Welding Process Audit Checklist

Audit

Supplier Information and Review.

Company Name

Add location

When was the Company Established.

What is the the Business Characterization.

What is the Size of the Facility?.

Shift Length (hrs).

How many Employees.

No. of Weld Inspectors

Are there any QA/QC Personnel on Staff

Is there a Certified Weld Inspector on Site?.

Is DCMA on Site?.

Is there ASNT Level I/II/III NDT Inspectors.

Are there any NAS- 410 NDT Inspectors on Staff?.

Does the Company Employ and Document any NDT Methods

Does the Company have Certified Welders on Staff

Does the Company have any Weld Supervisor's on Staff.

Does the Company have any Weld Engineers on Staff.

Does the Company have any MFG Engineers on Staff.

Does the Supplier presently do work for the Client?.

Quality Systems Approvals

Is there Separation in Reporting Duties for personnel responsible for Quality.

Does the Quality Control Inspector have the Authority to "Stop Work", the responsibility to Identify Quality Problems and Provide Recommendations.

Is there Objective Evidence of a Review Process of Certified Material Test Reports (CMTR) to ASTM Specifications. Note: If CMTR are not required to be kept of file per Contract Documents. the fabricator shall still show the capability of Reviewing the Reports.

Are materials identified and traceable as specified in the Technical Data Package (TDP). (Quality Program Receiving and Manufacturing Operations).

Do Purchase Orders for filler material specify the American Welding Society (AWS) Classification and Specification?.

Comments/ Recommendations:

Reference Library- All Reference Material Shall be to the Latest Published Version or Revision.

Does the Supplier have the Document "Aluminum Design Manual" from the Aluminum Association on File.

AMS-STD- 1595 (Qualification of Aircraft, Missile & Aerospace Fusion Welders) on File.

ANSI Z49.1 (Safety in Welding, Cutting and Allied Processes)

ASME Boiler and Pressure Vessel Code, Section V: Nondestructive Examination.

ASTM E 1444 (Standard Practice for Magnetic Particle Testing)

ASTM E1417 (Standard Practice for Liquid Penetrant Testing)

ASTM E1742 (Standard Practice for Radiographic Examination)

ASTM E164 (Standard Practice for Liquid UltrasonicTesting)

ASTM E1648 (Standard Reference Radiographs for Examination of Aluminum Fusion Welds)

AWS B1.11 (Guide for the Visual Examination of Welds)

AWS A3.0 (Standard Welding terms and Definitions)

AWS B2.1 ( Specification for Welding Procedure and Performance Qualification).

AWS B4.0 (Standard Methods for Mechanical Testing of Welds)

AWS D1.1 (Structural Welding Code- Steel)

AWS D1.2 (Structural Welding Code- Aluminum)

AWS D1.3 (Structural Welding Code- Sheet Steel)

AWS D1.6 (Structural Welding Code- Stainless Steel)

AWS D1.9 (Structural Welding Code- Titanium)

AWS D9.1 (Sheet Metal Welding Code)

AWS D17.1 (Specification for Fusion Welding for Aerospace Application)

AWS D17.2 (Specification for Resistance Welding for Aerospace Application)

AWS A2.4 (Standard Symbols for Welding, Brazing and Nondestructive Examination)

MIL-STD-2219 (Fusion Welding for Aerospace Application)

MIL-STD-271 (Requirements for Nondestructive Testing Methods)

MIL-STD-2035 (Nondestructive Testing Acceptance Criteria)

MIL-W-6858 (Welding, Resistance: Spot and Seam)

NADCAP welding documents (e.g., SAE AS 7110, NADCAP Requirements for Welding/Brazing)

NADCAP NDT Inspection Documents

NAVSEA Welding Standard 250-1500-1

NAVSEA Technical Publication S9074-AQ-GIB-010/248

NAVSEA Technical Publication S9074-AR-GIB-010/278

NAS-410 (Certification & Qualification of Nondestructive Test Personnel)

WS 33739 (Raytheon Process Specification for Aerospace Fusion Welding)

Certifications to:

Visual Inspection (VT)

Radiographic Inspection (RT)

Ultrasonic Inspection (UT)

Magnetic Particle (MT)

Dye Penetrant Inspection (PT)

Qualifications to:

ASTM E164

ASTM E1417

ASTM E1444

ASTM E1742

AWS QC1

Health and Safety

Is there an EH&S (Environmental Health & Safety) Officer or an Industrial Hygienist on Site?.

Is there objective evidence of a Welding Safety Program?

Is there objective evidence of Safety Training classes being conducted.

Is the facility environmentally controlled (i.e., fully heated and/ or air conditioned)

Is the relative humidity monitored and documented within the facility or the Welding Environment

Does the facility have a welding gas distribution system?.

Are the Oxygen levels Monitored?.

Is there a facility Equipment List/ Capabilities Profile sheet available?.

Does the facility have lifting crane capacity within the welding area?

What type of lifting crane?.

Does the facility employ welding positioners.

Is there a designated area for weld and/or Base Material grinding?.

Is the Welding / Fabrication Area Safe, Clean and Orderly.

Are there Welding Fume Extractors

Are Pre and Post Weld heat treatments (PWHT) performed at the Facility

Are there Separate Work Areas for Stainless Steel, Titanium, CArbon Steel or Aluminum

Is Blast cleaning performed at the Facility

Is Base material or Weld metal Analyzed

Laboratory Info.

Does the organization perform leak testing

What Type of Process?.

Is there objective evidence of weld operator annual vision test

Is there objective evidence of weld inspector's annual vision test

Comments/ Recommendations

Quality Control- Documentation

Does the Organization have a Quality and Procedures Manual

Are Sub-Tier Suppliers Qualified by a documented evaluation?.

Do purchase orders for base material (Nuts, washers, Bolts, Bar Stock etc specify the Grade?.

Is the base material currently being used on the shop floor traceable to a Certified Mill Test Report (CMTR)

Do purchase orders for filler material specify the American Welding Society (AWS) classification and specification.

Is the filler material currently being used on the shop floor traceable to a Certified Mill Test Report (CMTR)

Do purchase orders for Paint specify it's Requirements

Is the paint currently being used on the shop floor traceable to a Test Report (CMTR)

Have controls been established to monitor the receipt of incoming Material.

Is a quality control program in effect to allow management to assess whether work is being performed according to specification?.

Is there objective evidence of correction of non-conforming material or work in process

Are weldments traceable to a Qualified or Certified Welder

Is the objective evidence that a welder/ weld operator has worked with a particulate process, material type and weld joint geometry within the last 6 months

Is there a formal Material Review Board (MRB) process established to disposition weld defects?.

Is there objective evidence to assure that welds are not obstructed by subsequent operations and are inspected prior to being covered up (e.g. witness/ inspection hold points on traveller).

Are Requests for Information (RFI's) necessary to resolve discrepancies and variations from contract requirements documented?.

Is there a procedure for processing revised or voided drawings

Quality Control- Welding Consumables

Are sub-merged arc welding (SAW) fluxes and filler wire properly identified?.

Is the Filler wire and Flux stored in a secure, clean and dry environment?,

Are Flux and Filler materials stored per manufactures recommendations?.

Are there established procedures for the proper storage and control of low hydrogen Shielded Metal Arc Welding (SMAW) electrodes.

When Low hydrogen filler metal is used from an Oven is the environment with in the storage oven measured?.

Are welding filler metal traceable to a Certified Mill Test Report (CMTR)

Are the welding consumables Heat No. And Lot No. documented on the Traveler/ Router (If required by the contract specifications)

Do the Welding Consumables meet the Contract Specifications?.

Is weld filler wire distribution Controlled?.

Are used weld filler wire disposed of After welding activities (e.g. Stub-end Box),

Is the welding filler wire sent to an independent Material's Lab for Testing and P.O. verification prior to being employed.

If the Organization mixes their own shielding gases are Calibrated Mixture Chambers used?.

Procedure Qualification Records (PQR's) and Welding Procedure Specifications (WPS's) are qualified in accordance with what Code:

AWS B2.1

AWS D1.1

AWS D1.2

AWS D1.3

AWS D1.6

AWS D9.1

AWS D17.1

AWS D17.2

ASME IX

NAVSEA

MIL-W-6858

What position(s) are Welders qualified in:

Groove Welds:

6GR

Fillet Welds:

Has the Organization engaged in DOD/ Military (MIL-STD) welding activities prior to this audit?.

What is the percentage of Military Welding Activities?.

Quality Control- Welding Operations

Does the Organization utilize Weld Chambers?.

Are O2 Analyzers Installed?.

Are O2 Levels verified within a purge gas/ Weldment environment?.

Are Pre-Weld, Inter-pass and Post-Weld Cleaning Requirements defined to the Welding Procedure Specification (WPS)

Is there objective evidence that surface condition and cleanliness of the weld joint fraying surfaces and filler metal has been examined prior to welding?.

Are Preheat, Inter-pass and Post-Weld heat treatment addressed on the Welding Procedure Specification (WPS)

Surface contacting Pyrometer

Temperature Crayons

Liquid

Pellets

Stickers

IR heat sensor

For automatic/ mechanized welding (as defined in AWS A3.0), are the weld settings used in production within range of those documented on the WPS or PQR?.

Is there an established Calibration Program for the calibration of Welding Supplies, Panel Ammeters, Panel Voltmeters, Wire Feeders, Positioners etc.

For semi-automatic welding (as defined in AWS A3.0), are the weld settings used in production within range of those documented on the WPS or PQR?.

Is there an established Calibration Program for the calibration of Welding Supplies, Panel Ammeters, Panel Voltmeters, Wire Feeders, Positioners etc.

Quality Control- Weld Inspection.

Are weld inspectors qualified and knowledgeable with the Specifications, which apply to the Fabricators work

Are written welding procedures in close proximity to and used by the Welders

Are tools or aids used for visual weld inspection.

Fillet Weld Gage's

Borescopes

Fiberscopes

Videoscopes

Are there Hold Points at the facility strictly devoted to weld inspection?.

Is there objective evidence of Visual (VT) weld inspection being performed Before, During and After additional Stress inducing Operations (e.g. straightening or heat-treating)

Is there a formal Material Review Board (MRB) established for disposition of non-conforming weldments.

Welding Process Audit Checklist

Ensure Quality Welds with a Comprehensive Welding Process Audit Checklist

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