SAE ARP 4992-2012 Rev B Periodic Test for Processing Solutions

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AEROSPACEARP4992REV.BRECOMMENDEDIssued1996-08PRACTICERevised2012-01SupersedingARP4992APeriodicTestforProcessingSolutionsRATIONALEARP4992BresultsfromaFiveYearReviewandupdateofthisdocument.1.SCOPE1.1ScopeThisSAEAerospaceRecommendedPractice(ARP)describesamethodforclassifyingthefrequenciesofanalysisofsolutionsusedintheprocessingofmetals,suchaselectroplating,anodizing,andconversioncoatingandassociatedprocessesbutusageisnotlimitedtosuchapplications.1.2IntentThisdocumentisintendedtoestablishaperiodictestplanthatmaybeusedbyprocessorstosatisfytherequirementofanAerospaceMaterialSpecification(AMS)forachemicalprocessingsolutionperiodictestplanasacontrolfactor.1.3LimitationThisdocumentdoesnotfulfillthecriteriaforaformalstatisticalprocesscontrolprogram.2.APPLICABLEDOCUMENTSThissectionisnotapplicabletothisdocument.3.TECHNICALREQUIREMENTS3.1Theanalysisofprocesssolutionconstituentsshallbeperformedatsuchafrequencyastoensurethatthesolutionisnotoperatedbeyondtheconcentrationlimitsauthorizedbytheapplicablespecificationorworkinstruction.__________________________________________________________________________________________________________________________________________SAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,stabilizedorcancelled.SAEinvitesyourwrittencommentsandsuggestions.Copyright©2012SAEInternationalAllrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofSAE.TOPLACEADOCUMENTORDER:Tel:877-606-7323(insideUSAandCanada)SAEvaluesyourinput.Toprovidefeedback--````````,,`,`,,,,,,``,``,`,`,-`-`,,`,,`,`,,`---Tel:+1724-776-4970(outsideUSA)onthisTechnicalReport,pleasevisitFax:724-776-0790http://www.sae.org/technical/standards/ARP4992BCopyrightSAEInternationalEmail:CustomerService@sae.orgProvidedbyIHSunderlicensewithSAELicensee=TaikooAircraft/5910393001,User=Wu,LisaNoreproductionornetworkingpermittedwithoutlicensefromIHSSAEWEBADDRESS:http://www.sae.orgNotforResale,04/25/201219:08:13MDT SAEARP4992BPage2of43.2Classesoftestfrequencyusedherein.TABLE1–CLASSESOFTESTFREQUENCYClassFrequencyofAnalysisYAnnually2YSemiannually4YQuarterly6YBimonthlyMMonthly2MBiweeklyWWeekly2WSemiweekly3WThreetimeseachweekDDailySHOnceeachworkingshiftBPBeforeprocessingeachproductionload3.3Definitions3.3.1SpecificationRange:Theconcentrationrangeofaconstituentinasolutionrequiredbytheapplicableprocessspecificationorworkinstruction.3.3.2ProcessControlRange:Aconcentrationrangethatis75%oftheSpecificationRange.Itisatoolusedtoaidintheestablishmentofafrequencyofprocesscontroltesting.3.3.3WorkInstruction:Adocumentthatprovidesdetailedprocessingorsolutioncontrolinstructionsforfulfillingspecifiedrequirements.3.4CalculationofProcessControlRange3.4.1SubtractthelowerpermissibleconcentrationlimittotheSpecificationRange(A)foreachconstituentfromthe--````````,,`,`,,,,,,``,``,`,`,-`-`,,`,,`,`,,`---higherpermissibleconcentrationlimittotheSpecificationRange(B)andmultiplyby0.25.3.4.1.1Forthoseprocesseswhereaconstituent’sconcentrationdecreaseswithuse,addthisvaluetothelowerpermissiblelimit.Theupperlimitvalueremainsasspecifiedbytheprocessspecificationorworkinstruction(B).LowerlimittoProcessControlRange=[A+(B-A)x0.25].3.4.1.2Forthoseprocesseswhereaconstituent’sconcentrationincreaseswithuse,subtractthisvaluefromthehigherpermissiblelimit.Thelowerlimitvalueremainsasspecifiedbytheprocessspecificationorworkinstruction(A).UpperlimittoProcessControlRange=[B-(B-A)x0.25].3.4.2WhenthereisnolowerlimittotheSpecificationRange,onlyamaximumlimit,multiplythisnumberby0.75.UpperlimittoProcessControlRange=0.75xB.3.4.3WhenthereisnoupperlimittotheSpecificationRange,onlyaminimumlimit,multiplythisnumberby1.33.LowerlimittoProcessControlRange=1.33xA.CopyrightSAEInternationalProvidedbyIHSunderlicensewithSAELicensee=TaikooAircraft/5910393001,User=Wu,LisaNoreproductionornetworkingpermittedwithoutlicensefromIHSNotforResale,04/25/201219:08:13MDT SAEARP4992BPage3of43.5ExampleCalculationsThefollowingexampleappliestoAMS2649,EtchInspectionofHighStrengthSteels.Alltheseconcentrationsorvaluesnormallydecreasewithuse.TABLE2–EXAMPLESOFPROCESSCONTROLRANGEESTABLISHEDFROMASPECIFICATIONRANGEConstituentSpecificationRangeProcessControlRangeNitricAcid3to5%byvolume3.5to5%byvolumeSodiumHydroxide2to6%byweight3to6%byweightSodiumPhosphate0.5to1.0oz/gal(3.7to7.5g/L)0.625to1.0oz/gal(4.7to7.5g/L)3.6AdjustmentstotheconcentrationofanyconstituentshallbemadewheneveritsconcentrationisfoundtobeoutsidetheProcessControlRangeinordertobringtheconcentrationtowithintheProcessControlRange.ItispreferabletoadjusttheconcentrationtotheoppositeextremeoftheProcessControlRange(AorB).3.7DeterminationofClass3.7.1InitialFrequencyClass:Samplingfrequencyrateforasolutionforwhichthereisnohistory-of-useshouldbeanalyzedatafrequencyselectedbytheprocessorunlessspecifiedbythecognizantengineeringorqualityorganization.3.7.2AdjustmentofFrequency:IfthreeanalysesforanyindividualconstituentofaprocesssolutionoutoftheprevioustenconsecutiveanalysesshowthatconstituenttobeoutsideoftheProcessControlRange,thefrequencyofanalysisforthatconstituentshallbeincreasedbyprogressingtothenextmorefrequentanalysisclassstatedinTable1.IftenconsecutiveanalysesshowtheconstituenthasbeenwithintheProcessControlRange,thefrequencyofanalysismaybedecreasedbyselectinganadjacent(nextlessfrequentanalysis)classstatedinTable1.3.7.2.1InfrequentlyUsedSolutions:Ifasolutionisnotusedregularlyorhasnotbeenusedsincethelastanalysis,periodictestingmaybesuspended.However,thissolutionmustbeanalyzedandshallbewithintheSpecificationRangepriortouse.3.8UnspecifiedConcentrationsWhenthereisnoSpecificationRangeforanyconstituentcontainedintheapplicableprocessspecificationorworkinstruction,orthereisnorequirementthatanacceptablerangemustbeestablishedbytheprocessor,theprocesssolutionneednotbeanalyzed.Thesolutionshouldbediscardedandreplacedonaperiodicbasisorsubjectedtoperiodicanalysis.Thefrequencyofreplacementshallbeselectedbytheprocessorunlessspecifiedbythecognizantengineeringorganization.3.9AfreshlymixedsolutionshallbeanalyzedandallconstituentconcentrationsshallbewithintheapplicableSpecificationRangepriortousingthesolutiontoprocessproductionparts.3.10SamplingTechniquePriortotheremovalofanyaliquot(testsample)fromaprocesstank:(1)thelevelofthesolutioninthetankshouldbebroughttonormaloperatinglevel,(2)thesolutiontemperatureshallbeadjustedasnecessarytoensureallconstituentsaredissolvedinthesolutionand(3)ifthetanklevelneedstobeadjustedbyadditionofwater(orotherdiluent),thesolutionshallbemixedthoroughly.3.11WhentheconcentrationofanyconstituentisnotwithintheProcessControlRangeyetisstillwithintheSpecificationRange,thesolutionremainsusableandpartsprocessedthroughsuchasolutionarefullyacceptable(withrespecttoprocessingsolutions)andequivalenttothoseprocessedinasolutionwhichiswithintheProcessControlRange.NosolutionshallbeusedtoprocesspartsifanyconstituentconcentrationisnotwithintheapplicableSpecificationRangeunlessotherwiseauthorizedbythecognizantengineeringorganization.--````````,,`,`,,,,,,``,``,`,`,-`-`,,`,,`,`,,`---CopyrightSAEInternationalProvidedbyIHSunderlicensewithSAELicensee=TaikooAircraft/5910393001,User=Wu,LisaNoreproductionornetworkingpermittedwithoutlicensefromIHSNotforResale,04/25/201219:08:13MDT SAEARP4992BPage4of44.QUALITYASSURANCEREQUIREMENTS4.1Theprocessorshallberesponsibleforperformingallrequiredtests.4.2RecordsTheprocessorshallberesponsibleformaintainingrecordsforaminimumof3years.Changestotestfrequenciesandreasonsforthechangesshallbenotedintherecords.Recordsshallbemaintainedsequentiallyinwritingorelectronicmedia.4.3Analyticalproceduresshallbeperformedinamanneracceptabletothecognizantengineeringorqualityorganization.4.4Whenaconstituent’sconcentrationisnotwithintheSpecificationRangeorthesolutionhasnotbeenanalyzedonscheduleortheoperatingtemperatureisnotwithintherangerequiredbytheapplicableprocessspecificationorworkinstruction,theprocessorshalltakeappropriateactiontopreventtheprocessingofparts.Asolutionthathasbeensubjectedtoanycircumstancethatcouldresultinanout-ofspecification-rangeconditionsuchasanoverflowshallbeanalyzedandconcentrationsadjustedtospecificationrangepriortoreuse.Useofa“RedTag”onthetankorvesselisrecommended.AfteracorrectionismadetorestoreallconstituentconcentrationstowithintheSpecificationRange,thesolutionshallbere-analyzedtoestablishthattheconstituents’concentrationsarewithintheSpecificationRangebeforeprocessingofpartsisallowedtoresume.5.NOTES5.1Achangebar(|)locatedintheleftmarginisfortheconvenienceoftheuserinlocatingareaswheretechnicalrevisions,noteditorialchanges,havebeenmadetothepreviousissueofthisdocument.An(R)symboltotheleftofthedocumenttitleindicatesacompleterevisionofthedocument,includingtechnicalrevisions.Changebarsand(R)arenotusedinoriginalpublicationsnorindocumentsthatcontaineditorialchangesonly.--````````,,`,`,,,,,,``,``,`,`,-`-`,,`,,`,`,,`---PREPAREDBYAMSCOMMITTEE“B”CopyrightSAEInternationalProvidedbyIHSunderlicensewithSAELicensee=TaikooAircraft/5910393001,User=Wu,LisaNoreproductionornetworkingpermittedwithoutlicensefromIHSNotforResale,04/25/201219:08:13MDT