Standard Operating Practice S.O.P. No

Transcription

1 Page 1 of PURPOSE SAMPLE CASTING APPROVAL This specification documents the procedure and the requirements for the procurement of casting fixtures, gages and pattern equipment, approval of sample castings and casting process, risk sample Definition and casting production release. 2.0 SCOPE Applicable to all castings, casting pattern equipment, dies and fixtures used to produce castings for Eaton, FSD, Euclid. 3.0 TABLE OF CONTENTS 4.0 Procurement 5.0 Tooling Manufacture 6.0 Pattern Equipment or Die Requirements 7.0 Casting Qualification Fixtures 8.0 Core Stick Review 8.5 Investment Model Review 9.0 Conditions for Sample Casting Manufacture 9.3 Risk Casting Definition 10.0 Sample Inspection 10.4 First Article Inspection 10.5 Periodic Production Sample Evaluation 11.0 Destructive Testing 12.0 Evaluation and Dispositioning of Samples 13.0 Maintenance of Tooling 14.0 Foundry Process Control (Frozen Process) 15.0 Production Casting Inspection and Serialization 3.1 APPLICABLE DOCUMENTS ARG-693 Spec TAP-MS-642 SOP SOP Casting or Forging Sample Release or Rejection Part Marking Requirements For Evaluation of Castings Casting Tooling Development Control Procedure Inactive Casting Tooling Procedure Date of Issue Revision 1/20/09 - P 05/16/12 Revision complete Prepared by Approved by signature on file D. Neville signature on file G. Lallathin

2 Page 2 of PROCUREMENT 4.1 Quotations for new tooling shall include the following: A. A complete description of pattern equipment, molding process, fixtures and gages to be used for inspecting the casting. B. The quantity of castings the purchaser can expect to receive from each item of the proposed process equipment. C. The cost of blueprints and inspection of fixtures and gages, and inspection reports for each item. 4.2 The foundry shall maintain a sketch/photo defining only the critical elements of foundry in process fixtures and/or gages. 5.0 TOOLING MANUFACTURE 5.1 It is the foundry's responsibility to inform the pattern shop that the blueprint shall not be scaled for undefined features. If there is a difference between the configuration in blueprint views and blueprint dimensions, Eaton, FSD, Euclid shall be notified immediately. 5.2 Unless specifically waived in writing by Quality and Engineering, existing pattern equipment will be duplicated to produce any new equipment. Refurbishing of worn areas without changing dimensional sizes shall be made prior to duplication. 5.3 When pattern equipment is re-manufactured (not duplicated from model, plugs, dummies or existing equipment), Engineering and Quality shall determine the level of pump qualification test required prior to production release. 5.4 Casting patterns or dies that have been duplicated from old patterns shall only require First Article evaluation. 5.5 Documented accepted dimensional discrepancies duplicated from previous tooling are responsibility. Process related discrepancies and discrepancies resulting from wear or damage are the suppliers responsibility Tooling refurbishment shall be done in the most permanent manner. Carbide or metal fillers or better shall be used to repair worn areas for sand casting tooling. 5.6 New tooling shall be produced per SOP PATTERN EQUIPMENT OR DIES 6.1 Pattern equipment or dies shall be manufactured with the following considerations where possible: 6.2 Core joints, parting lines and rigging shall lie on surfaces which are machined. 6.3 Foundry rigging shall be constructed to support the shake-out vibration loads.

3 Page 3 of Cores which locate on strike-off surfaces shall have steel faces on the aluminum, plastic or wood core box frames. Strike-off fixtures or gages may be utilized in place of steel faces. 6.5 Casting datum locating points shall be produced by stable pattern equipment. Process rigging, set cores, loose pattern pieces or parting lines shall not be located on datum points without prior written approval. 6.6 Pattern equipment shall produce corner and fillet radii in all areas which will not be machined. Any exceptions shall be submitted for approval at core stick review. Sharp corners are permitted on surfaces which are to be machined. 6.7 Multi-cavity patterns shall have cast cavity identification. Dual patterns shall have vendor trademarks. This identification is to be on a surface which will not be machined. Request location for this marking through Purchasing. 6.8 Aluminum shell core boxes are NOT permitted. 6.9 Unless waived by Quality, all small cores shall have enlarged core prints to produce the exterior surface of the casting. This enlarged print area around cored passages shall be.062 minimum per side for visual inspection of core location. 7.0 CASTING QUALIFICATION FIXTURES AND GAGES shall be designed with the following considerations: 7.1 Scribe and profile features shall, as a minimum, verify that minimum material condition complies with blueprint requirements (eg. low limit for O.D. and high limit for I.D.). 7.2 Datum locators for datums on cast surfaces shall be a.250 minimum diameter sphere. 7.3 Inspection features shall be accurate within +/-.005 of casting drawing definition. 7.4 One vertical surface shall have a.062" deep recessed milled slot for the full length of the fixture, 2 gage maker set-up holes or 2 gage balls for gage inspection alignment. 8.0 SAND OR PLASTER PROCESS MODEL AND CORE STICK REVIEW 8.1 Supplier Quality will evaluate the model and core sticks. The model and core sticks shall be manufactured to the following state: 8.2 The exterior shall have all features completed except for fillets and finishing. The pattern shall not be mounted. 8.3 All interior core sticks shall be completed with core prints. 8.4 No part of the production tooling shall be completed at this point.

4 Page 4 of This review will consist of the following: A. Pouring attitude and chilling for optimum casting properties. B. Foundry producibility (eliminate foundry problem areas). C. Core configuration (restrictions, proper fuel flow, etc.). D. Assure pattern and core models comply with blueprint E. Eliminate all possible negative draft areas. F. If possible move cast designation and foundry logo location to eliminate set cores. G. Any changes will be marked up on three (3) sets of prints or documented in a letter if changes can be described adequately. These will be signed by and distributed to representatives of Eaton, the foundry and the tool shop. Any changes to a released blueprint will require an Engineering Order (E.O.) to be initiated by Eaton personnel. It is Eaton s option to immediately change the drawing or operate with a working E.O. per SOP Any changes to an unreleased blueprint will be incorporated in the released blueprint. 8.5 Investment Model Review After manufacture of investment die and prior to producing castings, a pattern review is required. For this review a sample of each soluble core, an undressed wax pattern with soluble cores encapsulated and wax pattern with soluble cores removed are to be submitted for review Eaton will review the wax pattern for obvious non-conformances such as missing fillets, thin walls and marking requirements Eaton Quality Assurance will issue a report of this evaluation to Purchasing Eaton will advise the supplier in writing of the disposition of any findings with regards to correction prior to producing castings. 8.6 Eaton review and approval of core stick, pattern, model or other device for evaluation of methods used to produce tool will, in no way, limit suppliers responsibility to produce accurate tooling. 9.0 CONDITIONS FOR SAMPLE CASTING MANUFACTURE 9.1 Sample castings shall be ordered and evaluated in accordance with this SOP. Samples and inspection shall be as contracted by Purchasing. All samples shall be source inspected unless this requirement is waived by Quality. 9.2 The first molds or investment patterns shall be assembled under the suppliers Quality or Engineering Department control. A report shall be generated and available with the first or reworked sample castings of the core fit, adjustments made to produce a VISUAL acceptable part, and the results of the mold assembly gages.

5 Page 5 of "Definition of Risk Casting Prior to Sample Approval (PSA)"; Prior to producing risk samples, the supplier is responsible for producing initial samples for the following: A. Establish mold assembly instructions and verify rigging. B. Confirm material properties. C. Verify material integrity by radiographic and fluorescent penetrant inspection. D. Verify wall thickness. E. Inspect for obvious "visual" errors when compared to a full size blueprint. F. Layout inspect a few key dimensions and/or evaluate a part in a qualifying fixture Any discrepancies found on the risk castings after these initial samples have been evaluated are subject to Eaton review via layout report. Deviated risk castings produced without sampling are the vendor's responsibility Eaton will source inspect all risk castings A First Article shall be submitted prior to the machining of any Eaton risk casting. After dispositioning layout report, Eaton will notify the machining supplier of any special machining instructions. 9.4 The foundry is not permitted to produce additional parts after risk castings until parts are released for production on ARG-693 report or without other written authorization from Engineering, Program Office and Quality department LAYOUT INSPECTION SAMPLE(S) 10.1 When laying out sample castings, the supplier MUST use locating points (datum system) as specified on the blueprint. If castings are balanced, qualified or targeted prior to layout any adjustment to datum points shall be reported. In addition, there shall be only minimum clean-up of flash or mismatch of partings or rigging. THIS IS EXTREMELY IMPORTANT; LAYOUTS WHICH DO NOT COMPLY WITH THIS REQUIREMENT MAY BE REJECTED. Layouts are for product of the tool, sanding or filing cores is not permitted. Characteristics that require this on existing tooling are to be reported A detailed report for any dimensional inspection contracted from the supplier shall be furnished indicating: 1. The serial number of the casting inspected. 2. Dimension reference numbers. 3. Blueprint sheet and zone location. 4. Blueprint dimension. 5. The actual size and location of all characteristics inspected. 6. Mechanical property results (for complete 1 st article). 7. Drawing change letter contracted by the purchase order. 8. The name of the inspector and date 9. All items inspected during layout are to be identified on a sketch and/or full size drawing and reported by a characteristic number. Copy of E.O s shall be included with the report. 10. All items that exceed drawing requirements are to be shown as rejected. 11. The layout inspector shall sign and date the drawings used for the inspection.

6 Page 6 of A full size blueprint with each characteristic identified with an item number is required. Eaton will copy this print and return it with a copy of form ARG-693 when disposition has been completed This blueprint may be used by the inspector to document actual inspection results. When the blueprint is so used, actual dimensions shall be recorded adjacent to the blueprint requirement and the print is to be signed and dated by the inspector Coordinate Measuring Machine Inspection: Coordinate measuring machines (CMM) are authorized for inspection of Eaton castings. The Eaton Source inspector reserves the right to re-inspect any characteristic on head or surface plate. Scribe-lines are not required for features on whole casting inspection Identified scribed reference lines and datum lines are required on all the sectioned pieces. These scribed lines are required for re-inspection of a section when required First Article Inspection: Sample castings and layout inspection will be contracted by the purchase order to support evaluation of the following: A. New pattern equipment. B. Altered pattern resulting from drawing changes or corrections required per Eaton layout reports. Eaton is to be notified before any dimensional tooling changes are made. This excludes routine maintenance, as long as dimensional characteristics are not changed. It is the foundry's responsibility to inspect the repaired area(s) on a casting after any pattern repair C. Process changes as defined by the Foundry Process Control section of this SOP. D. Pattern equipment transferred to another foundry The following evaluation shall be performed completed on the sample castings when specified on the purchase order: A. The First Sample Casting shall have all external features and locations of accessible internal features dimensionally inspected. Unless otherwise specified, the following applies to layout inspection of the First Sample Casting: 1. This casting shall have scribe-lines for external features. 2. This sample may be a metallurgical reject and in the unheat treated condition. 3. On multi-cavity patterns one casting shall be layout inspected. One casting from each cavity shall be layout inspected for a few key features. Wall thickness shall be inspected and a visual comparison shall be made to the layout piece. Any questionable observations resulting from the visual comparison shall be verified by layout inspection. B. The Second Sample Casting shall be scribed with datum lines and recorded reference cut lines. This casting shall be inspected for deviations found on the first sample casting and sectioned for complete internal dimensional inspection including wall thickness. Additional castings may be required to complete this evaluation. Unless otherwise specified this sample may be a metallurgical reject and in the unheat treated condition.

7 Page 7 of 12 C. The Third Sample Casting shall be heat treated and acceptable when inspected using NDT methods prior to sectioning. The casting shall be sectioned if any surfaces of cored passages are hidden from external view and/or section thickness exceeds 3/4". Castings shall be sectioned through each passage "PARALLEL TO THE HORIZONTAL" orientation in the mold as poured when possible, thus allowing NDT evaluations of each single wall section. Any radiographic or penetrant discontinuity caused by deficiencies in the casting process shall be cause for rejection. This evaluation shall be performed for one casting from each cavity of multi-cavity molds. The following data shall be recorded: 1. Wall thickness 2. Radiographic inspection results of each individual section. 3. Fluorescent Penetrant Inspection results of each section per VQR. 4. Mechanical properties. D. The Fourth Sample Casting may be a metallurgical reject. A 1/8 inch dia. hole shall be drilled through a pressure passage by the foundry and the casting shall be painted. The foundry shall tag this casting with Cast to Machine Sectioning Piece. Send To Quality After Machining. This casting will be machined complete to component print. This part can be used as machining lead piece. Any machining discrepancies (cast datum to machine datum, mislocated machined feature, over or undersize machine configuration) must be documented by the machining source. This part will be sectioned to verify design integrity as follows: 1. Cast to machined configuration wall thickness 2. Cast to cast wall thickness 3. Fluorescent penetrant inspect each section 4. Radiographic inspect each section Eaton will negotiate with vendor the degree of compliance to basic radiographic discontinuity requirement. 5. Visual discontinuities in the internal passages. Note: This sample is required for samples off new tooling for any casting that has cored passages or hidden features that can not be evaluated without sectioning Periodic Production Sample Evaluation: When a casting is being ordered after two or more years of inactivity, a periodic evaluation will be required. Supplier Quality may waive this evaluation when conditions, such as relatively new tooling, warrant. Documentation of waivers will be maintained in casting files. It shall be the responsibility of Supplier Quality to monitor castings for dimensional issues during normal daily activities or source inspection. When dimensional problems are suspected, a periodic evaluation may be requested.

8 Page 8 of Periodic Evaluation shall include all the external features and internal features which are accessible without sectioning This inspection shall be performed by individual(s) from the suppliers organization with responsibility for dimensional and metallurgical quality of the castings and shall include: a) A review of the NCR and CAR history. All characteristics that have shown as discrepant in the past shall be verified. b) A visual examination of the sample casting for evidence of process problems such as excessive grinding, mismatches, irregular fillets and other conditions which may indicate tooling wear and which may require corrective action. c) When a casting requires inspection in a fixture, characteristics which the fixture is used to inspect shall be reviewed for evidence of core shift, tooling wear and other abnormalities. Results of this review shall be documented and used when evaluating other dimensional data and when determining when corrective action is required to prevent discrepancies. d) Characteristics which have been reviewed using an inspection fixture do not require layout inspection. A notation indicating that the feature was acceptable by fixture inspection on the inspection report is acceptable Sample Identification Unless otherwise approved by Eaton, all samples which are not fully processed or NDT acceptable and submitted as a whole casting shall have a l/8" diameter drilled hole in a pressure passage wall. This will prevent the part from passing pressure test. In addition, if the casting is not sectioned or covered with blue or red dykum, the part shall be conspicuously identified with paint Sample castings serial numbers shall be marked in the area and by the method specified on the drawing or VQR. If the location is not specified or if a question arises as to the feasibility of marking, the supplier should obtain appropriate instructions through Purchasing Shipping containers shall be clearly marked "Sample Castings" DESTRUCTIVE TESTING 11.1 The supplier shall test material for mechanical properties per the blueprint and/or VQR After supplier testing, mechanical and chemical evaluation is to be submitted to and tested by Eaton Laboratories. Eaton laboratory s test results are to become part of the first article The location of tensile specimens excised from castings shall be clearly defined on a sketch accompanying the first article report Where blueprints do not require specimens cut from a casting, Eaton may require tensile-test specimens cut from a casting for an information basis on initial samples. These results will be used to evaluate a foundry process change and monitor casting production. This requirement will be specified on the purchase order The vendor shall include, with the sample report, the destroyed casting remains, a sketch indicating the areas tested and the tensile results for each area.

9 Page 9 of The vendor shall be advised of previously established mechanical properties and locations on castings when applicable. The new supplier will evaluate the same areas and report results. Results must be similar or superior to previously established mechanical properties Pratt & Whitney Casting Sectioning: When required by the VQR the Foundry control inspection shall include the sectioning of castings. The sectioning plan shall be approved by Eaton. When Pratt & Whitney Casting Sectioning is specified one casting shall be sectioned every 2 years except for a part number which is procured in quantities of less than 100 per year which will require sectioning every (36) thirty-six months or 200 pieces which ever comes first. A damaged part that is otherwise dimensionally and NDT acceptable and representative of the current production lot should be used for this requirement. The evaluation shall be the same as performed on the Third First Article Sample. (Mechanical testing is not required). The results of this evaluation shall be recorded and forwarded to Eaton Quality. The sectioned part shall be retained at the foundry until the next casting is sectioned General Casting Sectioning: When required by the VQR the Foundry control inspection shall include the sectioning of castings. The sectioning plan shall be approved by Eaton. When General Casting Sectioning is specified one casting shall be sectioned every 2 years except for a part number which is procured in quantities of less than 100 per year which will require sectioning every (36) thirty-six months or 200 pieces which ever comes first. A damaged part that is otherwise dimensionally and NDT acceptable and representative of the current production lot should be used for this requirement. The evaluation shall be the same as performed on the Third First Article Sample. (Mechanical testing is not required). The results of this evaluation shall be recorded and forwarded to Eaton. The sectioned part shall be retained until the next casting is sectioned Paragraphs 11.5 and 11.6, while having the same requirements are both listed to retain integrity of VQRs Sectioning is required from the first lot after anniversary date of the last sectioned part EVALUATION AND DISPOSITIONING OF SAMPLES 12.1 Materials Cell Quality Assurance shall document sample evaluation on form ARG-693 "Casting or Forging Sample Release or Rejection" The form ARG-693 shall list the date initiated, part name, part number, purchase order number, sample serial number(s), supplier name, latest blueprint change letter, material and heat treatment, purpose of the inspection, results of the inspection and disposition of samples When applicable, the form ARG-693 shall also list the Master Receiving Record Number, manufacturing lot number, heat number, casting weight and the quantity inspected Supplier Quality Assurance shall review inspection results for accuracy and completeness.

10 Page 10 of When there are no discrepancies listed, Supplier Quality will disposition the sample as acceptable. Dimensions that are near tolerance limits may require correction to prevent discrepancies due to casting process variation Any discrepancies which may effect tooling or finish stock will be reviewed by Supplier Quality and Process Engineering. Disposition shall be documented in section 2 of form ARG All discrepancies shall be reviewed by Supplier Quality Assurance and Product Engineering. One of the following dispositions shall be made for each discrepant characteristic and the disposition shall be documented in section 4 of form ARG-693: A. Acceptable, blueprint will not be changed: Discrepancy is acceptable for the life of the casting tooling. This discrepancy does not effect the design intent. B. Acceptable, blueprint will be changed: Discrepancy is acceptable and will become a permanent part of the design. C. Tooling Correction is required, parts currently in process or a limited quantity of parts having this discrepancy are acceptable. This disposition is used when parts in process can only be used conditionally such as for engineering development or the discrepancy would effect design intent if severity increases. Limitation shall be specified in the appropriate blocks in section 4 of form ARG D. Correction is required; parts exhibiting this discrepancy cannot be used. This disposition is used when Supplier Quality Assurance and/or Product Engineering determine that a discrepant characteristic would affect the design intent. φ 12.6 There shall be a final review of the first article by the Supplier Quality Manager or Casting Team Leader The supplier shall be notified by Purchasing of the final disposition with one copy of form ARG When casting weight control is a requirement on the blueprint the weight shall be determined from the first 100 castings. The established weight will be negotiated with supplier. Gates, risers and other positive metal surface irregularities on machined surfaces will be snagged to.010 maximum silhouette for weight determination. Any overweight casting will be unacceptable. The supplier shall determine the cause of the excessive weight. A. If excessive material on the machine surfaces is the cause of discrepancy, the sample shall be approved. B. Castings with excessive weight may have stock removed by an approved method within the blueprint tolerance from surfaces which "REMAIN CAST" on final configuration After completion of the required tests and inspection, the dimensional inspected samples shall be retained by Eaton. The First Article Sample shall be permanently identified by date and symbol circle f, stored in the layout retention area for life of tooling. Subsequent inspection samples may be stored until the next sample is placed in storage If the sample lot included more castings than required, the additional castings shall be transferred to production stock if dispositioned acceptable.

11 Page 11 of MAINTANANCE OF TOOLING 13.1 After samples have been accepted by Eaton, a certified tool list shall be furnished by the vendor. This shall include a basic description of each item, (core box, iron shell box, die etc.), number of same cavities, if different cavities identify component cavity in each box, and list the number of loose pieces which are not permanently fastened to basic item. This tool list shall be submitted on a vendor's letter head, or on form that is acceptable to Eaton Supplier Quality Eaton tooling at supplier facilities shall be maintained such as to produce acceptable castings. Proof of condition of patterns or die shall be provided upon request of Product Assurance, or at any point in the order where Eaton or the vendor detects a non-conforming or deteriorating condition. Additional tooling examination shall not interfere with product flow and should be made any time problems are suspected The supplier shall maintain fixtures to prevent damage and maintain accuracy. In lieu of annual fixture inspection, the vendor is permitted to scribe the target feature sizes and datum lines on a casting. This casting shall be kept with fixture. Prior to each use, the casting is evaluated in the fixture to assure fixture compliance to specification. Actual fixture inspection should be made only to resolve suspected problems Eaton property shall be stored to prevent deterioration, physical damage or corrosion Inactive casting tooling that the foundry does not want to store shall be processed per SOP FOUNDRY PROCESS CONTROL To control the "Frozen" casting process, as stated in applicable material specifications, QCP 5.8 and all casting VQR's, the foundry shall prepare a master control document. This document shall be type written or hand written in ink with no errors. An Eaton representative will sign the master control document at the foundry after metallurgical approval has been issued. Any changes or strike outs shall be initialed by Eaton. The procedure shall contain all the applicable characteristics listed below. These characteristics require process re-evaluation by Eaton prior to permanent change to the process and/or tooling. Specific elements and parameters not listed below that are critical to the process shall also be specified on the master control document and shall not be altered without prior Eaton approval. When different mold or core materials are introduced, Eaton shall be notified prior to production release. Any castings produced using an unapproved procedure, this includes samples from experimental process revisions, shall not be shipped without prior approval. On an audit visit the procedures on the floor will be compared to this master control document for compliance. NOTE: NONE OF THIS INFORMATION WILL LEAVE THE FOUNDRY. Critical elements where applicable shall include:

12 Page 12 of Tooling. Changes to tooling such as core register, core print, parting lines or replacement of lost or damaged pieces. Any dimensional corrections must be verified by inspecting sample castings prior to production release. The foundry shall maintain records of this verification Rigging. Any changes, additions or deletions in size, shape or location of runners, gates, risers, sprue, or integral specimen. Location includes contact area, shape and size. Verification of replacement of damaged rigging is foundry responsibility Chills. (Mold) Any change in size, contact area, location or chill material. Cast chills require a pattern or description. If machined, a sketch is required Investment Pattern. Type of wax, size and number of chills (inlays), number of patterns on clusters or tree, attitude of pattern to cluster and wax removal procedures Molds. (Molds include cores, body cores (stacks), green sand and investment molds.) A) Sand: Changes in binders, sand type (grain size or shape) or material, core making process (hand packed-vs-machine blown), core racking, core or mold coating, riser stack size or carbon blacking. The foundry shall be responsible for core box venting rework. B) Investment process: change from solid mold to shell, shell to solid or number of coats of shell or mold materials Mold Assembly. Any changes to fixtures, gages, procedures, mold venting and mold coating. For the gages or fixtures used in the manufacture of casting, the vendor shall have on file a sketch defining as a minimum the critical features of this equipment. Eaton reserves the right to review these fixtures and gages Pouring. Any change affecting pouring cycle time, pour temperature, mold temperature, vacuum assist and when vacuum is applied, length of time mold is held on vacuum, grain modification or refining, chemistry, degassing, sequence of metal preparation, and hot topping Mold Removal. Any changes to shake out, burn out or knock out procedures Heat Treat. Any changes in time, temp., atmosphere, quench procedures and media, racking procedures, and heat treat source Targeting/Qualifying. Any changes to methods or tooling PRODUCTION CASTINGS INSPECTION AND SERIALIZATION 15.1 Unless otherwise specified on the blueprint or VQR, inspection of production castings shall comply with TAP-MS Serialization shall marked in accordance with Eaton spec at the location and using the method specified on the blueprint and/or VQR.