Documente Academic
Documente Profesional
Documente Cultură
Facility Name:
Address:
Process Table E
Annealing
Normalizing
Stress-Relieving
Process Table F
Low Pressure Carburizing
Process Table G
Sinter Hardening
Process Table H
Ion Nitriding
Personnel Contacted:
Name: Title: Phone: Email:
Auditors/Assessors:
Name: Company: Phone: Email:
Assessment
2
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
3
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
4
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
Section
To demonstrate 1 - Management
each process is capable of Responsibility & Quality Planning
yielding acceptable product the organization shall
perform process capability studies for the initial
validation of each process, after relocation of any
process equipment, & after a major rebuild of any
equipment. The organization shall define what
constitutes a major rebuild. Initial process
capability studies shall be conducted for all heat
treat processes per furnace line defined in scope
of work & in accordance with customer
Has a valid process capability
requirements. A furnace line may include a
study been performed initially
combination of equipment that is integrated in the
1.7 and after process equipment
performance of a heat treatment process, e.g.,
has been relocated, or had a
hardening, quenching, and tempering. Capability
major rebuild?
study techniques shall be appropriate for the heat
treat product characteristics, e.g., tensile strength,
case depth, hardness. Any specific customer
requirements shall be met. In the absence of
customer requirements, the organization shall
establish acceptable ranges for measures of
capability. An action plan shall exist to address the
steps to followed in case capability indices fall
outside customer requirements or established
ranges.
5
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
6
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
7
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
8
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
Has the Heat Treater Section 1 - Management Responsibility & Quality Planning
The heat treater shall develop and maintain a
developed a critical spare part
critical spare parts list and shall ensure the
1.19 list and are the parts available
availability of such parts to minimize production
to minimize production
disruptions.
disruptions?
Is material from different steel Different steel mill heats or metals which require
mill heats or metals which different heat treat parameters, such as but not
may preclude achieving the limited to, austentizing, quenching, or tempering
1.20
specified metallurgical times and/or temperatures shall be processed
properties prevented from separately in order to achieve specified
being processed together? metallurgical properties.
9
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
Section 1 -2Management
Section Responsibility
- Floor and Material & Quality
Handling Planning
Responsibility
It is critical that all customer requirements and lot
identification be adequately transferred to internal
heat treat documents. The facility shall ensure that
the data entered in the receiving system match the
information on the customer's shipping documents.
Documented processes and evidence of
Does the facility ensure that compliance shall exist, e.g., shop travelers, work
the data entered in the orders, etc. Sometimes the material received does
2.1 receiving system matches the not precisely correspond to customer shipping
information on the customer's documents. The facility shall have a detailed
shipping documents? process in place to resolve receiving
discrepancies.
The requirements stated above also apply to
captive heat treat departments. This process
refers to receiving and shipping the parts in and
out of the heat treat department.
10
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
11
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
Handling,Section
storage, and1packaging
- Management
shall be Responsibility & Quality Planning
adequate to preserve product quality. The heat
treater’s furnace loading system, in-process
handling, and shipping process shall be assessed
Is the handling, storage and
for risk of part damage or other quality concerns.
2.9 packaging adequate to
Some equipment includes conveyors and other
preserve product quality?
moving components that may not be able to
handle all part configurations. Other practices
such as stacking of overloaded containers can
also increase the risk of part damage.
12
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
Section
The quenching system1shall
- Management
be monitored, Responsibility & Quality Planning
documented, and controlled. The temperature,
agitation, level, concentration (if applicable), time
in the quenchant, and additions shall be controlled
to the heat treater's specifications. Refer to
Process Tables, Sections 3.0 and 5.0, for
frequency of checks. Computer-monitoring
Is the quenching system
equipment, with alarms and alarm logs, satisfy the
2.12 monitored, documented, and
verification requirement. Quench delay tolerance
controlled?
and alarm is required for furnaces with integral
quench tanks.
13
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
Section 1 - Management
SectionResponsibility
3 - Equipment& Quality Planning
The heat-treat equipment including furnaces,
generators, and quench systems shall have proper
Do furnaces, generators, and process controls and related equipment. Examples
3.1 quench systems have proper include temperature, carbon potential/dew point,
process control equipment? gas flows, quench monitoring system including
agitation, temperature control, etc. as listed in the
applicable Process Tables, Section 1.0.
The calibration and certification of the process
Are process equipment equipment shall be checked at regular specified
3.2 calibrations and/or verification intervals. Refer to the applicable Process Tables,
certified, posted, and current? Sections 1.0 and 2.0, for equipment calibration or
certification time tables.
The thermocouples and protection tubes shall be
Are thermocouples &
checked or replaced in compliance to a preventive
3.3 protection tubes checked or
maintenance schedule. Refer to the applicable
replaced per Process Tables?
Process Tables, Section 2.0.
14
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
GeneratorSection
and furnace1atmosphere
- Managementcarbon Responsibility & Quality Planning
potential/dew point shall be continuously
monitored, automatically controlled, and
documented. Recorded carbon potential shall be
controlled within +/- 0.05 of the set point. Recorded
dew point shall be controlled within acceptable
limits specified in the control plan or internal
procedures.
15
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
16
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
Ammonia Section
pick-up can 1
be -undesirable
Management Responsibility
in parts and & Quality Planning
heat treat processes not specifying/requiring
ammonia as an addition.
17
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
18
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
19
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
Assessment
20
CQI-9
Special Processes: Heat Treat Systems Assessment
Version 3, Issued 10/11
Section 4 - Job Audit
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Heat Treat Requirements:
21
CQI-9
Special Processes: Heat Treat Systems Assessment
Version 3, Issued 10/11
Section 4 - Job Audit
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Heat Treat Requirements:
22
CQI-9
Special Processes: Heat Treat Systems Assessment
Version 3, Issued 10/11
Section 4 - Job Audit
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Heat Treat Requirements:
23
CQI-9
Special Processes: Heat Treat Systems Assessment
Version 3, Issued 10/11
Section 4 - Job Audit
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Heat Treat Requirements:
24
CQI-9
Special Processes: Heat Treat Systems Assessment
Version 3, Issued 10/11
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat
treater is conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #'
NA - Requirement not applicable
A1.6 3.2 Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use.
A1.7 3.2 Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum.
Oxygen probe controllers shall be calibrated quarterly (single-point or multi-point calibration) or semi-annual (multi-point
A1.8 3.2
calibration only; single-point calibration not allowed).
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per
A1.9 2.16
the applicable ASTM standard, ISO standard, JIS standard, or approved standard.
A1.10 2.16 Files for testing hardness shall be verified per the Customer requirement.
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled
A1.11 3.2
water) and calibrated annually (per manufacturer's requirements) at a minimum.
2.0 PYROMETRY OK / NOK / NA
A2.1 3.2 Thermocouples and calibration of thermocouples shall conform to Section 3.1
3.3
A2.2 3.2 Pyrometry Instrumentation and Calibration of instrumentation shall conform to Section 3.2
3.3
3.2 CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3
A2.3 3.3
A2.4 3.4 TUS shall be performed annually and after major rebuild per Section 3.4
Temperature uniformity tolerance for hardening furnaces shall be +/- 15oC (or +/- 25oF). Temperature uniformity tolerance for
tempering furnaces shall be +/- 10oC (or +/- 20oF).
A2.5 3.5 Recorded temperature(s) for austentizing processes shall be controlled within +/- 10oC (or +/- 15oF) of the set point as
evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
A2.6 3.5 Recorded temperature(s) for tempering and precipitation hardening processes shall be controlled within +/- 5oC (or +/- 10oF) of
the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times
starting at the lower tolerance limit (as defined above).
A2.7 3.2 Infrared pyrometers shall be calibrated annually using proper calibration methods or an approved manufacturer's procedure.
CQI-9
Special Processes: Heat Treat Systems Assessment
Version 3, Issued 10/11
Batch Continuous Atmosphere
3.0 PROCESS MONITOR FREQUENCIES OK / NOK / NA
Furnace Furnace Generation
A3.1 1.4 Monitor primary temperature control instrument(s). Continuous recording with Continuous recording with Sign-off required
2.14 sign-off every 2 hours or sign-off every 2 hours or for each shift for
each batch for processes each lot for processes generators.
under 2 hours. Alarm under 2 hours). Alarm
systems (if set per limits in systems (if set per limits in
A2.5 and A2.6) satisfy the A2.5 and A2.6) satisfy the
sign-off requirement. sign-off requirement
A3.2 1.4 Monitor atmosphere generation as applicable. Generators shall
2.14 be continuously
3.7 monitored and
alarmed. Other
systems, such as
nitrogen-methanol
systems, may
either be
continuously
monitored and
alarmed, or sign-
off every 2 hours.
A3.3 1.4 Monitor primary furnace atmosphere control(s) Continuous recording with Continuous recording with
2.14 sign-off every 2 hours or sign-off every 2 hours or
3.7 each batch for processes each lot for processes
under 2 hours. Alarm under 2 hours). Alarm
systems (if set per systems (if set per
acceptable limits) satisfy acceptable limits) satisfy
the sign-off requirement. the sign-off requirement
A3.4 1.4 Verify primary furnace atmosphere control method Daily Daily
2.14 by back-up method
3.7
3.8
A3.5 1.4 For austentizing salt baths: Salt chemistry (soluble Daily
2.14 oxides) or decarburization on the parts shall be
3.13 checked.
A3.6 1.4 Quench Media Process Parameters
2.12 Temperature Continuous recording with Continuous recording with
sign-off every 2 hours or sign-off every 2 hours or
each batch for processes each lot for processes
under 2 hours. Alarm under 2 hours). Alarm
systems (if set per systems (if set per
acceptable limits) satisfy acceptable limits) satisfy
the sign-off requirement. the sign-off requirement
A3.7 1.4 Monitor time in furnace, cycle time or belt speed. Each batch Twice/shift & after any
2.14 change in the belt speed.
A3.8 1.4 Monitor load size or fixturing or loading rate as Each batch Twice/shift & after any
2.7 applicable. change in loading rate.
A3.9 1.4 Quench Delay Time - Each batch Each basket for pusher-
2.12 Quench delay time shall be based on the time that type continuous furnaces
the furnace door starts to open to the time the where the loaded basket is
load is at the bottom of the quench tank. quenched.
A4.3 1.4 Core hardness (when specified) Each batch Every 4 hours
2.15
A4.4 1.4 Case depth (when specified) Each batch Every 4 hours
2.15
QUENCHANT AND SOLUTION TEST Batch Continuous OK / NOK / NA
5.0
FREQUENCIES Furnace Furnace
A5.1 2.12 Polymer Quench Media
3.14 Concentration Daily Daily
Cooling Curve Analysis Semi-annually Semi-annually
A5.2 2.12 Water Quench Media
3.14 Suspended solids Semi-annually Semi-annually
A5.3 2.12 Salt Quench Media
3.14 Analysis & Contaminants Semi-annually Semi-annually
A5.4 2.12 Brine or Caustic Quench Media
3.14 Concentration and/or Specific Gravity. Daily Daily
Suspended solids Semi-annually Semi-annually
A5.5 2.12 Oil Quench Media
3.14 Water content, suspended solids, viscosity, Semi-Annually Semi-Annually
cooling curve, total acid, and flash point.
A5.6 2.13 Rust Preventive - Soluble Oil
Concentration 2x / week 2x / week
A5.7 2.11 Washers
Concentration of cleaner Daily Daily
Temperature of solution (required if temperature Each shift Each shift
is specified to be above ambient temperature).
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is
conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #'
NA - Requirement not applicable
Item # Related
HTSA Category/Process Steps
Question #
1.0 OK / NOK / NA
PROCESS AND TEST EQUIPMENT REQUIREMENTS
B1.1 3.1 All furnaces, generators and quench systems shall have temperature indicating instruments.
3.7
B1.2 3.1 Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas
3.7 analyzer, etc. For salt bath, only temperature is required to be recorded.
B1.3 1.18 A program for furnace and generator burnout is required. Not required for retort gas nitriding.
B1.4 3.2 Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
B1.5 3.2 Dew pointers and gas analyzers, used to verify proper atmosphere in furnaces, shall be calibrated annually at a minimum.
B1.6 2.16 All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the applicable ASTM
standard, ISO standard, JIS standard, or approved standard.
B1.7 2.16 Files for testing hardness shall be verified per the Customer requirement.
B1.8 3.2 Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled water) and calibrated
annually (per manufacturer's requirements) at a minimum.
2.0 OK / NOK / NA
PYROMETRY
B2.1 3.2 Thermocouples and calibration of thermocouples shall conform to Section 3.1.
3.3
B2.2 3.2 Pyrometry Instrumentation and Calibration of instrumentation shall conform to Section 3.2
3.3
B2.3 3.2 CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3
3.3
B2.4 3.4 TUS shall be performed annually and after major rebuild per Section 3.4.
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
B2.6 3.2 Infrared pyrometers shall be calibrated annually using proper calibration methods or an approved manufacturer's procedure.
B3.3 1.4 Monitor primary furnace atmosphere control(s). Each batch (rotary furnaces Continuous recording with Daily
2.14 only) or continuous sign-off every 2 hours.
3.7 recording with sign-off Alarm systems satisfy the
3.8 every 2 hours. Alarm sign-off requirement
systems satisfy the sign-off
requirement
B3.4 1.4 Dissociation of ammonia shall be checked in gas Each batch and every 4 Every 4 hours Daily N/A
3.7 nitriding. hours minimum
B3.5 1.4 Gas ratios for ferritic nitrocarburizing shall be Each batch Every 2 hours minimum
3.7 checked.
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is
conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #'
NA - Requirement not applicable
Item # Related
HTSA Category/Process Steps
Question #
B3.6 1.4 Check salt chemistry (soluble oxides) in salt baths Daily
2.14 used for austenitizing, or decarburization on the parts.
3.13
B3.7 1.4 Quench Media Process Parameters
2.12 Temperature Each batch or continuous Each lot or continuous Each batch or
recording with sign-off recording with sign-off continuous
every 2 hours. Alarm every 2 hours. Alarm recording with
systems satisfy the sign-off systems satisfy the sign-off sign-off every
requirement. requirement. 2 hours.
Alarm systems
satisfy the sign-
off
requirement.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat
treater is conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
C1.2 3.1 Continuous strip charts and/or data loggers are required for temperature sensors.
C1.3 2.16 All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per
the applicable ASTM standard, ISO standard, JIS standard, or approved standard.
C1.4 3.2 Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
C1.5 3.2 Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled
water) and calibrated annually (per manufacturer's requirements) at a minimum.
Temperature Uniformity tolerance for solution and aging furnaces shall be +/- 5oC (+/- 10oF).
Temperature Uniformity tolerance for annealing furnaces shall be +/- 15oC (+/- 25oF)
Minimum and maximum temperature ranges shall be defined. Exception: If the operating range of the Qualified Work Zone is
equal to or less than 85oC (155oF) then only one temperature is required to be tested. The test temperature shall be within
the operating range of the Qualified Work Zone.
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
C2.5 3.5 For Solution Treating and Aging: Recorded temperature(s) shall be controlled within +/- 5C (or +/- 10F) of the set point as
evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone
C2.6 3.5 For Annealing Furnaces: Recorded temperature(s) shall be controlled within +/- 10C (or +/- 15F) of the set point as
evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone
C2.7 3.2 Infrared pyrometers shall be calibrated annually using proper calibration methods or an approved manufacturer's procedure.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat
treater is conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing
the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
D1.1 2.16 All hardness test equipment (for each scale used) shall be calibrated annually
minimum, and verified daily or prior to use, per the applicable ASTM standard,
ISO standard, JIS standard, or approved standard.
D1.2 2.16 Files for testing hardness shall be verified per the Customer requirement.
D1.3 3.2 Refractometers (typically used to check polymer quenchants and washer
solutions) shall be verified prior to use (with distilled water) and calibrated
annually (per manufacturer's requirements) at a minimum.
2.0 PYROMETRY
D2.1 3.2 Infrared pyrometers shall be calibrated annually using proper calibration
methods or an approved manufacturer's procedure.
All process parameters shall be checked the beginning of every shift, tool change, or any equipment
repair. In absence of process parameter alarms, also check process parameters at end of shift or lot
(whichever is the greater frequency).
D3.1 1.4
2.12 Quench Temperature Alarm system for high and low
temperature is required.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing
the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing
the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the audi
shall verify heat treater is conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
E1.1 3.1 All furnaces, generators and quench systems (where applicable) shall have temperature indicating instruments.
3.7
E1.2 3.1 Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew
3.7 point, oxygen probe, IR gas analyzer, etc.
E1.3 3.2 Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
E1.4 3.2 Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to
verify carbon potential in furnaces, shall be calibrated annually at a minimum. This is applicable when used in
controlling carbon-bearing atmospheres.
E1.5 3.2 Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to
use. This is applicable when used in controlling carbon-bearing atmospheres.
E1.6 3.2 Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum.
This is applicable when used in controlling carbon-bearing atmospheres.
E1.7 3.2 Oxygen probe controllers shall be calibrated quarterly (single-point or multi-point calibration) or semi-annual (multi-
point calibration only; single-point calibration not allowed). This is applicable when used in controlling carbon-
bearing atmospheres.
E1.8 2.16 All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior
to use, per the applicable ASTM standard, ISO standard, JIS standard, or approved standard.
E1.9 3.2 Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use
(with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.
2.0 PYROMETRY
E2.1 3.2 Thermocouples and calibration of thermocouples shall conform to Section 3.1.
3.3
E2.2 3.2 Pyrometry Instrumentation and Calibration shall conform to Section 3.2.
3.3
E2.3 3.2 CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per
3.3 Section 3.3.
E2.4 3.4 TUS shall be performed annually and after major rebuild per Section 3.4.
Temperature uniformity tolerance for furnaces operating at austenitizing temperatures shall be +/- 15oC
(or +/- 25oF). Temperature uniformity tolerance for tempering furnaces shall be +/- 10oC (or +/- 20oF).
CQI-9
Special Process: Heat Treat System Assessment
Version 3, Issue 10/11
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the audi
shall verify heat treater is conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
E2.5 3.5 Recorded temperature(s) for austentizing processes shall be controlled within +/- 10oC (or +/- 15oF) of the set point
as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times
starting at the lower tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
3.0 PROCESS MONITOR Continuous
Batch Furnace Generators
FREQUENCIES Furnace
E3.1 1.4 Monitor primary temperature Continuous Continuous Sign-off required for each shift for
2.14 control instrument(s). recording with sign- recording with generators.
off every 2 hours or sign-off every 2
each batch for hours or each lot
processes under 2 for processes
hours. Alarm under 2 hours).
systems (if set per Alarm systems (if
limits in E2.5) satisfy set per limits in
the sign-off E2.5) satisfy the
requirement. sign-off
requirement.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the audi
shall verify heat treater is conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
E3.6 1.4 Monitor time in furnace, cycle Each batch Twice/shift & after
2.14 time or belt speed. any change in the
belt speed.
E3.7 1.4 Monitor load size, fixturing or Each batch Twice/shift & after
2.7 loading rate as applicable. any change in
loading rate.
4.0 IN-PROCESS/FINAL TEST Batch Furnace Continuous
FREQUENCIES Furnace
E4.1 1.4 When specified - Daily per furnace Daily per furnace
2.15 Microstructure shall be unless specified by unless specified
checked at a minimum customer to be by customer to be
magnification of 100x and, checked with greater checked with
400x or above 400x. frequency, e.g., each greater frequency,
Microstructural visual bath. e.g., each bath.
references shall be available.
E4.2 1.4 Surface hardness (when Each batch Every 4 hours
2.15 specified)
E4.3 1.4 Core hardness (when Each batch Every 4 hours
2.15 specified)
5.0 SOLUTION TEST Continuous
Batch Furnace
FREQUENCIES Furnace
E5.1 2.13 Rust Preventive - Soluble
Oil
Concentration 2x / week 2x / week
E5.2 2.11 Washers
Concentration of cleaner Daily Daily
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify
treater is conforming to the customer's requirements.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
F1.8 2.16 All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the
applicable ASTM standard, ISO standard, JIS standard, or approved standard.
F1.9 2.16 Files for testing hardness shall be verified per the Customer requirement.
F1.10 3.2 Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled
water) and certified annually per manufacturer's requirements at a minimum.
2.0 PYROMETRY
F2.1 3.2 Thermocouples and calibration of thermocouples shall conform to Section 3.1.
3.3
F2.2 3.2 Pyrometry Instrumentation and Calibration of instrumentation shall conform to Section 3.2.
3.3
F2.3 3.2 CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3.
3.3
F2.4 3.4 TUS shall be performed annually and after major rebuild per Section 3.4.
Temperature uniformity tolerance for hardening and tempering furnaces shall be +/- 10 C or +/- 20 F.
F2.5 3.5 Recorded temperature(s) for austentizing and tempering processes shall be controlled within +/- 5 C or +/- 10 F of the set point as
evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
3.0 PROCESS MONITOR FREQUENCIES
F3.1 1.4 Monitor primary temperature control instrument(s). Continuous recording with sign-off every 2 hours or each batch for processes
2.14 under 2 hours. Alarm systems (if set per limits in F2.5) satisfy the sign-off requirement.
F3.2 1.4 Monitor primary furnace atmosphere control(s) or hydrocarbon flows. Continuous recording with sign-off every 2 hours or each
2.14 batch for processes under 2 hours. Alarm systems (if set per acceptable limits) satisfy the sign-off requirement.
F3.3 1.4 Monitor pressure in the carburizing and gas quenching process. Continuous recording with sign-off every 2 hours or each batch
2.14 for processes under 2 hours (carburizing process). Continuous recording with sign-off each batch (quenching process). Alarm
systems (if set per acceptable limits) satisfy the sign-off requirement.
F3.4 1.4 Verify primary atmosphere control method by back-up method by microstructural evaluation of parts or coupon, or carbon
2.14 analysis of shim stock or carbon bar. Verification shall be daily.
3.7
3.8
F3.5 1.2 Prior to production (APQP), the surface area of the parts shall be calculated and documented for each load configuration.
2.7
F3.6 1.4 Quench Media Process Parameters - Oil FREQUENCY
2.12 Temperature Continuous recording with alarm system is required.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify
treater is conforming to the customer's requirements.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
Cooling water temperature and flow rate Monitor each load. Alarm system is required
F4.1 1.4 Microstructure shall be checked at a minimum magnification of Daily per furnace (may rotate cells) or any time one of the
2.15 100x and, 400x or above 400x. Microstructural visual process parameters is out of specification.
references shall be available.
F4.2 1.4 Surface hardness Each batch
2.15
F4.3 1.4 Core hardness (when specified) Daily per furnace (may rotate cells) or any time one of the
2.15 process parameters is out of specification.
F4.4 1.4 Case depth (when specified) Daily per furnace (may rotate cells) or any time one of the
2.15 process parameters is out of specification.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treate
conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
Item # Related HTSA Category/Process Steps
Question #
1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTS
G1.1 3.1
All furnaces, generators and quench systems shall have temperature indicating instruments.
3.7
G1.2
3.1 Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR
3.7 gas analyzer, etc.
G1.3 3.1 Atmosphere flow meters/indicators are required.
G1.4 1.18 A program for furnace and generator burnout is required (applies to carbon bearing atmospheres).
G1.5 3.2 Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential
in furnaces, shall be calibrated annually at a minimum (applies to carbon bearing atmospheres).
G1.6 3.2 Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use (applies to carbon
bearing atmospheres).
G1.7 3.2 Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum (applies to carbon
bearing atmospheres).
G1.8 3.2 Oxygen probe controllers shall be calibrated quarterly (single-point or multi-point calibration) or semi-annual (multi-point calibration only;
single-point calibration not allowed). This applies to carbon bearing atmospheres.
G1.9 2.16 All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the
applicable ASTM standard, ISO standard, JIS standard, or approved standard.
2.0 PYROMETRY
G2.1 3.2 Thermocouples and calibration of thermocouples shall conform to Section 3.1.
3.3
G2.2 3.2 Pyrometry Instrumentation and Calibration of instrumentation shall conform to Section 3.2.
3.3
G2.3 3.2 CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3.
3.3
G2.4 3.4 TUS shall be performed annually and after major rebuild per Section 3.4.
Temperature uniformity tolerance for hardening furnaces shall be +/- 15ºC (or +/- 25ºF). Temperature uniformity tolerance for tempering
furnaces shall be +/- 10ºC (or +/- 20ºF).
G2.5 3.5 Recorded temperature(s) for sintering processes shall be controlled within +/- 10ºC (or +/- 15ºF) of the set point for processes operating
less than 1000ºC (1830ºF) and +/- 20ºC (+/- 35ºF) for processes operating greater than 1000ºC (1830ºF) as evidenced by continuous
recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treate
conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
Item # Related HTSA Category/Process Steps
Question #
G3.2 Monitor generator atmospheres. One of the three options is
required.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treate
conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
Item # Related HTSA Category/Process Steps
Question #
Agitation (Fan/Blower Speed) Alarm system is required Alarm system is required
to ensure proper operation to ensure proper
of the fans. operation of the fans.
Cooling water temperature and flow rate Monitor each load. Alarm system is required
G3.8 1.4 Monitor time in furnace, cycle time or belt speed. Each batch Twice/shift & after any
2.14 change in the belt speed.
G3.9 1.4 Monitor load size or fixturing or loading rate as Each batch Twice/shift & after any
2.7 applicable. change in loading rate.
G3.10 1.4 Quench Delay Time - Each batch Not applicable for belt
2.12 Quench delay time shall be based on the time that the furnaces.
furnace door starts to open to the time the load is at
the bottom of the quench tank (oil) or the start of the
gas pressure quenching (gas quench).
G4.1 1.4 Microstructure shall be checked at a minimum Daily per furnace unless Daily per furnace unless
2.15 magnification of 100x and, 400x or above 400x. specified by customer to specified by customer to
Microstructural visual references shall be available. be checked with greater be checked with greater
frequency, e.g., each frequency, e.g., each
G4.2 Mechanical Testing (when specified) Each Lot Each Lot
G4.3 1.4 Apparent hardness Each batch Every 4 hours
2.15
G4.4 1.4 Core hardness (when specified) Each batch Every 4 hours
2.15
CQI-9
Special Processes: Heat Treat Systems Assessment
Version 3, Issued 10/11
PROCESS TABLE H - Ion Nitriding
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the
customer's requirements.
Please note that the corresponding gas nitriding is Table "B" and the Plasma Ion Nitriding is is Table "H"
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #')
NA - Requirement not applicable
H1.5 3.2 Gas ratios controller / meters shall be calibrated / verified as recommended by the manufacturer. As an option gas composition may be analyzed using gas
mixture analyzer semi- annually and calibrated as recommended by the manufacturer.
H1.6 2.16 All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the applicable ASTM standard,
ISO standard, JIS standard, or approved standard.
H1.7 2.16 Files for testing hardness, if used, shall be verified per the Customer requirement.
H3.3 1.4 Pump down of 75 microns per hour or less and leak up of 90 microns per hour or less Each Batch
2.11 are required prior to initiating the cycle
2.12
H3.5 1.4 Monitor time in furnace, cycle time. Each batch
2.14
H3.6 1.4 Monitor load size or fixturing as applicable. Each batch
2.7
4.0 IN-PROCESS/FINAL TESTS FREQUENCY OK / NOK / NA
H4.1 1.4 Microstructure characteristics including compound zone and etched zone shall be Each Batch
2.15 checked. Microstructure shall be checked at a minimum magnification of 100x and,
400x or above 400x. Microstructural visual references shall be available.
H4.2 1.4 Surface hardness Each Batch
2.15
H4.3 1.4 Core hardness (when specified) Each Batch
2.15
H4.4 1.4 Case depth (when specified) Each Batch
2.15
5.0 SOLUTION TESTS FREQUENCY OK / NOK / NA
H5.1 2.13 Rust Preventive - Soluble Oil
Concentration - when not purchased as a mixed solution 2x / week or as appropriate for cleaning the parts or per customer
and Control Plan
55