance of commercial proficiency testing providers. and the scope of the accreditation corresponding). shall be compliant with Criterion 1 or Criterion 2 *Full Process Provider . Rule 2 Homogeneity study of material shall be explained and compliant with Rules 3 and 4: Rule 3 20 specimens per sheet. Laboratories are responsible to ensure the provider they use conforms to the rules of this appendix (listed below) at time of use. AC7101/1 Revision F . OR Criterion 2: ISO Guide 43 or ILAC G-13 Registration and the following rules. to be recognized by the MTLTG. Resources →Documents →Public Documents →Materials Testing →IPT Information).A provider that supplies the sample in a condition to require participating testing laboratory to utilize their entire process (e.eAuditNet. three other options are available in this appendix. Option 1 Using an unrecognized Proficiency Testing provider The laboratory can participate in PT by other commercial providers if at least 8 of the “Rules for acceptance of commercial proficiency testing providers” (listed below) are validated by the provider and verified by the laboratory. Rule 1 Materials and tests scope offered by the provider comply with our aeronautic requirements (Standard used are listed in our referenced documentation). Option 2 How to use a Subscriber Program as a Proficiency Testing Provider The laboratory can use a Subscriber specific program only after PRI Staff Engineer and Subscriber concur regarding confidentiality and method validation.22 - APPENDIX C SELECTION OF A PROFICIENCY TEST (PT) PROVIDER When not practical or feasible to use a provider from the PRI list of recognized providers (found at www. Rule 5 The number of participants per test program shall be more than 30 to have a robust statistical analyse (less than 10 not accepted (per ASTME2489)). Less than 10 specimens per sheet. Supplier shall retain an approved plan to meet this requirement. Rule 4 Risk analyses to exclude a participant because of an inhomogeneous material shall be less than 5%. (Not one that submits photographic sample for review only. tubes or batch analyses will not be accepted.com. Rule 7 Time process between the final reporting of results and the data analysis report shall be less than 3 months (Root cause analyses concern). Rule 9 Statistical analyses performed (repeatability. Rule 8 Numbers of specimens per test (sufficient number of specimens to ensure repeatability).PRI AC7101/1 Revision F . .23 - (Root cause analyses concern). Rule 10 Interpretability of the report shall be easy and without waste off time for the auditor (the raw data record the method used shall clearly appear). median & sigma or k studies). Thus. (B) Participants – Participants are qualified operators or candidates for qualification.24 - (A) Membership – A coordinator of the Internal Round Robin program shall be assigned.1 SPECIFIC TESTING PROTOCOL FOR INTERNAL ROUND ROBINS . (D) Between facility variability. equipment or environment. It may also be several qualified operators using the same equipment and operating procedures to produce test results. The laboratory procedure shall define the minimum quantity of tests to be conducted and also establish criteria for increasing the number of replicates per operator or equipment. a second operator measure the dimensions and a third operator may perform the test. referred to as repeatability. APPENDIX D D. distribute testing materials. and construct a final report based on the data obtained. guide the testing phase. concerns the variability between independent testing results obtained within a single facility in the shortest practical period of time by a single operator with a specific set of test apparatus using test specimens taken at random from a single quantity of homogeneous material obtained or prepared for the study. The single operator – single set of apparatus requirement means that given a particular step in the measurement process. are obtained in a time not less than in normal testing and not so long as to permit significant changes in the test material. referred to as Reproducibility.PRI AC7101/1 Revision F D. It is the coordinator’s responsibility to design the test method protocol. . the same combination of operator and apparatus is used for every test result (replicate) and on every material. mechanical and optical tests depending on time as well as cost factors associated with the test method. (B) Within facility variability.g. (C) Timing Precision . (C) Quantity of Test Results (Replicates) per test method – The minimum number of replicates per operator or equipment will normally be two to estimate repeatability. comparing results from three different Rockwell hardness testers). each of which has applied the test method to the test specimens taken at random from a single quantity of homogeneous material obtained or prepared for the study. deals with the variability between single test results obtained in different facilities.2 GENERAL TESTING PROTOCOL FOR INTERNAL ROUND ROBINS (IRR) AND PROFICIENCY TESTING (PT) (A) Basic Design – The testing protocol should be designed such that the results obtained from the chosen method can be classified easily to study the within – and between – facility variability without the influence of secondary effects. at least for one material. (D) IRR testing protocol is in accordance with general testing protocol for IRR and PT below D. one operator may prepare the test specimens.“Shortest practical period of time” means that the test results. It may be one operator using various equipment or procedures to perform the same test method (e. Three or four replicates per operator or equipment is desirable for chemical. if applicable. (I) Material Consistency . specifying any option(s) in apparatus or procedure selected.The name. if applicable. A written draft of the test method shall be constructed that describes the test procedure. Each cell.Each material selected shall be supplied by one source and made to be as homogeneous as possible. if applicable. Supply sheets on which test results can be calculated or combined with the raw data sheet(s). prior to its subdivision into test specimens. a log or schematic of the location referencing where each test specimen originated from the bulk material shall be maintained. The location of every test specimen from the bulk material shall be traceable through a letter and/or number designation indicated on each sample. (L) Handling and Conditioning – Stipulate the required care.25 - (E) Data Classification – One form of classification suggested is a separate matrix table for each property tested. in which the rows represent the facilities and the columns represent the materials (or vice versa). (J) Calibration Procedures – Calibration procedures required before every test result should be described in detail in the test method. identifies test conditions affecting the test results.g. (For practicality reasons regarding certain test methods. The participating laboratories shall be instructed to contact the coordinator when any questions arise as to the conduct of the proficiency testing. The test method shall include any special calibration procedure and the frequency of calibration required. The number of significant digits to be reported shall also be designated and shall follow. (M) Host Facility Data Collection – The host laboratory or provider may provide data sheets for recording the raw data as observed. or at regular intervals for testing which extends over several weeks. Test units and test data sheets should be given for each option. the terms material and property may be interchanged in this paragraph). The samples shall be randomized before distribution and a record shall be maintained of which facilities (EPT) or operators and equipment (IRR) are testing which sample number(s). e-mail address. (K) Specific Conditions Analyses – Characterize any special circumstances that must be addressed in executing the repeatability conditions (e. if applicable. Request that all raw data be sent as soon as the testing is completed.PRI AC7101/1 Revision F . (F) Test Method – The actual measurement process and the written description of the process. and specifies the proper degree of control of the test. In other words. (G) Global Instruction . the intersection of a row with a column. . Describe the coding system used to identify the material(s) to be tested. as a minimum. handling and conditioning of the material(s) to be tested. (H) Test Identification – Clearly identify the test method. the length of time between obtaining the test results for the same material). telephone and fax number of the key person(s) coordinating and supervising the proficiency testing should be provided in the protocol. contains the test results made by a particular laboratory for a particular material. address. g. The recorded comments will serve as a valuable source of information both in handling outlying data and for improving the test method for future proficiency testing.26 - (N) Data sheets should be provided so that each laboratory can record any special events that arise during any phase of the testing. . It can then be determined whether a new set of test specimens needs to be provided for a replacement test of the material(s). Instruct the facilities to notify the test coordinator immediately whenever an error in test procedure occurs. In addition to a ‘comments’ section. materials and the reported test results from all participants. Obtain suggestions for future testing regarding the test method and test materials. It is recommended that the host laboratory prepare enough of each material to supply 50% more than needed by the number of facilities committed to the testing program. Any information that would ensure that the laboratory complied with the requirements specified for the test method or that may be needed to prepare for the final report should also be requested. (O) Replacement – The protocol must contain information about the availability of the material(s) for replacement tests. (P) Final Report – A formal report shall be distributed by the host to all participants. Participants shall be identified by code to minimize the possibility of bias during data analysis.PRI AC7101/1 Revision F . containing a description or summary of the test method. This testing fulfills Nadcap requirements for Stress Rupture in January of 2010). questions pertinent to the test method may be asked to get a better idea of how the test was carried out as long as the information is not proprietary. Each participant shall be informed of its code assigned by the host to maintain confidentiality. Testing sponsored by Nadcap-accredited facilities should clearly state which Nadcap testing requirement(s) are met (e. . AC7101/1 Revision F .. Recommended Practice 1. Calibration extension shall be allowed only if documented historical data and standard calibration practices substantiate the extension of calibration frequencies. Test Temperature Indicators) Laboratory Facility Temperature/Humidity Measuring Instruments REQUIRED FREQUENCY 3 Months 1 Year Recording Systems: To + 1% of full scale range (e. Calibration frequencies defined by standard methods or supplier requirements shall not be extended.PRI E.27 - APPENDIX E CALIBRATION FREQUENCY (MAXIMUM) GENERAL EQUIPMENT Precision Indicators (e.g. or other recognized statistical review process to support the extended time interval. X-Y Strip Charts) 6 Months Precision Potentiometers 3 Months Micrometers/Verniers 6 Months Optical Comparator 1 Year Oscilloscopes 1 Year Note:Calibration cycles may be extended as defined by the NCSL (National Conference of Standards Laboratories).g..