HARDNESS INSPECTION

1 PURPOSE & APPLICATION

1.1 This work instruction defines requirements for hardness testing on all products to meet customer requirements. 1.2 It applies to all MTI employees who perform hardness inspection on product. 3.2.1 Perform equipment calibration per Measurement and Test Equipment Calibration, MQ-05-02-00-00. 3.2.1.1 Label the instrument with calibration sticker to indicate calibration status. 3.2.2 Inspector performing hardness inspections shall be certified by means of a period of on the job training under an experienced Inspector/instructor and testing. Re-certification will be performed annually. 3.3 Accuracy Checks 3.3.1 Perform accuracy checks at the beginning of each shift whenever equipment is used, or if the setup (anvil or penetrator) is changed. If the check is being made because of a change in setup, make two preliminary penetrations to ensure that the components are properly seated. These preliminary indentations may be made in scrap stock. 3.3.1.1 Perform the accuracy check of the hardness tester by using a standard test block with a hardness value within 10 hardness numbers of the material to be inspected. 3.3.1.2 Indicated values shall be within standardized test block tolerance. Do not use equipment if indicated values exceed the limits of the test block. 3.3.2 Retrieve certified hardness standard block. 3.3.3 Set hardness load weight and penetrator ball to required setting for the standard block scale per the instructions on the hardness tester. 3.3.4 Prior to obtaining hardness readings, a clean surface shall be maintained on test block standard and anvil. 3.3.4.1 If the penetrator or anvil is changed, a new accuracy test is performed. 3.3.5 Take 3 readings from hardness test block standard at random locations of the upper surface of the block. 3.3.5.1 No impression shall be closer than three impression diameters to a previous impression (center to center) or to an edge of the block (center to edge). Note: If impressions are made any closer than these limits, they are discarded and

2 RESPONSIBILITIES
2.1 Quality Director reviews personnel certification and verifies and audits processes per MTI procedure. 2.2 The Quality Engineering Manager 2.2.1 Oversees employee training and certification. 2.2.2 Reviews daily Accuracy Checks. 2.3 The inspector: 2.3.1 Ensures cleanliness of the work area and equipment. 2.3.2 Maintains records. 2.3.3 Performs preventive maintenance on equipment. 2.3.4 Enters data into production router and applicable databases.

3 INSTRUCTION
3.1 Related Documents 3.1.1 ASTM E18 Rockwell Hardness and Rockwell Superficial Hardness 3.1.2 BAC 5946 Temper Inspection of Aluminum Alloys 3.1.3 BAC 5650 Hardness Testing 3.1.4 DPS 1.05 Hardness Inspection 3.1.5 LES 1106 Hardness Testing 3.1.6 NDTS 1501 Hardness Testing 3.1.7 QES0021 Temper Inspection 3.1.8 BSS 7350 Rockwell Hardness Testing Procedures 3.1.9 RPS 18.11 Hardness and Conductivity Testing 3.1.10 PS 37 Hardness and Conductivity Testing of Metals 3.1.11 AMS 2658 Hardness and Conductivity Inspection of Wrought Aluminum Alloy Parts 3.1.12 BSS 7350 Rockwell Hardness Testing Procedures 3.1.13 5PTPCG09 F 22 Hardness Testing 3.2 General

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another reading is taken.

3.3.5.2 Use the original surface of the test blocks only. Blocks that are punched out or have impressions on both surfaces are to be disqualified and destroyed. 3.3.5.3 If any of the 3 readings are greater than the tolerance listed on the test block, do not use the machine until the cause for the inaccurate reading is found and corrected. If the cause is found to be other than an imperfect anvil, penetrator, or improper seating or load, a qualified person is to perform the repair and recertify the equipment. 3.3.6 Record readings taken from the test block standard in the applicable database. 3.3.6.1 If values are temporarily recorded on paper, use MQ-0422-01-02 to write the values before entering into the applicable database. Take care to record the proper information, leaving no fields blank. After the information is entered into the applicable database, the temporary paper record may be discarded. 3.4 Referee Testing If the result of testing by a second party (vendor or customer) is contested by MTI testing, a certified outside testing facility will be used as a referee to determine the validity of the test. 3.5 Instructions 3.5.1 Count parts and verify quantity to production router requirement. 3.5.2 From the production router, verify material type, temper, and thickness. 3.5.2.1 Using calipers or micrometer, verify actual thickness of one part. 3.5.3 From hardness inspection sequence on the production router, obtain the required hardness values for the parts to be tested to establish which scale should be used for the testing. 3.5.4 Set up hardness tester to achieve the proper load conditions for the scale and material to be checked.

3.5.4.1 If a different scale is used, verify new scale setting using certified standard test block. 3.5.4.2 Red line the production router to reflect new values, verify, and obtain stamps from EDI and Quality. 3.5.5 Hardness inspect parts. 3.5.6 Ensure surfaces to be inspected (both the penetrated and the anvil side) are clean, dry, and free from scale, pits and any other condition that may affect results. 3.5.6.1 If deemed necessary to remove coatings, 120 grit or finer sandpaper shall be used to remove the coating(s). Note: Finishes must be restored to blueprint requirements after testing. 3.5.7 If soft or thin material is tested and an impression is left on the opposite side of the material, the hardness reading is considered invalid. 3.5.8 If material is too thin to be tested, heat treat verification, is accomplished through verification of process paperwork, shop routers, and furnace control charts. 3.5.9 Hardness testing is prohibited on surface plating that is harder than the base metal. 3.5.9.1 10% inspection is required of all shop orders processed with the following exceptions: 3.5.9.1.1 100% inspection required if the parts were hot joggled after solution heat treatment. 3.5.9.1.2 100% inspection required if the parts are too small for conductivity inspection. 3.5.9.1.3 100% inspection required on all 6000 series alloys and any 7000 series alloys in T7XXX condition. 3.5.9.1.3.1 7000 series alloys in T7XXX condition processed per BAC-5602 fall under the 10% inspection requirement. 3.5.9.1.4 If customer requirements state different requirement than 10% inspection. 3.5.9.1.5 100% hardness is required if any part in the lot fails to meet hardness requirements. 3.5.9.1.6 The 10% inspection shall include the part with the highest conductivity testing results and the lowest conductivity testing results. 3.5.9.2 Hardness testing may be performed on test coupons under the following conditions: 3.5.9.2.1 Parts cannot be hardness tested because of size, configuration, or coating. Date Printed

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3.5.9.2.2 Test coupons are from the same lot of material as the parts. 3.5.9.2.3 When applicable, coupons are heat treated in the same heat treat load as the parts. 3.5.9.2.4 All jobs hardness inspected using test coupons must be documented as such on the production router. 3.5.9.3 Inspect parts by making one hardness impression per part (or coupon). 3.5.9.3.1 When reading the dial on the Series 500 ensure that the dial is read at eye level and straight on to preclude the erroneous reading caused by parallax error. 3.5.9.3.2 If the initial reading is outside the expected range the operator will evaluate the test performed to ensure that all appropriate setup and performance parameters were correct (surface finish, parallelism, flatness). 3.5.9.3.2.1 If errors in setup or performance are identified, correct the error and retest the part. 3.5.9.3.2.2 If applicable select a load that provides maximum sensitivity of readings (higher loads for higher hardness). 3.5.9.3.2.3 If the reading was on the Series 500 machine move it to the Series 2000 and utilize the direct reading digital readout. 3.5.9.3.2.4 After taking the actions above take 3 impressions. All impressions must conform to specification. Report the median value. 3.5.9.4 Record the highest and lowest hardness values from the parts tested. For digital readout equipment record the actual hardness displayed, for standard analog equipment record to the nearest one-half-point. 3.5.9.4.1 Corrected values shall be documented as follows: 3.5.9.4.1.1 Record actual value in parenthesis with corrected value listed to the left, (i.e., 91.5 (90.0) HRB.) 3.5.9.4.1.2 Conversion to a different scale shall have actual value and scale inside parenthesis, with converted scale and value outside parenthesis. (i.e., 95.0 (85.0 HRB) HR15T) 3.5.10 Record all applicable information into the production router and applicable database.

3.5.11 Records of daily equipment checks are maintained at the equipment for a minimum of 6-months. Records are then archived as Quality records per MQ-01-07-00-00.

4 REVISION HISTORY Authored by Ray Smith, approved 13 Sep

2002. 4.1 Added requirement for two preliminary penetrations after change of setup prior to Performance of accuracy checks. Specified that one penetration is satisfactory to perform a test. Added requirement to avoid parallax when reading the Series 500 dial. Added referee criteria when the initial reading is in error. Authored by Ray Smith, approved 18 Feb 2003. 4.2 Changed the requirement for accuracy checks from 5 to 3 readings and from the average of 5 readings to requiring all 3 readings to be within the tolerance listed on the standard test block. Authored by Jeff Lennert, approved 6 May 2003. 4.3 Added reference for referee testing. Authored by Steve Adams approved 21 June 2004. 4.4 Added sketch to clarify indent spacing. Authored by Russel Brunson, approved 27 March 2007. 4.5 Updated to incorporate Boeing requirements as applicable to the 10% hardness inspection requirement also changed reference to 6061 series alloys to 6000 series alloys in paragraph 3.5.9.1.3.1. Authored by Steve Reno Adams, approved 23 May 2007. 4.6 Added provision for temporary recording of calibration values before entering into database. Added responsibility for record review. Authored by Corey Judd, Approved July 7, 2010.

Hardness Inspection MQ-04-22-01-00 rev 06

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Approvals
7 July 2010 Date

Document Custodian

Quality Director

7 July, 2010 Date

Hardness Inspection MQ-04-22-01-00 rev 06

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Date Printed

Jul 7, 2010