REV.

AC7110/4 E
AUDIT Issued 1995-01-06
161 Thorn Hill Road, CRITERIA Revised 2006-08-02
Warrendale, PA 15086-7527
Superseding AC7110/4 REV D

TO BE USED ON AUDITS AFTER 1st March 2007

Nadcap
AUDIT CRITERIA FOR
RESISTANCE WELDING (SPOT, SEAM, PROJECTION)

1. SCOPE

This checklist is to be used as a supplement to PRI AC7110 for seeking Resistance

Welding (spot, seam, projection) accreditation.

2. GENERAL INFORMATION

This checklist has been agreed with all mandating prime members. All questions in the
baseline document are required to be answered. Additional checklist supplements are
to be identified as applicable and questions in those supplements answered. Any NO
answer requires the issuance of a nonconformance report.

The base document defines the minimum requirement for this process. Supplements
related to specific processes, materials and unique customer requirements are also
contained in this checklist and must be identified prior to the audit so that they can be
included in the audit scope

2.1 Welding Scope

Processes performed at the facility (check appropriate boxes)
Baseline Applicable to all processes/materials etc
Spot
Seam
Projection
Aluminum/Magnesium Additional requirements for
Shear Testing Additional requirements for
Microspot Welding Additional requirements for

PRI operating procedures provide that "This report is published by PRI to advance the state of technical, engineering, and
quality 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."

PRI invites your written comments and suggestions.

Copyright 2000 Performance Review Institute

All rights reserved. Printed in U.S.A
 PRI AC7110/4 REV E

2.1 (Continued from previous page)

GTA Tack Welding Additional requirements for
Filler Materials Additional requirements for
Stress Relieve Heat Treatment (Furnace & Oven) Additional
requirements for
Chisel Testing Additional requirements for
Non-Nadcap Accredited Metallurgical Test Laboratories

3. REFERENCES

3.1 Customer Specifications

Are applicable customer specifications available at the facility? YES NO

4. MATERIAL CONTROL

4.1 Cleaning Materials, Chemical Solvents & Etching Solutions

Are cleaning materials, chemical solvents, or etching solutions as YES NO
specified on part drawings or certified/qualified welding
procedures/schedules?

5. EQUIPMENT

5.1 Equipment Capability

Is there a documented procedure to ensure welding machines, YES NO
fixtures, tooling and tooling material are suitable and capable of
consistently producing acceptable welds?

5.2 Equipment for Evaluation of Production Witness Coupons

Is the equipment used to evaluate production witness coupons YES NO
capable of accurately measuring nugget characteristics?

5.3 Equipment Calibration

Is there a documented procedure that defines the calibration of YES NO
equipment at established intervals?

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5.4 Qualification Records

Are qualification records/results that meet procedure requirements YES NO
available for each machine?

5.5 Control of Electrode Materials and Shapes

Are electrode materials and shapes controlled and identified as YES NO
specified on the certified weld schedules?

5.6 Tooling and Fixtures

Is there a documented procedure to ensure that tooling and fixtures YES NO
are so designed that magnetic material is not present in the throat of
the machine, insofar as possible?

5.7 Shunting
Is there a documented procedure to ensure that jigs and fixtures are YES NO
so designed that welding current cannot shunt through them?

5.8 Qualification of Welding Machines

5.8.1 Documentation of Welding Conditions

Are welding conditions/settings documented on Machine Qualification YES NO
Test Reports or equivalent?

5.8.2 Machine Qualification Test Reports

Is evidence of Machine Qualification Test reports, or equivalent, and YES NO
supporting data available to machine operators, inspectors, and
customer representative?

5.8.3 Machine Qualifications

Are machines qualified for the material type and thickness for which YES NO
they are intended to be used in production?

5.8.4 Re-qualification of Welding Machines

Are welding machines re-qualified if rebuilt, relocated, or if significant YES NO
operational changes are made?

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6. PROCEDURE CONTROL

6.1 Qualified Welding Schedules

6.1.1 Welding Schedule Established

Is there a documented procedure to ensure qualified welding YES NO
procedures/schedules are established for each production weld where
qualification is required by the customer/specification?

6.1.2 Customer Procedure Approval

Is there a documented procedure that includes a provision for YES NO
obtaining customer approval when the customer requires welding
procedure approval?

6.1.3 Customer Schedule Approval

Is there a documented procedure that includes a provision for YES NO
obtaining customer approval when the customer requires welding
schedule approval?

6.2 Use of Resistance Tack Welds

6.2.1 Tack Weld Procedure

Is there a documented procedure that ensures resistance tack welding YES NO
of details is accomplished in accordance with specification
requirements?

6.2.2 Qualification of Tack Welds

Is there a documented procedure to ensure that the resistance tack YES NO
welds are welded in accordance with an approved schedule?

6.2.3 Resistance Tack Weld Consumption

Is there a documented procedure to ensure that the resistance tack YES NO
weld is totally consumed and within the confines of the finished weld
when required?

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6.3 GTA Tack Welding

Is GTA tack welding prohibited or, if used, is Supplement D for GTA YES NO
tack welding control included in the audit?

6.4 Filler Material Control

Do supplier procedures specifically prohibit the use of filler material or YES NO
if not is Supplement E for filler material control included in the scope
of the audit?

6.5 Stress Relief

Is there a process to ensure stress relief of weldments is performed in YES NO
accordance with applicable requirements? (If this is performed in-
house and stress relief operations are NOT performed in a Nadcap
accredited Heat Treat facility then is Supplement F used)

6.6 Heat Treatment

Is there a process to ensure heat treatment of weldments are YES NO
performed in accordance with applicable requirements?

6.7 Certification

6.7.1 Certification of Welding Procedures

Is there a documented procedure to define the requirements for YES NO
certification of welding procedures/schedules ?

6.7.2 Certification Tests

Are tests conducted and documented for the purposes of welding YES NO
schedule/procedure certification?

6.7.3 Certification Test Reports

Are Certification Test Reports available to the customer YES NO
representatives?

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6.7.4 Traceability of Test Reports

Is there a Certification Test Report traceable to each machine and YES NO
each combination of relevant materials, material conditions, surface
conditions, electrode configurations, and thickness combinations?

6.7.5 Certification Test Report Data

Does each certification report contain all applicable requirements? For YES NO
example: Shear strength and/or peel data on each weld, the average,
the number of specimens with shear values outside set limits, and the
nugget diameters for each metallographic specimen as required?

6.7.6 Compliance with Certification Criteria

Does the Certification Test Report indicate the success or failure to YES NO
meet certification criteria?

7. PROCESS CONTROL

7.1 Cleaning

7.1.1 Cleaning Process

Is there a documented procedure to control the cleaning process prior YES NO
to welding?

7.1.2 Surface Conditions

Are parts properly cleaned to assure surfaces of the details and YES NO
representative test specimens are free from contaminants such as
oxides, scale, oil, dirt, ink, or other surface conditions that are
detrimental to the joining process?

7.1.3 Protection of Cleaned Material

Are part details protected after cleaning until welding can be YES NO
performed?

7.1.4 Time Limits

Is there a documented procedure to ensure that after cleaning, all part YES NO
details are welded within specified time limits?

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7.1.5 Handling
Is there a documented procedure to ensure that after surface YES NO
preparation, parts are handled and protected to prevent
contamination?

7.1.6 Jigs, Fixtures, and Measuring Devices

Are jigs, fixtures, and measuring devices free of scale, grease, YES NO
protective coatings, oxides, dust, oil, and other foreign matter
detrimental to the welding process?

7.2 Instructions

7.2.1 Sequence of Operations

Does the router list the sequence of operations that control YES NO
manufacturing and inspection operations?

7.2.2 Detailed Operation Sheet

Are there detailed operation sheets/weld schedules with parameter YES NO
settings for each part number?

7.3 Qualification Test Reports

7.3.1 Test Reports

Are parameter settings on operation sheets traceable to qualification YES NO
test reports?

7.3.2 Retention of Test Reports

Are qualification test reports documented and held on file for customer YES NO
review ?

7.3.3 Metallurgical Evaluation

Does the facility performing weld evaluations comply with AC7110/13 YES NO
or is Supplement H used in this audit?

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7.4 Test Specimens

7.4.1 Identification of Test Specimens

Are test specimens for production parts identified? YES NO

7.4.2 Pre-Production Tests

If acceptable pre-production tests cannot be obtained within the YES NO
permitted schedule latitude adjustment, is welding stopped and the
machine checked for faulty operation?

7.4.3 Production Witness Welds

Are results of production witness welds (e.g. etch, peel, chisel, tensile, YES NO
metallographic) maintained in a register near the welding machine?

7.4.4 Micro/Macro Test Sections

Are metallographic test sections being evaluated to specification YES NO
requirements with proper magnification?

7.4.5 Metallurgical equipment for assessing test specimens

Is metallographic equipment available and suitable for evaluating YES NO
production witness weld specimens?

7.4.6 Nonconforming Specimens

Whenever specimen test results do not meet specified requirements, YES NO
is welding stopped and all parts produced since the last acceptable
test identified as nonconforming and segregated?

7.4.7 Register
Does the register include traceability to part number, serial numbers., YES NO
or lot/job numbers, production witness results, machine number, and
coupon weld times?

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7.4.8 Deterioration of Welds

YES NO
Is there a documented procedure to ensure, that when deterioration of
welding is encountered, an investigation is conducted to assign the
cause, and implement corrective action?

7.4.9 Requalification
Is there a documented procedure to ensure that where the assigned
YES NO
cause is attributed to the qualified machine/schedule being unable to
produce acceptable welds , the supplier stops welding and requalifies
the machine/schedule in accordance with the applicable specification
requirement?

7.5 Mating Parts

Is there a process to ensure that mating parts are in contact with YES NO
manual pressure prior to welding?

7.6 Location of Welds

7.6.1 Location Devices

Is there a documented procedure to control methods for the location of YES NO
resistance welds?

7.7 Control of Electronic Programs and Data

Is there a documented procedure in effect to assure the control of YES NO
electronic programs and data?

8. PERSONNEL

8.1 Operator Qualifications

Is there a documented procedure to ensure welding operators are YES NO
qualified/trained?

8.2 Qualification of Tack Weld Personnel

Is there a documented procedure to ensure tack weld personnel are YES NO
qualified/trained?

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8.3 Inspector Training/Qualification

Is there a documented procedure in place to train and qualify welding YES NO
visual inspectors?

8.4 Inspector Qualifications

Is there documented evidence of training and qualification of welding YES NO
visual inspectors?

8.5 Evaluation of Production Weld Coupons

Does the training of operators/inspectors that evaluate production weld YES NO
coupons include, but not limited to the measurement of nugget
characteristics (nugget size, penetration min/max, indentation depth)?

9. INSPECTION AND ACCEPTANCE CRITERIA

9.1 Examination of Production Welds

Are production welds examined for conformance in accordance with YES NO
applicable specifications?

9.2 Traceability
Are welded parts traceable to the welding machine, approved YES NO
procedure, operator, and inspector?

9.3 Visual Inspection

Is there a documented procedure to ensure all welds are inspected by YES NO
qualified visual inspectors?

9.4 Dimensional Inspection

Are inspection tools to measure dimensional features available to the YES NO
inspector?

9.5 Inspection Equipment

Does the facility have the proper inspection equipment to inspect weld YES NO
characteristics?

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9.6 NDT Inspection

Does the supplier have a process in place to ensure all required NDT YES NO
inspections are performed?

9.7 Records
Is there a documented procedure that defines the record retention YES NO
requirements for inspection records, including radiographic films or
digital equivalent?

10. PERIODIC MAINTENANCE

10.1 Preventative Maintenance

Do written procedures require preventative maintenance of weld YES NO
equipment and tooling at a specified frequency?

10.2 Maintenance Records

Do records indicate that maintenance is performed on weld equipment YES NO
and tooling in accordance with the procedures and appropriate
standards?

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11. COMPLIANCE
NOTE: Compliance to applicable specifications and customer
requirements shall be demonstrated by auditing two in-process jobs.
Copy of procedure/technique to be submitted for each job audit.

11.1 Job Audit #1

Complete
Job Status
In-Process
Job Audit Properties
Customer/Prime Contractor
Unique Work Order # or Lot #
Quantity

Job Identification

Drawing #
Part Name
Material Name
Material Specification
Top Thickness
Intermediate Thickness(es)
Bottom Thickness
Number of Sheets
Operation Sequence Number
Operator

Welding Process Spot

Seam
Projection

Welding Method Manual

Automatic
Semi-Automatic
Reference Specifications
Customer Specification/Rev.
MIL/Industry Specification/Rev.
Class
Welding requirements from purchase order, drawing or specification
Pre-weld/requirement/cleaning/preheat/prep/assembly on shop paper
Actual pre-weld conditions of parts observed at weld operation
Comments/Sketch

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11.2 Operator Qualification

Has the operator shown competence for the job being performed? YES NO

11.3 Authorization to Weld Production Hardware

Is the supplier authorized to weld the part specified in 11.1? YES NO

11.4 Certified Welding Schedule

Have the requirements for a certified welding schedule been YES NO
addressed?

11.5 Use of Approved/Certified Welding Schedule

Is an approved/certified welding schedule in use? YES NO

11.6 Compliance with Customer Requirements

Does the welding schedule address all customer requirements? YES NO

11.7 Pre-Weld Preparations

Are the pre-weld preparations defined and in accordance with YES NO
customer requirements?

11.8 Compliance to the Welding Schedule

Has the supplier demonstrated compliance to the welding schedule? YES NO

11.9 Verification of Weld Requirements

Is there documented evidence that all NDT and visual inspections (eg YES NO
Visual, FPI, X-ray) have been performed to customer requirements?

11.10 Process Control Test Specimens

Do all process control test specimens conform to the production parts YES NO
they represent with respect to material, thickness combination, surface
condition, preparation, geometry, and heat treatment condition?

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11.11 Completion of Process Control Test Specimens

Have all process control specimens been performed at the required YES NO
intervals, evaluated and results recorded?

11.12 Process Approval

Can the supplier provide evidence of the prime customer approval for YES NO
the welding process being used?

11.13 Calibration
Is equipment calibrated in accordance with established procedures? YES NO

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12. COMPLIANCE
NOTE: Compliance to applicable specifications and customer
requirements shall be demonstrated by auditing two in-process jobs.
Copy of procedure/technique to be submitted for each job audit.

12.1 Job Audit #2

Complete
Job Status
In-Process
Job Audit Properties
Customer/Prime Contractor
Unique Work Order # or Lot #
Quantity

Job Identification

Drawing #
Part Name
Material Name
Material Specification
Top Thickness
Intermediate Thickness(es)
Bottom Thickness
Number of Sheets
Operation Sequence Number
Operator

Welding Process Spot

Seam
Projection

Welding Method Manual

Automatic
Semi-Automatic
Reference Specifications
Customer Specification/Rev.
MIL/Industry Specification/Rev.
Class
Welding requirements from purchase order, drawing or specification
Pre-weld/requirement/cleaning/preheat/prep/assembly on shop paper
Actual pre-weld conditions of parts observed at weld operation
Comments/Sketch

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12.2 Operator Qualification

Has the operator shown competence for the job being performed? YES NO

12.3 Authorization to Weld Production Hardware

Is the supplier authorized to weld the part specified in 12.1? YES NO

12.4 Certified Welding Schedule

Have the requirements for a certified welding schedule been YES NO
addressed?

12.5 Use of Approved/Certified Welding Schedule

Is an approved/certified welding schedule in use? YES NO

12.6 Compliance with Customer Requirements

Does the welding schedule address all customer requirements? YES NO

12.7 Pre-Weld Preparations

Are the pre-weld preparations defined and in accordance with YES NO
customer requirements?

12.8 Compliance to the Welding Schedule

Has the supplier demonstrated compliance to the welding schedule? YES NO

12.9 Verification of Weld Requirements

Is there documented evidence that all NDT and Visual inspections (eg YES NO
Visual, FPI, X-ray) have been performed to customer requirements?

12.10 Process Control Test Specimens

Do all process control test specimens conform to the production parts YES NO
they represent with respect to material, thickness combination, surface
condition, preparation, geometry, and heat treatment condition?

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12.11 Completion of Process Control Test Specimens

Have all process control specimens been performed, evaluated, and YES NO
results recorded?

12.12 Process Approval

Can the supplier provide evidence of the prime customer approval for YES NO
the welding process being used?

12.13 Calibration
Is equipment calibrated in accordance with established procedures? YES NO

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SUPPLEMENTS

ALUMINUM/MAGNESIUM ALLOYS SUPPLEMENT A

A If this supplement is not required / identified in the audit scope, check N/A

A.1 Daily Check of Surface Resistance

Is there a documented procedure to control surface resistance YES NO
checks?

A.1.1 Compliance to procedure

Is the procedure for surface resistance checks being complied with? YES NO

A.1.2 Surface Resistance Indicators

Are one or more surface resistance indicators available for checking YES NO
the effectiveness of cleaning?

A.2 Time Limits

Has the contractor identified maximum time limits between cleaning YES NO
and welding?

A.3 Control Specimen

Are process specimens cleaned with the parts they represent? YES NO

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SHEAR TESTING SUPPLEMENT B

B If this supplement is not required / identified in the audit scope, check N/A

B.1 Calibration and Accuracy of the Shear Test Machines

Are shear testing machines accurate and calibrated within 2% of the YES NO
indicated reading?

B.2 Frequency of Calibration of Shear Test Machines

Are spot weld shear test machines checked for accuracy at specified YES NO
intervals?

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MICROSPOT WELDING SUPPLEMENT C

C If this supplement is not required / identified in the audit scope, check N/A

C.1 Weld Current

Is the equipment capable of producing the weld current by capacitor YES NO
discharge or transformer output?

C.2 Arc Prevention

Are electrodes insulated to prevent stray arcs? YES NO

C.3 Electrode Materials

Are electrodes manufactured from allowed material? YES NO

C.4 Electrode Configuration

Are electrode tip configurations in accordance with applicable YES NO
requirements?

C.5 Peel Tests

Are peel tests performed in accordance with applicable requirements? YES NO

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GTA TACK WELDING SUPPLEMENT D

D If this supplement is not required / identified in the audit scope, check N/A

D.1 Qualification of Fusion Tack welds

Is the tack process performed using a WPS/weld schedule? YES NO

D.2 Personnel Qualifications

Is the tack process performed by qualified personnel? YES NO

D.3 Procedure Control

Is tack welding controlled by a written procedure? YES NO

D.3.1 Tack Welding Authorization

Is tack welding permitted (or at least not prohibited) by the Cognizant YES NO
Engineering Organization?

D.4 Tack Weld Control

When performing tack welding are controls used to prevent stray arc, YES NO
under cut, and oxidation?

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FILLER MATERIALS SUPPLEMENT E

E If this supplement is not required / identified in the audit scope, check N/A

E.1 Control Procedures

Is there a documented filler material control system? YES NO

E.2 Purchasing Instructions

Do purchasing instructions specify filler material specification, size, YES NO
and identification requirements?

E.3 Receiving

E.3.1 Filler Material Certifications

Do certifications accompany the filler material at receiving inspection YES NO
verification?

E.3.1.1 Filler Material Certifications Accessibility

Are the chemistry certifications for filler material maintained in an YES NO
accessible filing system?

E.3.2 Filler Material Compliance

Does the filler material meet the specifications requirements? YES NO

E.3.3 Filler Material Markings

Does the marking on filler material comply with the requirements of the YES NO
purchase order?

E.3.4 Filler Material Container Release

Are filler material containers stamped with material release stamp YES NO
when required by customer or marked with other positive identification
(e.g. tag, marking, etc.) prior to placing material in storage crib?

E.3.5 Filler Material Receiving Inspection

Is verification performed as required by procedure? YES NO

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E.4 Storage/Release

E.4.1 Filler Material Storage

Is filler material stored in a clean, dry environment? YES NO

E.4.2 Filler Material Segregation

Is filler material segregated in such a manner to prevent co-mingling of YES NO
different sizes or filler material specification numbers?

E.4.3 Filler Material Access

Is access to filler material storage area addressed procedurally? YES NO

E.4.3.1 Compliance
Are filler material access procedures being followed? YES NO

E.5 Control In Shop

E.5.1 Chemical Composition of Filler Material

Is there only one specification of filler material within the welders or YES NO
welding operators immediate work zone at one time?

E.5.2 Missing Filler Material ID

If filler material identification markings are lost, missing, or destroyed, YES NO
is the material scrapped?

E.5.3 Filler Material Cleanliness

Can the cleanliness of filler material be demonstrated immediately YES NO
prior to welding?

E.5.4 Disposal of Filler Materials

Is there a documented procedure describing disposal of filler material? YES NO
(E.g. Stubs, shim etc)

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E.5.4.1 Compliance with Disposal Procedures

After welding, is unusable filler material discarded according to YES NO
disposal procedures? (E.g., into non-retrievable cans, tubes, etc.)?

E.6 Identification

E.6.1 Proper Filler Material ID

Is the filler material properly identified? YES NO

E.6.2 Filler Material Container Traceability

Are filler material containers marked to provide for positive traceability YES NO
to heat and/or lot number?

E.6.3 Filler Material Identification

Is there a method that allows the welder to easily identify the filler YES NO
material type?

E.6.4 Filler Material Requirements

Are filler material requirements specified on drawings or welding YES NO
procedures/schedules/shop paper?

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REQUIREMENTS FOR STRESS RELIEF (FURNACE & OVEN)

SUPPLEMENT F

F If this supplement is not required / identified in the audit scope, check N/A

F.1 Temperature Uniformity Test

YES NO
Is there a documented procedure for temperature uniformity and
system accuracy tests?

F. 2 Temperature Uniformity Test Procedure Content

Does the procedure specify the following as a minimum:

a) Test Frequency YES NO

b) Test temperature(s) and range(s)? YES NO
c) Temperature range covering all thermal operations?
YES NO
d) Placement and recording of thermocouples in accordance with
specification? YES NO
e) Period of monitoring after temperature stabilization? YES NO
f) Calibration of test instruments traceable to a national standard YES NO
certification body

F.3 Temperature Recorder

YES NO
When in use, does the oven (furnace) employ a continuous
temperature recorder?

F.4 Test Records/Results

YES NO
Are test records / results that meet procedure requirements available
for each furnace / oven?

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CHISEL TESTING SUPPLEMENT G

G If this supplement is not required / identified in the audit scope, check N/A

G.1 Chisel Testing

Are chisel tests performed at the specified frequency and are the YES NO
results in accordance with applicable requirements?

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NON-Nadcap ACCREDITED METALLURGICAL TEST LABORATORIES

SUPPLEMENT H

H If this supplement is not required / identified in the audit scope, check N/A

H.1 Test Laboratory Accreditation

Does the testing facility hold a national or international accreditation in YES NO
lieu of AC7110/13 for the metallurgical evaluation of welds?

H.2 Test Laboratory Approval

Is the testing facility accreditation acceptable to the design authority? YES NO

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