AIAG CQI-27 Sspecial Process:CastingSystemAssessment Version 2 Issue 3/2018 CQI-27 Special Process: Casting System Assessment Complete Foundry Name: Complete Address: Phone Number: Website: Date of Assessment: Date of Previous Assessment(s) Date of Re-Assessment (if necessary) Foundry Personnel Contacted: Name: Tile: Phone: Email: Auditors/Assessors Name: Company: Phone: [Email: Number of Conforming Number of Not Number of Non- Types of Casting Processes at this Foundry: Findings Conforming Findings Applicable Findings Process TableA Sand Casting (lron/Steel) Process Table B Centrifugal Castings Process TableC Centrifugal Liners Process Table D Investment Castings (lron/Steel) Process TableE ProcessTableF Aluminum Sand Castings Process TableG Aluminum Metal Mold Process Table H Aluminum High Pressure Die Cast ProcessTablel Magnesium High Pressure Die Cast Process TableJ Zinc High Pressure Die Cast @2018 Automotive Industry Action Group ISBN#:978160534 388 4 AIAG CQI-27 SpecialProcess: Casting SystemAssessment Version 2, 3/2018 PROCESS TABLEA-Sand Castings (lron/Steel) All requirements given below are subordinate to customer specific requirements. When performing the CQi-27 Casting Assessment the auditor shall verify foundry is conforming to customer requirements; including a customer approved Control Plan defining the agreed upon inspection testing and frequencies. *If minimum requirements are not met, provide supporting records to justify actual conditions. What is the scope covered by this audit? ? The entire foundry? A specific product line? A specific part number? Other? Describe the scope of the audit: Conforming / Observations / Comments Item Category/Process Step Requirement Non-Conforming / aboutActual Condition Not Applicable 1.0 Casting Design and Tooling castings used in automotive applications.There is a wide variety of molding processes Casting Process including green sand, air set bonded sands, shell molding, stacking molding, precision sand core packages. 1. Casting plant must be compliant to customer specific software requirements. A1.1 Design Software transfer for the tooling and for part Drawings / Models. 1.The casting plant must use solidification modeling software such as MagmaSoft, AnyCasting, ProCast, EKK,FLOW-3D or similar software approved by the customer Product Engineering on the casting as part of the design process for the gating and A1.2 feeding system prior to tooling construction and prototype part submission. Simulation Casting Simulation must include both flland solification analysis. 2. Results must be reviewed with the Customer Product Engineering. 3. At any high stress features in the FEA, the simulation should avoid hot spots, air entrapment, multiple metal fronts converging. 1. The design responsible party must complete an FEA (Finite Element Analysis) for the casting. The ultimate tensile strength, yield strength, and percent elongation used in the FEA must be over the lower limit of engineering requirement for the specified ally for similar applications. 2. The foundry should know the specific features of the casting where maximum FEA Analysis stresses exceed 50% of the Yield Strength. For purposes of this assessment, the A1.3 Part One 3. Yield Strength as used in this discussion is the x-bar (mean value) minus 3s (three sigma)statisticalcalculationfrom tensilebarspulled at the casting source. 4. Any high stress features identified in the FEA must be evaluated when casting simulations are reviewed, and when establishing product audits such as wall thickness, microstructure, hardness, x-ray, crack inspections. @ 2018 Automotive Industry Action Group ISBN#: 978160534388 4 A2 AIAG CQI-27 SpecialProcess: Casting SystemAssessment Version 2, 3/2018 PROCESS TABLE A - Sand Castings (lron/Steel) All requirements given below are subordinate to customer specific requirements. When performing the CQi-27 Casting Assessment the auditor shall verify foundry is conforming to customer requirements; in