SAE AS 7200 1A-1994 National Aerospace and Defence Contractors Accreditation Program (NADCAP) Audit and Inspection Procedures and Checklists for the Sealant Manufacturers Accredita.pdf

1、The Engineering Society For Advancing Mobility Land Sea Air and SpaceI N T E R N A T I O N A L400 Commonwealth Drive, Warrendale, PA 15096-0001AEROSPACESTANDARDCopyright 1994 Society of Automotive Engineers, Inc.All rights reserved.Printed in U.S.ASAE Technical Standards Board Rules provide that: “T

2、his report is published by SAE to advance the state of technical andengineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use ,including any patent infringement arising therefrom, is the sole responsibility of the user.”SAE revie

3、ws each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invit esyour written comments and suggestions.Submitted for recognition as an American National StandardREV.AIssued 1990-07Revised 1994-04AS7200/1NATIONAL AEROSPACE AND DEFENSE CONTRACTO

4、RSACCREDITATION PROGRAM (NADCAP)AUDIT AND INSPECTION PROCEDURES AND CHECKLISTS FOR THESEALANT MANUFACTURERS ACCREDITATION PROGRAM1. SCOPE:1.1 This standard includes the procedures and forms to be used by a third party for auditing and on-goinginspection for assessing the capability of sealant manufa

5、cturers to furnish products to indicatedstandards.2. REFERENCES:2.1 Applicable Documents:The following publications form a part of this specification to the extent specified herein. The latestissue of SAE publications shall apply. The applicable issue of other documents shall be the issue ineffect o

6、n the date of the contract.2.1.1 SAE Publications :Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.AS7001 National Aerospace and Defense Contractors Accreditation Program (NADCAP) - Program DescriptionAS7002 National Aerospace and Defense Contractors Accreditation Program(NADCA

7、P) - Rules for ImplementationAS7003 National Aerospace and Defense Contractors Accreditation Program(NADCAP) - Program Operation2.1.2 Military Publications :Available from DODSSP, Subscription Services Desk, Building 4D, 700Robbins Avenue, Philadelphia, PA 19111-5094.FED-STD-368 Quality Control Syst

8、em RequirementsMIL-STD-1535 Supplier Quality Assurance Program RequirementsMIL-STD-45662 Calibration Systems Requirements MIL-S-8802 Sealing Compound, Temperature-Resistant, Integral Fuel Tanks and Fuel CellCavities, High AdhesionMIL-Q-9858 Quality Program RequirementsMIL-I-45208 Inspection System R

9、equirementsCopyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7200/1 Revision A2.1.3 ISO Publications:Available from American National Standards Institute, 11 West 42nd Street, NewYork, NY 10036.ISO

10、 9001 Quality Systems - Model for Quality Assurance in Design/Development, Production,Installation, and ServicingISO 9002 Quality Systems - Model for Quality Assurance in Production and InstallationISO 9003 Quality Systems - Model for Quality Assurance in Final Inspection and Test3. REQUIREMENTS:3.1

11、 The NADCAP program for sealant manufacturers shall consist of the following four parts:Yearly Accreditation of Quality SystemSemi-annual Recheck of Quality SystemBatch by Batch Inspection of Quality Conformance TestsRandom Testing at an Independent laboratory to Confirm Suppliers Quality Conformanc

12、e Tests3.2 The NADCAP program for sealant manufacturers shall use the checklists in the appendices as follows:Appendix A Summary of Sealant Manufacturer Audit (Yearly Accreditation of Quality System)Appendix B Continuous Audit Checklist (Semi-annual Recheck of Quality System)Appendix C Instructions

13、for Audit of Quality Conformance Tests (Batch by Batch Inspection ofQuality Conformance Tests)Appendix D Quality Conformance Tests Checklist (Batch by Batch Inspection of QualityConformance Tests)3.3 Discrepancies:3.3.1 Audit findings are reported in writing to the manufacturer at the exit interview

14、 and to the NADCAPadministrative office in the audit report.3.3.2 Discrepancies in accordance with this document found during ongoing surveillance affecting aparticular batch should be handled between the auditor and the manufacturer. An example of this typeof discrepancy would be the incorrect repo

15、rting of a test value. This may require a change in the testreport or retesting. All discrepancies shall be reported to the NADCAP administrative office. If adisagreement between the auditor and the manufacturer persists, the NADCAP administrative officeshall contact the designated member(s) of the

16、sealant task group for a decision.3.3.3 Discrepancies found during ongoing surveillance affecting multiple batches shall be reportedimmediately to the NADCAP administrative office for placement on the information system. If possible,a statement from the manufacturer should accompany the report. An e

17、xample of this type ofdiscrepancy is a test procedure that has routinely been incorrectly performed. The NADCAPadministrative office should notify the designated member(s) of the task group. The task group shallinvestigate the discrepancy and recommend a course of action.- 2 -Copyright SAE Internati

18、onal Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7200/1 Revision A3.3.4 Discrepancies found when spot checking using AS7200/1 shall be reported to the NADCAPadministrative office. The NADCAP administrative office shall

19、report the discrepancies to thedesignated member(s) of the task group for a recommended course of action and possible inclusionon the information system.4. GLOSSARY:AREA, RESTRICTED ACCESS - An area delineated by barrier or floor marking which is clearly postedagainst unauthorized removal of materia

20、l. Authorization to remove material from a restricted accessarea can come from the Quality Control department only.ACCELERATOR - An ingredient used in a sealant formulation to accelerate the rate of cure.ACCEPTANCE TEST - (also called conformance test) - One of a number of tests called out by aseala

21、nt specification to assure the conformance of a particular batch of product to the physical andchemical requirements for the material. May or may not include all the tests listed in the specification.Acceptance tests are usually performed on each batch of material.ADHESIVE STRENGTH - The strength of

22、 the bond between the sealant and the substrate. It isdesired that the adhesive bond be stronger than the sealant itself. Thus, if an attempt were made topeel the sealant from the surface, the sealant would pull apart before the bond between substrate andsealant would fail.APPLICATION TIME - The tim

23、e available for sealant application following mixing or thawing premixedand frozen sealant. Acceptability limits established for “A“ class, brushable sealants are expressed inthe time required for the viscosity to increase to a specified level at standard conditions. Theacceptability limits for “B“

24、class, extrudable sealants are expressed in terms of the extrusion rate of asealant at standard conditions.ASSEMBLY TIME - (also called “work life“ or “open time“ or “squeeze-out life“) - A term used inreference to faying surface sealants. It refers to the amount of time at standard conditions avail

25、ableafter mixing or thawing in which work can be done before the overlapping surfaces must be closed, stillpermitting squeeze-out of the curing sealant.BASE COMPOUND - The major component of a two-part curing type sealant containing theprepolymer.BATCH - A mass of base compound or catalyst manufactu

26、red at one time. Its identity is maintained byan assigned batch number.BLOCK FLOW - The distance freshly mixed, uncured sealant will sag while hanging from a verticalsurface for approximately one-half hour at standard conditions.CALIBRATION - The comparison of a standard with a higher ranking refere

27、nce standard.CATALYST - The component of a two-part curing type sealant which causes the prepolymer topolymerize.- 3 -Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7200/1 Revision A4. (Continue

28、d):COHESIVE STRENGTH - The strength of internal forces holding a sealant together.CONFORMANCE TEST - See “Acceptance Test“.CURE RATE - A measure of the rate of polymerization based upon the increasing hardness of thesealant with time. The time required to reach the specified hardness varies widely w

29、ith the type ofsealant and with the temperature and relative humidity. Testing is performed at standard conditions.CURE TIME - A measure of the time required for the polymerization to advance to a given hardness atstandard conditions.DUROMETER - A mechanical device used to measure the hardness of a

30、sealant. A Shore A or REX Areading is produced. Some materials are measured on a Shore D scale, which encompasses a higherhardness range.INSPECTION, FINAL - Quality control inspector certification performed after the last in-plant fabrication or assembly operation and prior to preparation for shipme

31、nt.INSPECTION, QUALITY CONTROL - A critical comparison of characteristics to standards required bythe customer.JET REFERENCE FLUID (JRF) - A combination of aliphatic and aromatic liquids, also containingmercaptans, used as a harsh environment to test the resistance of integral fuel tank sealants to

32、jetfuels.KIT - A container or containers in which a one-part or a two-part sealant is packaged. Two-componentkits consist of the base compound in one container and the catalyst in the other.LOT (2-PART MATERIAL) - A quantity of material packaged from a batch of base compound and abatch of catalyst,

33、given a specific identity, and offered for acceptance. This definition also pertains toone-part material except that it is produced from a single batch.MEGOHMMETER - A device which measures the electrical resistance of a sealant (and othermaterials as well).NONCONFORMING MATERIAL - Contract material

34、 which has physical, functional and/or dimensionalvariation or deviation from the applicable specification, or is incomplete.NONVOLATILE MATTER (NVM) TEST - A test for the percentage of nonvolatile matter in a sealant.Generally, volatile solvents are used to produce the desired amount of flow in bru

35、shable and sprayablesealants in particular.OPEN TIME - See “Assembly Time“.PEEL TEST - Sealant is cured on a selected substrate, then peeled from it using one of several typesof testing machines (Scott, Instron, Tinius-Olson). Two factors are of particular importance: the forcerequired to peel it of

36、f and the site of the failure. If it is within the sealant, it is called “cohesive failure“. Ifit fails at the bond line, it is called “adhesive failure“. The former type of failure is preferred.- 4 -Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or n

37、etworking permitted without license from IHS-,-SAE AS7200/1 Revision A4. (Continued):QUALITY ASSURANCE SYSTEM - The combination of policy, organization, personnel, procedures,inspection and test plans which assure that from receipt of materials to shipment of product, the qualityof the product will

38、not be compromised and the performance requirements will be met.REWORK - The action taken to restore nonconforming materials to an acceptable configuration.REX “A“ HARDNESS - The hardness of a sealant as measured by a REX “A“ hardness gauge. It isessentially the same value as Shore “A“ hardness.SEAL

39、 KIT - A copyrighted product. See description under “Two Component Plastic Injection Kit“.SEMKIT - A copyrighted product. See description under “Two Component Plastic Injection Kit“.SHORE “A“ HARDNESS - The hardness of a sealant as measured by a Shore “A“ hardness gauge. Itis essentially the same va

40、lue as Rex “A“ hardness.SOAK TEST - Sealants are soaked in fluids as specified in specifications to determine resistance tothese materials. The conditions are somewhat harsher than are found in actual use.SHEAR TEST - Two narrow strips of aluminum are overlapped at one end by approximately 1 inch an

41、dbonded in this area by sealant. After cure, the specimen is mounted in a testing machine and pulled inopposite directions, creating shear forces in the sealant. The force required for the sealant to fail inshear is a measure of its shear strength.SQUEEZE-OUT TIME - A test performed on faying surfac

42、e sealants at standard conditions. It isessentially the time from the start of mixing of a two-part kit (or the thawing of a frozen tube of sealant)to the tightening of two surfaces with sealant between them. That period of time which still allows thepartially cured sealant to be squeezed out to a p

43、reselected thickness between the two surfaces iscalled the squeeze-out time.STANDARD CONDITIONS - Standard conditions for preparation of sealant samples and testing are77 F 2 (25 C 1) and 50% 5 relative humidity.STANDARD, CONTROL - A measuring or controlling device used to provide assurance that all

44、owableprocess variation has not been exceeded.STANDARD, REFERENCE - The most accurate company utilized device for assuring the accuracy ofcontrol and acceptance standards by periodic comparison.STANDARD, TRANSFER - A standard device of reference-standard caliber to be used in calibratingcontrol or a

45、cceptance standards which cannot readily be brought to the reference standard.- 5 -Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-SA E AS7200/1 Revision A4. (Continued):TACK FREE TIME - The time requi

46、red at standard conditions for a curing sealant to lose its surfacetackiness as determined by placing a small piece of polyethylene film on its surface and then peelingthe film away. The sealant is tack free when no sealant is removed by the film.TECH KIT - A copyrighted product. See “Two Component

47、Plastic Injection Kit“.TEST REPORT - A report listing physical and chemical properties of a sealant. Test reports aregenerated for every batch of aerospace sealant manufactured. Generally, the tests are thoseacceptance tests called for by a given specification.TRAVELER - Documentation which travels

48、with material in-process, identifying it, indicating the stepsof processing necessary, the inspections required, the approvals as initialled by compounders andinspectors. Compounders indicate steps completed. Inspectors confirm quality standards have notbeen compromised.TWO COMPONENT PLASTIC INJECTI

49、ON KIT - A two component plastic injection kit packages thebase compound and catalyst of a two-part sealant in separate sections until the time of use. The basecompound is contained in a 2-1/2 or 6 fluid ounces polyethylene cartridge, fitted with a plunger at oneend and a hollow dasher rod (in which the catalyst is stored) at the other. An agitator is attached to thedasher rod inside the cartridge. The catalyst is mixed with the base compound by inserting a ramrodinto the dasher rod, f