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Certification of Aerospace Products to international quality Standards
Certification of Aerospace Products to international quality Standards
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Qualification test report EN3007-050:
Page 3/64, §3.6:
Reminder: for qualification, 25 parts shall be fluorescent penetrant inspected as it has been done here.
For acceptance (to release these 96 parts, batch Nr. 41688/30), 100% FPI shall be done since we have AQL = 0,065%, so 200 parts to be tested (prEN2576, tables 3 and 4)
Page 3/64, §3.7:
ISO 6507-1 is a standard for Vickers hardness.
Hereafter, we have conformity against 26 to 35 HRC (as prEN2576 requires).
ISO 6508-1 is a standard for Rockwell hardness.
Perhaps, HRC is not suitable for this kind of bolt (not enough room or material thickness to perform Rockwell hardness).
However, ISO 18265 annex B has been used for converting Vickers into Rockwell (as we can read this in Annex 4). Could you please confirm?
Page 11/64, §3.9:
As per prEN2576 (07/2015), § 5.5.5:
“a Vickers hardness reading within 0,08 mm of an unrolled surface which exceeds the reading in the core by more than 30 points shall be evidence of non-conformance to this requirement.”
Bolt Nr. 1 has 299 HV30 (bolt end) and 331 HV30 (middle thread).
Bolt Nr. 4 has 312 HV30 (head) and 348 HV30 (middle thread).
So, these two bolts show more than 30 points difference between two areas.
Where are these HV tests located precisely on these bolts (near the surface? in the core?) ?
Page 12/64, §3.11:
As per EN3007, silver thickness shall be between 3 to 6 µm on pitch diameter and other areas shall be completely covered, without any thickness requirement.
Here, requirement is 3 to 7 µm.
We have a difference of 1 µm, which does not matter.
Nevertheless, we do not know where thickness measurements have been done in § 3.11 and in Annex 6 as well.
Could you please confirm that thickness measurements are located in pitch diameter area?
Gamme-Technique-EN3007-050016-signe:
Operation RES15: please, take into account the latest issue of prEN2576, which is prEN 2576:2015. For acceptance, applicable tables are 3 and 4 for sampling.
Operation COD34: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Could you please mention that a Vickers to Rockwell hardness conversion is required?
ISO 6507-1: Vickers hardness test method
ISO 6508-1: Rockwell hardness test method
Operation MA13: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation MI13: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation TRA06: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
For acceptance, sampling shall be done as per Table 8, column B or Table 9.
Operation TRI06: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation CO03: could you please confirm that go / no go gauge is MJ5x0,80-4h6h?
Many thanks in advance and have a good day.
1 ) Julien gauter comments :
Page 3/64, §3.6 :
Reminder: for qualification, 25 parts shall be fluorescent penetrant inspected as it has been done here.
For acceptance (to release these 96 parts, batch Nr. 41688/30), 100% FPI shall be done since we have AQL = 0,065%, so 200 parts to be tested (prEN2576, tables 3 and 4)
Auditor answers:
DECOMATIC confirms their misunderstanding about the requierements for qualification and delivery inspection . Only 25 parts have proceed the DPI . 84 parts have been released without FPI. I have asked to Decomatic to inform its customer about this gap for acceptance.
2 ) Julien Gauther comments
Page 3/64, §3.7:
ISO 6507-1 is a standard for Vickers hardness.
Hereafter, we have conformity against 26 to 35 HRC (as prEN2576 requires).
ISO 6508-1 is a standard for Rockwell hardness.
Perhaps, HRC is not suitable for this kind of bolt (not enough room or material thickness to perform Rockwell hardness).
However, ISO 18265 annex B has been used for converting Vickers into Rockwell (as we can read this in Annex 4). Could you please confirm?
Auditor answer :
DECOMATIC confirms to make the test with Vickers hardness and they use the ISO 18265 for converting Vickers into Rockwell.( see annex B)
3 ) Julien Gauther comments :
Page 11/64, §3.9:
As per prEN2576 (07/2015), § 5.5.5:
“a Vickers hardness reading within 0,08 mm of an unrolled surface which exceeds the reading in the core by more than 30 points shall be evidence of non-conformance to this requirement.”
Bolt Nr. 1 has 299 HV30 (bolt end) and 331 HV30 (middle thread).
Bolt Nr. 4 has 312 HV30 (head) and 348 HV30 (middle thread).
So, these two bolts show more than 30 points difference between two areas.
Where are these HV tests located precisely on these bolts (near the surface? in the core?)
Auditor answer :
DECOMATIC has remake the inspection and identify the position of the measurement
The report has been updated and has been uploaded in the web site
4) julien Gauther comment :
Page 12/64, §3.11:
As per EN3007, silver thickness shall be between 3 to 6 µm on pitch diameter and other areas shall be completely covered, without any thickness requirement.
Here, requirement is 3 to 7 µm.
We have a difference of 1 µm, which does not matter.
Nevertheless, we do not know where thickness measurements have been done in § 3.11 and in Annex 6 as well.
Could you please confirm that thickness measurements are located in pitch diameter area?
Auditor answer :
DECOMATIC has made micrography examination on the thread. Thickness are uniform and in accordance with the specification. The test report has been added in the web site
5 ) Julien Gauther comments
Operation RES15: please, take into account the latest issue of prEN2576, which is prEN 2576:2015. For acceptance, applicable tables are 3 and 4 for sampling.
Operation COD34: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Could you please mention that a Vickers into Rockwell hardness conversion is required?
ISO 6507-1: Vickers hardness test method
ISO 6508-1: Rockwell hardness test method
Operation MA13: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation MI13: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation TRA06: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
For acceptance, sampling shall be done as per Table 8, column B or Table 9.
Operation TRI06: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation CO03: could you please confirm that go / no go gauge is MJ5x0,80-4h6h?
Auditor answer:
DECOMATIC has changed is ERP system since the manufacturing of these parts. It is why the aswers has been handwriting . The new manufacturing route with comments has been uploaded in the web site.
Page 3/64, §3.6 :
Reminder: for qualification, 25 parts shall be fluorescent penetrant inspected as it has been done here.
For acceptance (to release these 96 parts, batch Nr. 41688/30), 100% FPI shall be done since we have AQL = 0,065%, so 200 parts to be tested (prEN2576, tables 3 and 4)
DECOMATIC’s answer: The penetrant inspection was only realized on simple 25 parts( 25 parts of qualification).
As I understand it, for the lot to qualify, we have to do the test on the 96 pieces which implies a de-processing and reprocessing of the whole lot?
We take note of your comments and apply them to future files.
Page 3/64, §3.7:
ISO 6507-1 is a standard for Vickers hardness.
Hereafter, we have conformity against 26 to 35 HRC (as prEN2576 requires).
ISO 6508-1 is a standard for Rockwell hardness.
Perhaps, HRC is not suitable for this kind of bolt (not enough room or material thickness to perform Rockwell hardness).
However, ISO 18265 annex B has been used for converting Vickers into Rockwell (as we can read this in Annex 4). Could you please confirm?
DECOMATIC’s answer: Yes, we confirm that we used the ISO 18265 annex B for converting Vickers into Rockwell.
Page 11/64, §3.9:
As per prEN2576 (07/2015), § 5.5.5:
“a Vickers hardness reading within 0,08 mm of an unrolled surface which exceeds the reading in the core by more than 30 points shall be evidence of non-conformance to this requirement.”
Bolt Nr. 1 has 299 HV30 (bolt end) and 331 HV30 (middle thread).
Bolt Nr. 4 has 312 HV30 (head) and 348 HV30 (middle thread).
So, these two bolts show more than 30 points difference between two areas.
Where are these HV tests located precisely on these bolts (near the surface? in the core?) ?
DECOMATIC’s answer: Please see Qualification test report § 3.9 Surface hardness
Nous avons repris les plots, identifiés les points et remesuré avec plus de précisions.
Modification du rapport de qualification (Cf pièce jointe)
Page 12/64, §3.11:
As per EN3007, silver thickness shall be between 3 to 6 µm on pitch diameter and other areas shall be completely covered, without any thickness requirement.
Here, requirement is 3 to 7 µm.
We have a difference of 1 µm, which does not matter.
Nevertheless, we do not know where thickness measurements have been done in § 3.11 and in Annex 6 as well.
Could you please confirm that thickness measurements are located in pitch diameter area?
DECOMATIC’s answer: Measurements of surface treatment were made at the end of the screw.
Gamme-Technique-EN3007-050016-signe:
Operation RES15: please, take into account the latest issue of prEN2576, which is prEN 2576:2015. For acceptance, applicable tables are 3 and 4 for sampling.
Operation COD34: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Could you please mention that a Vickers into Rockwell hardness conversion is required?
ISO 6507-1: Vickers hardness test method
ISO 6508-1: Rockwell hardness test method
Operation MA13: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation MI13: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation TRA06: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
For acceptance, sampling shall be done as per Table 8, column B or Table 9.
Operation TRI06: please, take into account the latest issue of prEN2576, which is prEN 2576:2015.
Operation CO03: could you please confirm that go / no go gauge is MJ5x0,80-4h6h?
DECOMATIC’s answer: Since the realization of this manufacturing, we have changed our ERP system; that the reason why the changes were handwritten .
DECOMATIC’s answer: The penetrant inspection was only realized on simple 25 parts( 25 parts of qualification).
As I understand it, for the lot to qualify, we have to do the test on the 96 pieces which implies a de-processing and reprocessing of the whole lot?
We take note of your comments and apply them to future files.
=> If this mfg batch is intended to be sold to a customer, acceptance sampling should be done.
As per EN2576, for qualification, 25 parts have to be FP inspected.
For acceptance, sampling is defined by tables 3 and 4 (AQL = 0,065%, single sampling, normal inspection).
DECOMATIC’s answer: Measurements of surface treatment were made at the end of the screw.
=> EN3007 requires silver thickness measurements on pitch diameter (3 to 6 µm).
Since silver plating here is an electrolytic process, we may have thickness variations due to current line concentrations (depending on geometry).
I assume thickness measurements were done by X-ray fluorescence.
If it is, this may explain why thickness measurements on pitch diameter locations were not performed (not really possible by X-ray fluorescence directly on screw threads).
Is is possible to do some measurements on micrographic cuts?
Many thanks,
Regards.
Thank you for replying Daniel.
So, one topic remaining:
“Auditor answers:
DECOMATIC confirms their misunderstanding about the requierements for qualification and delivery inspection . Only 25 parts have proceed the DPI . 84 parts have been released without FPI. I have asked to Decomatic to inform its customer about this gap for acceptance.”
Dis DECOMATIC get any answer from customer? (Accept or reject?)
Many thanks in advance,
Regards.
Julien
DECOMATIC has asked its customer whether they accept or reject this mfg batch due to sampling issue on FPI.
So, qualification approved, but pay attention for applying correct FPI sampling for future batches .