quality control instruction

42
1110 Maple Street P.O. Box 300 Elma, New York 14059-0300 716-655-5990 FAX 716-655-6012 QCI 98 Rev M This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc. QUALITY CONTROL INSTRUCTION NUMBER QCI 98 REVISION M TITLE: Visual Inspection Criteria PURPOSE: To provide standard procedures to properly define “Appearance and Condition” criteria for Visual Inspection CUSTOMER (if applicable) Servotronics, Inc. ADDITIONAL INFORMATION:

Upload: others

Post on 10-Dec-2021

5 views

Category:

Documents


0 download

TRANSCRIPT

Page 1: QUALITY CONTROL INSTRUCTION

1110 Maple Street ♦ P.O. Box 300 ♦ Elma, New York 14059-0300 ♦ 716-655-5990 ♦ FAX 716-655-6012

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

QUALITY CONTROL INSTRUCTION

NUMBER QCI 98 REVISION M

TITLE: Visual Inspection Criteria

PURPOSE: To provide standard procedures to properly define “Appearance and Condition” criteria for Visual Inspection

CUSTOMER (if applicable)

Servotronics, Inc.

ADDITIONAL INFORMATION:

Page 2: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

2

TABLE OF CONTENTS 1.0 Purpose 3

2.0 Scope 3

3.0 Applicable Documents 3 4.0 Definitions 3-4

5.0 Responsibilities 4 6.0 Procedure

6.1 General Requirements 5

6.2 Foreign Object Debris (FOD) 5-6

6.3 Machined Parts/Components 6

6.4 Metering Posts 7-10

6.5 Braze Joints 11-12

6.6 Sandblasted Solder Joints 12-14

6.7 Castings 15

6.8 Surface Condition 15-22

6.9 Paint / Coated Surfaces 23-24

6.10 Coils 25-27

6.11 Tubing and Lead Wires 28-29

6.12 Appearance of Fasteners 29

6.13 Elastomeric Components 30

6.14 Parts Marking / Stamping / Laser 30-31

6.15 Connectors 31

6.16 Lock Wire 32

6.17 Workmanship 33-34

7.0 General Quality Acceptance Limits 35-39

Page 3: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

3

1.0 PURPOSE

To provide standard procedures to properly define “Appearance and Condition” criteria for Visual Inspection. 2.0 SCOPE

This procedure is applicable to all Servotronics, Inc. personnel performing visual inspection. Drawing and approved process specification documents take precedence over this procedure.

3.0 APPLICABLE DOCUMENTS

3.1 General The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents in effect at the time of release of this document shall be in effect.

3.2 Non-Government Publications

• J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies • IPC-A-610 Acceptability of Electronic Assemblies • Student Handbook, Worker Proficiency Training, IPC-A-610 PTH

3.3 Servotronics Publications

• Memo Dated 2/1/88 Defining “Appearance And Condition” • EI 178 Brazing Of Steels, Copper, Copper Alloys & Nickel Alloys • EI 685 Paint specification for Garrett Fluid Systems Programs • EI 690 General Work Instructions for Lock Wiring and Safety Cable • EI 833 Inspection of Stranded Wire, Lead Wire-Magnet Wire, Wire Solder Joints and Lead Wire-

Connector Solder Joints • EI 903 Coil Manufacturing • ER 1715 Investigation of PWC Returned PN 31J2857-04 (SN TR1773) REV A • QCI 42 Non-Conforming Material • QCI 96 Flourosilicone Material (O-Rings) • QCI 129 Surface Finish Verification • QSP 112 Inspection & Test Status

3.4 Hamilton Sundstrand

• HS1550 Rev. J – Process specifications for Cleanliness, Preservation and Handling of Products

3.5 Woodward • QP-1039 Rev. 21 – Visual Inspection Controls

3.6 Honeywell

• 41-10748 Rev. E – Workmanship Manual • GPS3300-1 Rev. AN – Paint Coating, Application of • HPS1010 Rev. C – Application of Paint Coatings

3.7 Aero Engine Controls

• ES-31-035 Issue 6 – Visual Acceptance Guideline

3.8 Pratt and Whitney Canada • CPW 543 Rev. L – General Requirements for Visual Inspection

Page 4: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

4

4.0 DEFINITIONS

• Base Metal – The metal or alloy that is brazed.

• Braze Joint – A component or components that have been fit up and prepared for brazing.

• Brazing – A group of joining processes that produce the coalescence of materials by heating them to the brazing temperature in the presence of a brazing filler metal having a liquidus above 840˚F (450˚C) and below the solidus of the base metal. The brazing filler metal, which may be preplaced or formed, is distributed and held between the closely fitted faying surfaces of the joint by capillary action.

• FOD – Foreign Object Debris or Foreign Object Damage (used interchangeably)

• Foreign Object – Unwanted object, debris, or article that has the potential to negatively impact a

component, subsystem, or system.

• Fastener – Screw, bolt, plug or other hardware device that mechanically joins or affixes two or more objects together.

• Fit – The ability of a product to interconnect with or become an integral part of another product.

• Flux – A material used to hinder or prevent the formation of oxides and other undesirable substances in

molten metal and on solid metal surfaces, and dissolve or otherwise facilitate the removal of such substances.

• Form – The shape, size, dimensions, and other physically measurable parameters that characterize a

product.

• Function – The action or actions that a product is designed to perform.

• Joint – The junction of the component(s) or the edges of the components that are to be joined or have been joined.

• Lock Wire – Lock wiring is the securing together of two or more parts with a wire, which shall be installed so

that any tendency for a part to loosen will cause an additional tightening of the lock wire. Lock wire is not a means of obtaining or maintaining torque, but a safety device used to prevent disengagement of the part.

• Major Dimension/Feature – A characteristic or feature, other than critical, which could contain a defect that

is likely to result in partial performance degradation which may result in a marginal reduction in the products performance and intended purpose.

• Minor Dimension/Feature – Characteristic or feature which could contain a defect that is not likely to result

in performance degradation therefore it would have little or no effect on the operation or use of the end product.

• Non-Conforming Product/Material – Material, component, subassembly or finished product that does not

conform to specified requirements. It also includes non-conforming product returned from a customer.

• Pigtail – Termination point of lock wire.

• Porosity – Cavity-type discontinuities formed by gas entrapment during solidification.

• Rework- actions taken to a nonconforming part or product to make it conform to original requirements.

• Scrap- nonconforming product or material which is unusable for its intended purpose and cannot be returned to a conforming condition.

All other definitions pertaining to quality requirements can be found in section 7.0, General Quality Acceptance Limits.

Page 5: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

5

5.0 RESPONSIBILITIES

5.1 Servotronics Inc. Employees Responsible for Visual Inspection of Parts Visually inspect parts/components in accordance with this procedure.

6.0 PROCEDURE

6.1 General Requirements Unless otherwise specified, visual inspection shall be performed without the use of magnification under normal lighting conditions (100 foot candles minimum). If abnormalities are found, optical magnification is permissible.

Visual Inspection Requirements Inspection Level

Parts marking (including serialization) and acceptance symbols 100% Completeness of assembly 100% Damage 100% Orientation and alignment 100% Welds and Brazes 100% Presence of sealants and lubricants 100% Presence of protective end caps (tubes, hoses, electrical connectors) 100% Plating, Coating, Surface Treatment and Protective Finishes 100% Fuel holes and oil holes/passages 100% Cleanliness 100% Corrosion 100% Adhesive Bond 100% Evidence of Staking 100% Contamination and freedom of debris in internal passages 100% Radii 100% Surface Finish Cosmetic Appearance (Scratches, fingerprints, uniform color, etc.) 100%

6.2 Foreign Object Debris (FOD) 6.2.1 Visual inspection of parts for FOD shall be 100% visually inspected with an unaided eye at a

minimum distance of 18”. If abnormalities are found, optical magnification is permissible. If no abnormalities are found, part is deemed acceptable

UNACCEPTABLE – FOD UNACCEPTABLE – FOD

Page 6: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

6

6.3 Machined Parts/Components 6.3.1 The external surfaces of machined parts/components shall be visually inspected to make certain

there are no nicks, gouges, scratches, dents or burrs which may violate the surface finish or edge break requirements specified by the drawing (refer to QCI 129, for surface finish inspection requirements). Three (3) diopter illuminated (100 foot candles minimum) magnification may be used to aid in the inspection process.

6.3.2 Machined parts/components which have internal passages shall be inspected to the criteria listed above, using 5 to 10X illuminated magnification, or to the criteria listed on the ICL Card Operation Sheet, Engineering Instruction Drawings, Engineering Instruction #1272 or Quality Control Instruction.

6.3.3 Valve Body and Nozzle Block Surfaces

6.3.3.1 All valve bodies and nozzle blocks must be 100% visually inspected for scratches, nicks, gouges, dents or burrs which may violate the surface finish or edge break requirements specified by the drawing.

6.3.3.2 Visual inspection shall be performed without magnification however, if a nonconformance is suspected magnification may be used to aid in evaluating the condition.

6.3.3.3 Any valve body or nozzle block with a surface imperfection such as a scratch or dent which cannot be clearly defined as acceptable or rejectable should be evaluated using the surface defect scriber as per QCI 129, surface finish verification.

UNACCEPTABLE – FOD

UNACCEPTABLE – FOD UNACCEPTABLE – FOD

Page 7: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

7

6.4 Metering Posts

6.4.1 This section is intended to clarify the inspection method and disposition of surface finish found on

metering posts that could be affected by scratches.

6.4.2 General Conditions:

6.4.2.1 A scratch must appear under 10x power using a microscope (0.1” or less in length). A maximum of three scratches are allowed on each end (0.200”) of the two diameters. Only use a higher magnification (20x max) to identify damage.

6.4.2.2 Scratches are not to be included in surface finish measurements.

6.4.3 Critical Area: A 0.015” boundary around each orifice (4), see Figure 4.

6.4.4 Process:

6.4.4.1 Using the surface finish comparator as per QCI 129 verify all metering posts meet the

surface finish requirements specified by the drawing. If the requirements have not been met disposition the parts as per QCI 42.

6.4.4.2 Visually inspect for scratches, nicks, gouges, dents or burrs which may violate the

surface finish or edge break requirements specified by the drawing. Visual inspection should be performed without magnification however, if a nonconformance is suspected magnification may be used to aid in evaluating the condition.

Ground Flats

Small Diameter Orifice Large Diameter

Critical Area Boundary

Figure 1

Page 8: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

8

6.4.5 Surface Finish Categories for Metering Posts:

6.4.5.1 Minor

A minor surface finish defect is one with a superficial scratch with an apparent depth (thumbnail check) in a non-critical area under normal lighting conditions.

A minor superficial scratch does not have raised material (burr) that could be sheared or separated during assembly. A minor scratch is considered acceptable to Servotronics engineering as cosmetic on an insignificant surface area; therefore it is not to be rejected for surface finish. This type of scratch will not affect the fit, form or function of the assembly.

6.4.5.2 Major A major surface finish defect is one in a critical area and is likely to cause a loss of functionality or performance due to its location. A major scratch exhibits raised material that could be sheared or separated during assembly. A major scratch in a critical area cannot be used and must be rejected and dispositioned as scrap. A major scratch in a non-critical area can be reworked and re-inspected as necessary.

Acceptable – minor, non-critical area Acceptable – minor, non-critical area

Page 9: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

9

Rework – major, non-critical area Rework – major, non-critical area

Rework – major, non-critical area Rework – major, non-critical area

Raised Material

Raised Material

Page 10: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

10

Scrap – major, non-critical area, leak path Scrap – major critical area, leak path

Scrap – major, critical area, leak path

Scrap – major, critical area, leak path Scrap – major, critical area

Page 11: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

11

6.5 Braze Joints 6.5.1 Braze joints shall be visually examined under 3 diopter illuminated (100 foot candles minimum)

magnification. 6.5.2 The braze joint shall have a uniform fillet with no evidence of excessive voids, external porosity,

concentrated surface porosity, linear surface porosity, cracks, blistering, undercutting or evidence of flux residue. There shall be no evidence of excessive braze in the f area which would affect the function of the component. Braze alloy on the active length of cantilever or torsional springs shall not be allowed. (reference Brazing on Spring-Armature-Flapper Assembly for spring area on SAFA)

• Voids - The joint shall not contain voids in excess of 15 percent of the total joint area.

• External Porosity (Pinholes) - The maximum diameter permissible is 0.015 inch with a maximum of one pinhole of the maximum diameter per 0.25 linear inch of braze joint. The maximum depth of the maximum diameter pinhole shall not exceed 10 percent of the braze depth.

• Concentrated Surface Porosity - An area of concentrated porosity which is less than 50 percent of the faying (brazed) surface is acceptable providing the sum of the diameters of the pinholes in the area does not exceed 0.015 inch. Only one such concentrated area shall be permitted per linear braze joint.

• Linear Surface Porosity - Linear porosity shall not exceed 0.187 inch and the sum of the diameters of the pinholes shall not exceed 0.015 inch.

• Blistering - Overheating of the base material resulting in blistering on the surface of the base metal shall be cause for rejection.

• Undercutting - Melting or erosion of the base metal adjacent to the braze joint shall be limited to a maximum depth of 5 percent of the stock thickness and a maximum of 15 percent, cumulative, of the braze fillet length.

• Cracks - There shall be no evidence of cracks in the braze joint or the adjacent base material.

• Flux Residue - A greenish glass-like substance on or in the area of the braze joint is characteristic of flux residue. This could lead to long term corrosion and failure of the joint and is not acceptable. If noted, the components should be re-cleaned by immersion in heated clean water.

6.5.3 Brazing on Spring-Armature-Flapper Assembly (SAFA) The spring and transition radius area for all SAFA’s must be completely free of braze. Fracturing may occur in the soft/weak braze material and the fracture may spread to the spring (or transition radius) over time and cause it to break. Reference: ER 1715 Investigation of PWC Returned PN 31J2857-04 (SN TR1773) REV A

Page 12: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

12

6.6 Sandblasted Solder Joints

6.6.1 Sandblasted Solder Joints shall be visually examined at 1.75X to 3X magnification (J-STD-001 table 11-2), supplemental illumination may be necessary. The joint shall have a uniform fillet with no evidence of excessive voids, external porosity, or evidence of flux residue.

• Wetted Solder - The destination land area does not have to be covered with wetted solder.

• External Porosity (Pinholes) - The maximum diameter permissible is 0.015 inch with a maximum of one pinhole per 0.25 linear inch of solder joint. The maximum depth of the pinhole shall not extend to the frame.

• Vertical Fill – Solder must fill 75% of the height between the wire support and the hole in torque motor frame (“wall” of hole) but may exceed 100% fill provided evidence of wetting (fillet) exists, to a maximum of 25% of the height of the barrel portion of the wire support and same distance from barrel on frame.

No Braze allowed in indicated areas

Broken spring as a result of brazing left

on area

Page 13: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

13

“Wall” of hole is in lighter gray

6.6.2 Visual Inspection Criteria for sandblasted solder of wire support on Honeywell 99-D0403 and similar units: 6.6.2.1 The visible side of the soldered wire support is the destination side of the solder, (not

the source side) and should be inspected only to the criteria of destination side solder: 6.6.2.2 Circumferential wetting (solder flow at less than a 90˚ angle) shall be 270˚ minimum,

but no voids between the barrel portion of the wire support and the wall portion of the hole in the frame shall be visible. Flange of wire support shall not be visible. See diagrams.

REFERENCE: Student Handbook, Worker Proficiency Training, IPC-A-610 PTH, Supported: Table 6-2 & J-STD-001 9.2.5.1, Table 9-1, 11.2.2, 11.2.2.1

WIRE SUPPORT Destination side of wire support before soldering – note gap between barrel and hole is greatly exaggerated: (below)

Page 14: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

14

BARREL OF WIRE SUPPORT POSITIONED THROUGH HOLE IN FRAME After soldering, the joint looks like this:

Land area - here the frame around the hole – does not need to be covered with wetted solder.

Vertical fill of solder needs to be 75% of the height of the “wall” of the hole minimum, but can be above 100% above as shown, with a fillet not exceeding 25% of the barrel height.

After sandblasting, an acceptable visual - Note pinholes do not penetrate to the wall of the hole:

Per Student Handbook, Worker Proficiency Training, IPC-A-610 PTH, Supported: Table 6-2:

Reference: Student Handbook, Worker Proficiency Training, IPC-A-610 PTH, Supported: Table 6-2 & J-STD-001 9.2.5.1, Table 9-1, 11.2.2, 11.2.2.1

Page 15: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

15

6.7 Castings 6.7.1 The external and/or internal surfaces of casting shall be visual inspected to be certain that they

do not contain pitting, scaling, sand or gas holes. A minimum of three (3) diopter illuminated (100 foot candles minimum) magnification shall be used to aid in the inspection process.

6.7.2 Where the drawing or purchase order do not provide detailed requirements for casting quality verification the following visual criteria shall be used:

• Surface Finish - Casting surface finishes are not easily measured by methods that work

well for machined products; therefore, a visual surface comparison shall be made. All surface finishes shall be 125 RMS or better. All surface roughness, positive metal, and negatives which will be removed by subsequent machining are considered acceptable.

• Positive Metal - Due to the nature of the investment casting process, random positives are encountered and vary by alloy and part configuration. Unless otherwise specified they will be limited to a size of 0.015 - 0.030 inch high by 0.125 inch by 0.125 inch and no more than one per square inch. Smaller defects of all sizes may be present at random, but not in places where they interfere with the function of the part - such as holes, knurls, or lettering, etc.

• Surface Pits - Random negatives may also occur. They will be limited to 0.030 - 0.060 inch diameter by 0.030 inch deep, no more than one per square inch, unless otherwise specified. Smaller negatives may be present, providing they do not interfere with the function of the part.

• Non-Fill - Edges may be rounded up to 0.015 radius, unless otherwise specified.

• Linear Indications - Parts shall not contain linear cold shuts, or discontinuities.

• Cold Shut - An imperfect junction between two flows of metal in a mold caused by the surface of the streams of metal chilling too rapidly, or in effect, being chilled to the extent that fusion does not occur. This discontinuity may have the appearance of a crack or seam with smooth or rounded edges.

• Discontinuity - An interruption in the normal physical structure or configuration of a part such as cracks, inclusions, and porosity, which may or may not affect the usefulness of a part.

• Cleanliness - Castings will be sand, grit or shot blasted to remove casting and heat treatment scale or other foreign material. Castings may have sand blasted, grit blasted or vibro-polished surfaces and be of uniform appearance typical of those processes, unless otherwise specified.

6.7.3 If the drawing/purchase order requires the castings to be X-rayed the X-rays must be examined to be certain that the castings do not contain porosity which would violate the casting classification specified.

6.8 Surface condition: Unaided Visual Inspection

6.8.1 The external surfaces of components shall be 100% visually inspected with an unaided eye at a

maximum distance of 12” to make certain there are no scratches, nicks, gouges, pits, dents, burrs and other surface imperfections which may violate the surface finish or edge break requirements specified by the appropriate customer drawing/specification.

6.8.2 Scratches can be categorized into 4 categories based on severity, refer to General Quality Acceptance limits for clarification. If a scratch cannot be clearly defined as acceptable or rejectable use a surface defect scriber as per QCI 129 to evaluate the condition.

Page 16: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

16

6.8.3 Reference QCI 129, Surface Finish Verification for Evaluation of O-ring Port Sealing Surfaces, Evaluation of Isolation Tube O-ring groove Sealing Surfaces and Evaluation of Machined Surfaces (non-sealing).

6.8.4 Unless otherwise specified from the drawing, edges must be broken (blended) of all sharp edges,

0.003” - 0.015” and all corners to have fillets of 0.005” - 0.020”.

6.8.5 Tapped, drilled and reamed holes shall be free from dirt, chips and burrs.

6.8.6 If the flaw is confirmed and components do not meet drawing requirements for surface finish and require rework or repair, they shall be processed in accordance with QCI 42, nonconforming material.

6.8.7 Flaws which affect part function are not acceptable regardless of size.

6.8.8 Anodized Parts

6.8.8.1 Anodized surfaces shall be 100% visually inspected with an unaided eye at a

maximum distance of 12”. Scratches should be examined for evidence of penetration to the base metal. Penetration to base metal is unacceptable.

6.8.8.2 Intentional breaking of anodize: This specification requires avoidance of mechanical

damage to anodize. At times, there are requirements for part marking that allow for invasive methods such as lasering, scribing, engraving or impression stamping. SVT will allow such marking followed by localized conversion coating to ensure corrosion protection.

6.8.8.3 The total of all localized conversion coating restoration of protection on anodized parts

is not to exceed the allowance of five (5) percent of the part surface.

ACCEPTABLE Superficial Scratch (CAT 1)

ACCEPTABLE No raised edges

ACCEPTABLE Blemish: No parent Metal exposed

ACCEPTABLE Blemish: No parent Metal exposed

Page 17: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

17

ACCEPTABLE Surface finish

ACCEPTABLE Surface finish

ACCEPTABLE Machine mark no raised material ACCEPTABLE

Machine mark no raised material

UNACCEPTABLE (CAT 3)

UNACCEPTABLE (CAT 3)

UNACCEPTABLE (CAT 3)

UNACCEPTABLE (CAT 3)

Page 18: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

18

UNACCEPTABLE – Scratch (CAT 2)

UNACCEPTABLE Scratch (CAT 2)

UNACCEPTABLE Scratch (CAT 2)

UNACCEPTABLE - Dent UNACCEPTABLE - Dent exhibits raised material

UNACCEPTABLE Burr: Raised Material

UNACCEPTABLE – Dent exhibits raised material

UNACCEPTABLE – Dent exhibits raised material

Page 19: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

19

UNACCEPTABLE – Pitting

UNACCEPTABLE – Dent exhibits raised material

UNACCEPTABLE – Ding

UNACCEPTABLE - Dent

UNACCEPTABLE – Part damage

UNACCEPTABLE - Dent

UNACCEPTABLE - Dent

UNACCEPTABLE – Damage

Page 20: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

20

6.8.9 Plating:

6.8.9.1 Electroplated coatings shall be 100% visually inspected with an unaided eye at a maximum distance of 12”. Electroplated coatings such as chrome, nickel and copper may exhibit slight surface discontinuities.

6.8.9.2 Plating on optional areas of parts is subject to inspection for adhesion and visual

inspection for blistering, pitting, flaking and discoloration.

6.8.9.3 Slight discoloration caused by baking for hardness, adhesion or other specification requirement is normally cause for rejection. Heavy oxides, sulfides, pitting and similar conditions are not proper workmanship and are cause for rejection.

UNACCEPTABLE Thread damage UNACCEPTABLE

Thread damage

ACCEPTABLE Discoloration and surface Marking

Page 21: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

21

6.8.10 Acceptance Criteria for surface imperfections (i.e. dents, scratches, gouges, nicks) 6.8.10.1 This acceptance criteria applies to machined components, particularly valve bodies

and nozzle blocks and is to be used a guide to determine when a surface imperfection/damage on a part is acceptable.

6.8.10.2 When deciding if an imperfection /damage on a part is acceptable the following should

be considered:

1. Will the imperfection affect form, fit or function? consider location of the defect

2. Does the imperfection violate drawing, process or customer requirements?

(refer to applicable drawings, E.I’s, Op sheets, QCI’s, or customer documents when necessary)

a. If the imperfection will affect form, fit or function and/or violates drawing, process or customer requirements, the part shall be rejected (per QCI 42) and either reworked or scrapped.

b. If the damage will not affect form fit or function and does not violate

drawing, process or customer requirements, proceed to question 3.

3. Is the imperfection easily identifiable without magnification? a. No - the part is acceptable. b. Yes - proceed to the next question.

4. Does the part appear to have depth?

a. Yes, use the surface defect scriber with a 1mm probe (as per QCI 129) to determine if the imperfection has depth. If the imperfection can be felt with the 1mm probe the part shall be reworked when possible. If the imperfection cannot be reworked the part shall be dispositioned as scrap.

b. If the imperfection does not appear to have depth and/or cannot be felt with the 1mm probe, the part may be accepted provided that is meets the acceptance criteria defined in the previous steps.

Page 22: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

22

6.8.10.3 Process flow diagram - Guide for determining when surface imperfection is acceptable

Will the imperfection affect

form, fit or funciton?

YesNo Reject/Rework

Surface Imperfection Identified

Will it violate drawing or customer

requirements?

No Yes

Can the imperfection be easily identified without

magnification?YesNo

AcceptDoes the part

appear to have depth?

YesNo

Use surface defect scriber

with 1mm probe

Can the imperfection be felt

when using the 1mm probe?

No Yes

Page 23: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

23

6.9 Paint/Coated surfaces: Unaided Visual Inspection 6.9.1 Painted coatings are used to provide protection from corrosion and/or as a cosmetic coating to

provide uniformity of appearance or identity of function. 6.9.2 Color: Slight variation on color from batch to batch is acceptable. Slight variation in color within a

lot of parts is acceptable. Variation of color on a single part is not acceptable.

6.9.3 Unless otherwise specified, all Painted / Coated surfaces shall be 100% visually inspected with an unaided eye at a minimum distance of 18”. At a minimum distance of 18”, surfaces shall have complete uniform coverage without noted blemishes, paint buildup, brush marks or overspray. All Painted / Coated surfaces shall be free from dirt, grease, oil, nicks, scratches, void/pin holes, blisters, sags, runs, orange peel, Fisheyes, peeling, cracks, and other irregularities per Definitions/Abbreviations in Section 5.0.

6.9.4 Special attention shall be given to bores and passages to verify that blockage does not occur as a

result of application of primer or top coat.

UNACCEPTABLE Paint blockage in passage

UNACCEPTABLE – Paint on body

UNACCEPTABLE – Void UNACCEPTABLE – Paint on body

UNACCEPTABLE – Peeling UNACCEPTABLE FOD if visible at 18″ distance

Page 24: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

24

UNACCEPTABLE – Void UNACCEPTABLE – Blister

UNACCEPTABLE – Blemish UNACCEPTABLE – Peeling

UNACCEPTABLE – Overspray UNACCEPTABLE – Sag

UNACCEPTABLE Paint overspray on wires

Page 25: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

25

6.10 Coils for individual coil inspection prior to assembly into torque motor or servovalve 6.10.1 Visually inspect coils 100% for the following using five (5) to ten (10) diopter magnification and a

minimum illumination of 100 foot candles.

NOTICE Extreme care must be taken during the coil manufacturing and inspection processes, especially when handling the coil lead wires.

No extreme bending of the lead wires is permitted, especially in the area where they exit the

coil body.

6.10.2 Surface contamination such as grease, oil, dirt, epoxy and other foreign materials should not be present.

6.10.3 Foreign material is not embedded in the encapsulation epoxy nor are loose particles/chips of epoxy or fiberglass on the coil surface.

6.10.4 Visually inspect per pictorial conformity to drawing.

6.10.5 Flashing must be removed from the window area.

6.10.6 Flashing must be removed from the outer edges.

Figure 3 (Unacceptable Coil)

Wires are swollen and tapered. Note the white discoloration of the wire due to stretching. Wire insulation is broken at the coil interface.

Figure 2 (Good Coil)

Good Coil is free of flashing in the window area and outside edges. Wires are clean of epoxy and no foreign objects are embedded in the epoxy. No delamination exists and note the color and location of the lead wires.

Page 26: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

26

6.10.7 No delamination of epoxy/face shims shall occur on edges. There shall be no major cracks in the coil epoxy that would cause it to fail hypot. If in question have the coil retested for hypot requirement. Delamination of the coil may not exceed 10 percent of the total surface and must pass hypot. The amount of delamination that peels, chips or flakes away shall be left up to the applicable project engineer.

6.10.8 Ensure lead wires are the correct colors.

6.10.9 Lead wire insulation shall not be damaged (nicked) to the extent that hypot failure could occur. No, kinks are allowed adjacent to lead wire/coil interface. The outside diameter of the lead wire shall be uniform. Limp wires with a white discoloration and the wire tapering down toward the coil body are indications of damaged wire strands. The lead wire insulation shall not be stretched, or swollen from solder wicking under the insulation.

6.10.10 Ensure epoxy has not wicked up onto the lead wires at coil interface. Epoxy that is located under

the tubing with no possibility of becoming free shall be deemed acceptable. If nicks or tears are present in the tubing combined with epoxy underneath, refer to the cognizant project engineer for final acceptance, rejection, or repair.

6.10.11 Lead wires must exit the coils from the correct locations.

6.10.12 Lead wires must have the correct 45 degree bend, inside the encapsulation epoxy (if applicable).

6.10.13 Verify shims are installed (if applicable).

6.10.14 Using a caliper, measure the length and width of the coil window per print.

Figure 4 (Acceptable Coil Wires)

Pay attention to the wires above. Wires are free from epoxy, have no nicks and there is no sign of wire stretching.

Page 27: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

27

6.10.15 Using a caliper measure the parallelism of the window to the outside of the coil. This is achieved by measuring the distance from the outside edge of the coil to the inside of the window at both ends of the window. Window taper not to exceed 0.005.

6.10.16 Using a caliper, measure the overall length and width of the outside of the coil per print.

6.10.17 Using a caliper measure the thickness of the part per print.

6.10.18 Visually inspect the coil to insure that the corner radii are present per print.

6.10.19 An area of concentrated porosity which is less than 50 percent of the surface along its major axis

is acceptable provided that the sum of the pinholes in the area does not exceed 0.050 inch. Only one such concentrated area shall be permitted. Areas of chipped or missing epoxy along the coil edge shall not be more than 15% of the total coil surface.

6.10.20 The maximum diameter of voids and pinholes permissible is 0.050 inch with the depth of not more than 10 percent of the thickness of the coil.

6.10.21 Past 1/8 inch from the body, small holes, nicks and tears in the sleeving are permissible. Within

1/8 inch from the body, holes are permitted in the sleeving when:

• there are no holes, nicks, cuts in the wire’s insulation

• The wire’s insulation shows no signs of stress, exhibited by white color or pinched surface.

• The action taken to cause the hole has not pulled, pinched, and torn the remainder of

the sleeving at the location of the hole.

• The hole or holes total width is less than 25% of the circumference of the sleeved wire.

6.10.22 Chipped, broken or cracked coil “nubs” are not permissible. Coils having “nubs” that are chipped,

broken or cracked shall be referred to the cognizant project engineer for final acceptance, rejection, or repair.

Page 28: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

28

6.11 Tubing and Lead Wires on Torque Motor and Servovalves Does not apply to tubing and lead wires on individual coil piece parts. For inspecting tubing and lead wires on individual coils prior to assembly, refer to coils section of this document. 6.11.1 Lead Wires

Lead Wires shall be 100% visually inspected with an unaided eye at a maximum distance of 12” to be certain that they do not contain cuts or breaks and are not pinched or ragged. There shall be no exposed wiring.

• Check for pinched or crushed wires

• Check for cuts, breaks, cracks or splits in the lead wire insulation. Reference:

o EI 833 Inspection of Stranded Wire, Lead Wire-Magnet Wire, Wire Solder Joints, and Lead Wire-Connector Solder Joints

o J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies

o IPC-A-610 Acceptability of Electronic Assemblies

• Check that insulation thickness has not been reduced by more than 20%. Reference:

o EI 833 Inspection of Stranded Wire, Lead Wire-Magnet Wire, Wire Solder Joints and Lead Wire-Connector Solder Joints

o J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies

o IPC-A-610 Acceptability of Electronic Assemblies

• Check for uneven or ragged pieces of insulation (frays, tails and/or tags) greater than 50% of the insulation outside diameter. Reference:

o EI 833 Inspection of Stranded Wire, Lead Wire-Magnet Wire, Wire Solder Joints, and Lead Wire-Connector Solder Joints

o J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies

o IPC-A-610 Acceptability of Electronic Assemblies

6.11.2 Heat Shrunk Tubing

Tubing that has been heat shrunk shall be 100% visually inspected with an unaided eye at a maximum distance of 12” to be certain that they do not contain cuts, tears, creases, blisters, splits, holes, or dark or cloudy areas (possible indication of overheating).

6.11.3 Tubing Tubing shall be 100% visually inspected with an unaided eye at a maximum distance of 12” to be certain that they do not contain cuts, tears, creases, blisters, splits or holes.

ACCEPTABLE – Tubing is clamped UNACCEPTABLE Tubing is not clamped

Page 29: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

29

6.12 Appearance of Fasteners 6.12.1 Fasteners shall be 100% visually inspected with an unaided eye at a maximum distance of 12”.

Large burrs (higher than 0.015 in.) or edge damage to the slots greater than 0.020 in. wide is not acceptable. Distortion of the slot exceeding 50 percent of the original slot width is not acceptable. For socket types (Allen, Torex, etc.) including cap screws, the limits are half that for slotted, except that the limit for burrs is the same as the slotted.

6.12.2 For fasteners that will be lockwired subsequent to tightening, any nicks, burrs or disturbed metal that interferes with or damages the lock wire is not acceptable.

UNACCEPTABLE – Exposed Wire

ACCEPTABLE ACCEPTABLE

UNACCEPTABLE – Burr UNACCEPTABLE – Burr

Page 30: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

30

6.13 Elastomeric Components (O-rings, gaskets, molded rubber components, etc.)

6.13.1 These components shall be visually inspected to be certain that they do not contain tears, cuts,

voids, excessive flash or mold mismatch. Three (3) diopter illuminated (100 foot candles minimum) magnification shall be used to aid in the inspection process.

• Tears - shall not be allowed in O-rings or pressure seal gaskets/devices.

• Cuts - shall not be allowed in O-rings or pressure seal gaskets/devices.

• Voids - There shall be no voids in O-rings or pressure seal gaskets/devices. Other components may contain voids providing they are limited to a maximum of 15 percent of the total surface area.

• Excessive Flash - Flash shall not exceed 0.015 of an inch or as specified by the drawing/specification. Flash is a thin section of the molded material which extends beyond the normal dimensional characteristic of the component and is normally caused by mold wear or a partially closed mold.

• Mold mismatch shall not exceed 0.015 of an inch or as specified by the drawing or specification. Mold mismatch is a misalignment of the molded part caused by an offset of the mold when it is closed. An example of this condition would be the offset of the upper and lower sections of an O-ring at the mold parting line which is present at the O-ring I.D. and O.D.

6.13.2 The following color representation shall be used as a visual indication of material type along with review of material certification.

POLYMER COLOR SPECIFICATION Ethylene Propylene Purple 2AA815A13F17L14 Fluorocarbon Brown MILL-R-83248 TY.1, TY.2 Fluorosilicone Blue MILL-R-25988 CL.1, GR.70 Neoprene Red AMS 3209 Nitrile Black 3CH 720 A25B14E16E36 Silicone Rust AMS 3304

NOTICE All Fluorosilicone and Fluorocarbon material must be tested in accordance with QCI 96 for verification of material type.

6.14 Parts Marking / Stamping / Laser etching (no magnification).

6.14.1 Parts shall be 100% visually inspected with an unaided eye at a maximum distance of 12” for

legible numbering, lettering and required acceptance symbols.

6.14.2 Blurred, illegible or incomplete stamping, marking, laser etching of information will be considered unacceptable.

UNACCEPTABLE – Overwritten marking

Page 31: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

31

6.15 Connectors 6.15.1 Connectors shall be 100% visually inspected with an unaided eye at a maximum distance of 12”.

There shall be no visible damage to the connector shell or internal contacts (pins).

6.15.2 The connector shall not be bent, damaged or deformed.

6.15.3 There shall be no FOD in the connector or contacts (socket).

6.15.4 All contacts (pins) shall be seated, no noted recessed contacts.

UNACCEPTABLE Incomplete, missing Dash

UNACCEPTABLE – Incorrectly seated

ACCEPTABLE UNACCEPTABLE – Bent contacts (pins)

UNACCEPTABLE - FOD

Page 32: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

32

6.16 Lock Wire 6.16.1 Lock wire shall be 100% visually inspected with an unaided eye at a maximum distance of 12” to

a sure accordance with EI 690 General Work Instructions for Lock Wire and Safety Cabling.

Reference EI 690

ACCEPTABLE – Pig Tail UNACCEPTABLE – Pig Tail

UNACCEPTABLE - Tie Wire

UNACCEPTABLE - Tie Wire

ACCEPTABLE - Tie Wire

ACCEPTABLE - Tie Wire

Page 33: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

33

6.17 Workmanship - The degree of skill with which a product is made or a job done. 100% visually inspect with an unaided eye at a maximum distance of 12”.

Note screw height

ACCEPTABLE UNACCEPTABLE

ACCEPTABLE - Washers present UNACCEPTABLE - Missing washers

UNACCEPTABLE - Tang is not removed from Heli-coil.

UNACCEPTABLE – Gaps in RTV

Page 34: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

34

UNACCEPTABLE - Workmanship Visual appearance is poor

ACCEPTABLE – Workmanship

UNACCEPTABLE Screw is not seated properly, not flush with cover

ACCEPTABLE Screw is seated properly, flush with cover

Page 35: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

35

7.0 General Quality Acceptance Limits

Condition DEFINITIONS APPLICABLE PARTS ACCEPT /

REJECT CONDITION ACTIONS

Abrasion A wearing away, grinding or rubbing away of small amounts of material. Surface finish may be smooth or rough.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance Procedure. See Process map.

Bent Sharply curved or having an angle. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance Procedure. See Process map.

Blemish A small mark or flaw that changes the appearance of an object.

All parts and details. Accept Provided part meets drawing surface requirements.

Blister A localized lifting of coating, plating or paint from base material, appearing as a protuberance that may break when probed.

All coated, plated or painted parts and details.

Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Blur An entity that cannot be seen clearly. Not clear enough to be read.

All parts and details. N/A Definition only

Braze Void A gap in a braze joint creating a separation between the braze material and parent material.

Reject Reject at source. Follow QCI 42, nonconformance Procedure. See Process map.

Break An interruption of continuity or uniformity. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Brush Marks The indented lines sometimes left by the bristles of a brush on a painted surface.

All painted parts. Accept Inspect at minimum 18” distance.

Bump A protuberance on a level surface. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Burnish Mark A local smoothing of a metal surface, often to a high luster resulting from rubbing. It may contain scratches of no apparent depth. Definition includes buffing and polishing marks.

All parts and details. Accept Provided that material thickness meets drawing requirements.

Burr A rough edge or a sharp protrusion on the edge or surface of the parent metal. A fragment of metal which remains attached to the surface after machining.

All parts and details. Reject All burrs are to be removed immediately at source.

Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Chatter Mark A tool mark on material caused by vibration or jumping of a machining cutting tool.

All parts and details. Accept

Provided part meets drawing surface requirements.

Assess per drawing requirements.

O-ring sealing surface. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Chip Chips are detached particles resulting from the machining process to which the parts have been subjected.

All parts and details. Reject All chips are to be removed immediately at source.

Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Cleanliness Cleanliness is the absence of all films and all foreign particles.

All parts and details. N/A Definition only.

Concave Having an outline or surface that curves inward like an interior of a circle or sphere.

All parts and details. N/A Definition only.

Contamination The presence of unwanted material or residue on or inside of a part or product.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Convex Having a surface that is curved or rounded outward.

All parts and details. N/A Definition only.

Page 36: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

36

Condition DEFINITIONS APPLICABLE PARTS ACCEPT / REJECT CONDITION ACTIONS

Corrosion A deterioration of the metal resulting in change of color or leaving a rough surface that may show pits (small cavities).

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Crack A separation of material visible to the naked eye.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Crazing A network of fine cracks. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Crease A line, mark or indentation produced by folding, pressing, or wrinkling.

All parts and details. N/A Definition only

Cut A narrow, deep impression in material created by a sharp edged instrument.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Damage Physical harm caused to something in such a way as to impair its value, usefulness, or normal function.

All parts and details. N/A Definition only

Deformation Concave or convex change in a profile of a part.

All parts and details. Accept Providing part meets drawing requirements.

Dent A depression in a surface, normally, but not always having rounded edges, corners and bottom, caused by impact with an object.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Ding Same as Dent. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Discoloration A local or general change in color from that normally encountered or originally produced.

All heat treated parts and details made of steels, nickel alloys and cobalt alloys.

Accept Provided it is an even light straw or light blue color free of corrosion.

All nitrided parts and details.

Accept

Provided it is light to dark grey in color.

All electrolytic deburred parts and details.

Accept Provided that it shows no pits.

All etched anodized parts.

Accept

All parts processed by EDM showing arc burns or spark out.

Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Chromic Acid Anodizing. Accept Provided it is an even color. Shade variation is acceptable.

Sulfuric Acid Anodizing. Accept Provided it is uniform color on machined areas.

Provided it is of opaque/natural appearance.

Hard Anodizing. Accept Provided it is adherent, uniform in color and not powdery.

Provided it is a dense continuous film free from powdery areas.

Page 37: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

37

Condition DEFINITIONS APPLICABLE PARTS ACCEPT / REJECT CONDITION ACTIONS

Chemical Conversion Coat (i.e. Alocrom or Iridite).

Accept Provided it is a uniform color. Color variation is acceptable on touched-up areas.

Distortion A condition that causes a part to differ from original shape.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Finger print Stain left by unprotected hands. All parts and details. Accept Provided action is taken to clean the component.

Remove at source. Follow QCI 42, nonconformance procedure. See Process map.

Fisheyes A dimpled or grainy surface texture. All parts and details. Accept Inspect at minimum 18” distance.

Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Flake A small piece of material. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Flaking/Scale Loose, scale-like fragments on surface/raised areas of coating or plating on a coated or plated part, indicative of poor bonding.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Foreign Object Debris (FOD)

A solid or liquid material or substance not integral to a part. Such material or substance may or may not be adherent to part surfaces or passages. Material chips shall be considered.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Fretting 1. Removal of excess material from casting flash/forging seams & other similar parts. 2. Removal of surface defects from castings, forgings and similar parts.

All parts and details. Accept/ Reject depending on casting condition.

Following fretting, parts must be blended/uniform & drawing limits must be maintained at all times.

If unable to disposition see project engineer. If rejected follow QCI 42, nonconforming procedure. See Process map.

Gouge A wide, rough scratch or group of scratches, usually with one or more sharply impressed corners, and frequently accompanied by deformation or removal of parent material. Similar to a nick but generally larger.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Groove A long narrow continuous impression caused by material displacement or removal resulting from pressure of a moving surface in contact with the base metal.

All parts and details. Accept Grooves on machine surfaces are permitted provided they do not cause the surface finish requirements to be exceeded or do not violate drawing requirements.

Illegible See Blur. All parts and details. N/A Definition only.

Kink A buckled condition, a short tight twist or curl in tubing caused by a bending or winding of the tubing.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Knurling (Light) A knurl which does not go to full depth i.e. the crests do not meet at a sharp point.

All parts and details. Accept

Knurling (Poor) A knurl which exhibits damage due to double knurling or a frosty appearance at the trough due to significant tool wear.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Misalignment Positioning of parts which prevents proper assembly or results in faulty operation and ultimately failure.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Page 38: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

38

Condition DEFINITIONS APPLICABLE PARTS ACCEPT / REJECT CONDITION ACTIONS

Nick A surface impression with sharp corners or bottom, usually caused by pressure or impact from a sharp-edged foreign body. The parent material is displaced, but usually none is separated.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Nodule A small, rounded raised particle of metal, plating or coating material.

All parts and details. Accept Provided it does not affection function and is firmly attached to the part.

Orange peel A dimpled or grainy surface texture resembling an orange peel.

All parts and details. Accept Inspect at minimum 18” distance.

Over Spray Excess paint or other liquid that spreads or blows beyond an area being sprayed.

All parts and details. N/A Definition only.

Peeling Section of a coating or plating lifting away from the coated or plated surface.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Pinched Distorted or misalignment of one or more surfaces of parent material.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Pit A minute depression or cavity, with no sharp high stress corners, in the surface of the material. Pits are usually caused by chemical reaction (rusting, chemical corrosion).

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Polish A finishing operation which produces a smooth surface finish.

All parts and details. Accept Providing it meets drawing requirements.

Porosity A series of holes or pits caused by air or gas trapped in the metal during solidification.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Ragged Having a rough, irregular or uneven surface, edge or outline.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Raised edge A narrow ridge of material along an edge raised above the general contour of the part.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Raised Imperfection

An imperfection which is above the general surface of the part.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Sag A downward curve or bulge. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Scratch A long narrow sharp-cornered impression caused by the movement of a sharp object across the surface of the parent material.

All parts and details. N/A Definition only.

Superficial Scratch CAT 1

A scratch which has no apparent depth (cannot be felt by probe when using surface defect scriber) and under immediate inspection in normal lighting conditions the scratch does not clearly stand out (10mm less in length).

All parts and details. Accept Rework option will apply if deemed applicable.

Wider Scratch Marks CAT 2

A scratch which has occurred in a treated/coated material and is CLEARLY visible in normal lighting conditions.

All parts and details. Reject Due to width of the scratch, the appearance of the surface is extremely poor and is immediately evident to the inspector.

Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Page 39: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

39

Condition DEFINITIONS APPLICABLE PARTS ACCEPT / REJECT CONDITION ACTIONS

Scratch with apparent depth CAT 3

Significant damage of surface area in length and depth and can be felt with probe.

All parts and details. Reject Major damage with significant depth.

Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Scratch on sealing surface critical bore with apparent depth. CAT 4

The scratch is not purely superficial and the scratch is likely to cause a loss of functionality or performance due to its location.

All parts and details. Reject Scratch is on a critical area or surface/bore. Further consultation is required if unsure whether area is critical.

Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Scuff Surface roughening resulting from wear. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Slight Small in degree; inconsiderable. All parts and details. N/A Definition only.

Smooth A surface that is continuously even, free of irregularities, presenting no resistance to the sliding of a finger or tool.

All parts and details. Accept Providing it meets drawing requirement.

Split A tear or crack in something. All parts and details. N/A Definition only. Stain/Excess Process Material

Surface discoloration due to liquids drying on the part. Includes any process material which is visible on component.

All parts and details. Accept Provided there is no visible change in height and excess process material has been cleaned. Must meet drawing requirements.

Remove any excess immediately at source.

Step An abrupt change in the surface contour which looks like a step in cross section.

All parts and details. Accept Providing it meets drawing requirements.

Surface Finish The result of the machining process defined by the drawing surface finish requirements.

All parts and details. N/A Definition only. Must meet drawing requirements.

Tear A split in something caused by it having been pulled apart forcefully.

All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Tool Mark A mark in the direction of the machining lay left by the machining tool or across the lay caused by improper tool withdrawal or metal chips. Marks can be straight, circular or spiral. Can also be caused by dull or broken tool.

All parts and details. Accept Providing it meets drawing/surface requirements.

Undercut A groove or recess cut into a surface near a shoulder or other projection.

All machine parts and details.

Accept Provided it blends smoothly with adjacent surfaces and that it is within drawing tolerance.

Examine against drawing requirements.

Void A completely empty space. All parts and details. Reject Reject at source. Follow QCI 42, nonconformance procedure. See Process map.

Waviness A smooth like variation in a flat or curved surface.

Accept Providing it meets drawing/surface requirements.

Workmanship The degree of skill with which a product is made or a job done.

All parts and details. N/A Definition only.

Page 40: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

40

CHANGE RECORD

Rev. Description of Change 12/9/1991

Effectivity Date

N/C Initial release Richard P. Mann 12/9/1991 Originator Date

Ray Zielinski 12/9/1991 Quality Approval Date Operations Approval Date

Rev. Description of Change 8/24/1992

Effectivity Date

A Added molded parts RCZ 8/24/1992 Originator Date

RCZ 8/24/1992 Quality Approval Date Operations Approval Date

Rev. Description of Change 11/18/1994

Effectivity Date

B Document retyped, all visual criteria expanded upon, criteria added for Elastomeric components RCZ 11/18/1994 Originator Date

RCZ 11/18/1994 Quality Approval Date Operations Approval Date

Rev. Description of Change 12/1/1995

Effectivity Date

C Define minimum lighting conditions throughout Revise visual casting criteria Previous revisions on file for historical reference

RCZ 12/1/1995 Originator Date

RCZ 12/1/1995 Quality Approval Date Operations Approval Date

Rev. Description of Change 2/26/1999

Effectivity Date

D Included visual coil inspection criteria MRL 2/25/1999 Originator Date

RCZ 2/25/1999 Quality Approval Date Operations Approval Date

Rev. Description of Change 8/28/2003

Effectivity Date

E Clarified coil inspection criteria in paragraphs 5.2.1, 5.2.1.1 and 5.2.1.8 Previous revisions on file for historical reference

MRL 8/25/2003 Originator Date Department Approval

if required Date

RCZ 8/25/2003 Quality Approval Date Operations Approval Date

Page 41: QUALITY CONTROL INSTRUCTION

QCI 98 Rev M

This document contains proprietary information and such information may not be disclosed to others for any purpose nor used for manufacturing purposes without written consent from Servotronics, Inc.

41

CHANGE RECORD continued

Rev. Description of Change 11/4/2005

Effectivity Date

F

Incorporated new document format, previous documents kept on file for historical reference Changed 5.1.2 from linear inch to .25 linear inch Added last sentence to 5.1.8 Added re-verification of hypot requirement, if coil retains cracks, to 7.2.1.6 Added Fluorocarbon to note in section 8.2 Added additional documentation listing to 9.2

RCZ 11/2/2005

Originator Date

MRL 11/4/2005 RCZ 11/2/2005 Quality Approval Date Operations Approval Date

Rev. Description of Change 11/1/2010

Effectivity Date

G Reformat to current standards Added Section 5.4 Coils

Mary E. Steiner 10/29/2010

Originator Date

Michael G. Elhage 11/1/2010 Jim Takacs 11/1/2010 Quality Approval Date Operations Approval Date

Rev. Description of Change 3/12/2012

Effectivity Date

H Added section 5.7 - Tubing on Lead wires and 5.8 Sandblasted Solder Joints Mary E. Harris 1/18/2012 Bob Harsch 1/18/2012 Originator Date Department Approval

if required Date

Michael G. Elhage 2/24/2012 Jim Takacs 3/12/2012 Quality Approval Date Operations Approval Date

Rev. Description of Change 5/3/2012

Effectivity Date

J Engineering approved detailed instructions and special considerations for pass/fail criteria when inspecting metering posts. This information was added under section 5.9 – 5.4 added clarification for individual coil inspection prior to assembly into torque motor or Servovalve 5.7 added clarification on Torque Motor and Servovalves, not on individual coils

Dave Oddy 4/27/2012

Mike Franz 5/2/2012

Paul J. Kolniak

5/2/2012 Originator

Date

Department Approval

Date

Engineering Approval

Date

Michael G. Elhage

5/2/2012

Jim Takacs 5/2/2012

Quality Approval

Date

Operations Approval

Date

Rev. Description of Change

3/5/2013 Effectivity Date

K Add reference to end of sec. 5.2.1 opening paragraph Add section 5.6.3 Brazing on Spring-Armature-Flapper Assemby (SAFA) Add additional pictures to 5.9, clarified Surface Finish Categories Minor – was: an insignificant surface area to be rejected for surface finish; is: an insignificant surface area; therefore it is not to be rejected for surface finish

Mary E. Harris 1/4/2013

M.J. Franz 1/4/2013

Paul J. Kolniak

3/4/2013 Originator

Date

Department Approval

Date

Engineering Approval

Date

Charlie Rottner

1/4/2013

Jim Takacs 2/19/2013

Quality Approval

Date

Operations Approval

Date

Rev. Description of Change

10/26/2015

Effectivity Date

K1 Section 5.4 Coils - Step 20 Coil Tubing modified to include additional detail. (See page 10)

Michael R Gunn 10/23/2015

Scott Rodgers 10/23/2015

Paul J Kolniak

10/23/2015 Originator

Date

Department Approval

Date

Engineering Approval

Date

Michael G Elhage

10/23/2015

Jim Takacs 10/26/2015

Quality Approval

Date

Operations Approval

Date

Page 42: QUALITY CONTROL INSTRUCTION