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    Process Validation Record

    Uploaded by

    Rodrigo Kawamura
    The document summarizes the results of process validation tests for hardening and tempering of various steel parts. For hardening, different furnace temperatures, soak times, quenchant temperatures and flow rates, and carbon concentrations were tested. The optimal hardening conditions were determined to be 860-880°C for 180-200 minutes with a maximum quenchant temperature of 45°C, flow rate of 0.2 L/hr, and carbon concentration of 2.5-3.0%. For tempering, different temperatures and soak times were tested for various steel parts to achieve the required hardness values. The optimal tempering conditions were identified as 500-600°C for 80-90 minutes.

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    Process Validation Record

    Uploaded by

    Rodrigo Kawamura
    242 views11 pages
    The document summarizes the results of process validation tests for hardening and tempering of various steel parts. For hardening, different furnace temperatures, soak times, quenchant temperatures and flow rates, and carbon concentrations were tested. The optimal hardening conditions were determined to be 860-880°C for 180-200 minutes with a maximum quenchant temperature of 45°C, flow rate of 0.2 L/hr, and carbon concentration of 2.5-3.0%. For tempering, different temperatures and soak times were tested for various steel parts to achieve the required hardness values. The optimal tempering conditions were identified as 500-600°C for 80-90 minutes.

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    Template sheet from a quenching process validation

    Original Title

    325103961-process-validation-record-xls

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    The document summarizes the results of process validation tests for hardening and tempering of various steel parts. For hardening, different furnace temperatures, soak times, quenchant temperatures and flow rates, and carbon concentrations were tested. The optimal hardening conditions were determined to be 860-880°C for 180-200 minutes with a maximum quenchant temperature of 45°C, flow rate of 0.2 L/hr, and carbon concentration of 2.5-3.0%. For tempering, different temperatures and soak times were tested for various steel parts to achieve the required hardness values. The optimal tempering conditions were identified as 500-600°C for 80-90 minutes.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    242 views11 pages

    Process Validation Record

    Uploaded by

    Rodrigo Kawamura
    The document summarizes the results of process validation tests for hardening and tempering of various steel parts. For hardening, different furnace temperatures, soak times, quenchant temperatures and flow rates, and carbon concentrations were tested. The optimal hardening conditions were determined to be 860-880°C for 180-200 minutes with a maximum quenchant temperature of 45°C, flow rate of 0.2 L/hr, and carbon concentration of 2.5-3.0%. For tempering, different temperatures and soak times were tested for various steel parts to achieve the required hardness values. The optimal tempering conditions were identified as 500-600°C for 80-90 minutes.

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    You are on page 1of 11

    Eastman DOC NO.

    FMT/PROD/04
    Process Validation Record (Hardening)
    Cast & Forge Limited ISSUE NO. 02
    ISSUE DATE. 10.03.16

    Carbon Concentration Hardness


    Hardening Quenching Hardness
    Date R.M.Grade Furnace No. Soaking Time Flow of quenching Reqd. Remarks
    Temp. water temp. Observed
    (Ltr/Hr) media(%age) (HRC)
    10.03.16 EN8D[ Tommy bar GCF-1 8500C 180 Min 40 0.20 2.50 50-55 Not Ok
    no. 3, Wheel
    Spanner 27 X 30 GCF-1 8600C 180 Min 40 0.20 2.50 50-55 Part Ok
    Extra Length,
    Tommy bar No. 5, GCF-1 8800C 180 Min 40 0.20 2.50 50-55 Part Ok
    Tommy bar all
    GCF-1 8900C 180 Min 40 0.20 2.50 50-55 Part not ok
    sizes drive square]
    GCF-1 8700C 160 Min 40 0.20 2.50 50-55 Part Not Ok
    GCF-1 8700C 180 Min 40 0.20 2.50 50-55 Part Ok
    GCF-1 8700C 200 Min 40 0.20 2.50 50-55 Part Ok
    GCF-1 8700C 210 Min 40 0.20 2.50 50-55 Part Not Ok
    GCF-1 8700C 180 Min 20 0.20 2.50 50-55 Part Ok
    GCF-1 8700C 180 Min 30 0.20 2.50 50-55 Part Ok
    GCF-1 8700C 180 Min 45 0.20 2.50 50-55 Part Ok
    GCF-1 8700C 180 Min 50 0.20 2.50 50-55 Part Not Ok
    GCF-1 8700C 180 Min 40 0.18 2.50 50-55 Part Not Ok
    GCF-1 8700C 180 Min 40 0.20 2.50 50-55 Part Ok
    GCF-1 8700C 180 Min 40 0.23 2.50 50-55 Part not Ok
    GCF-1 8700C 180 Min 40 0.30 2.50 50-55 Part Not Ok
    GCF-1 8700C 180 Min 40 0.20 2.45 50-55 Part Not Ok
    GCF-1 8700C 180 Min 40 0.20 2.50 50-55 Part Ok
    GCF-1 8700C 180 Min 40 0.20 3.00 50-55 Part Ok
    GCF-1 8700C 180 Min 40 0.20 3.15 50-55 Part Not Ok
    Conclusion GCF-1 860°C - 880°C 180-200 Min Max 45° 0.2 2.5-3.0 Part Ok

    Reviewed & Approved By :-


    Eastman Process Validation Record DOC NO. FMT/PROD/04/A

    Cast & Forge Limited (Tempering) ISSUE NO. 02


    ISSUE DATE. 10.03.16

    Hardness
    Tempering Soaking Hardness
    Date R.M.Grade Furnace No. required Remarks
    Temp. Time(Min) observed
    (HRC)
    Temp-1 5200C 90 Part Not Ok
    Temp-1 530 C
    0
    90 Part Ok
    Temp-1 5800C 90 Part Ok
    EN8D( Tommy bar Temp-1 5900C 90 Part Not Ok
    10.03.16 30-36
    no. 3) Temp-1 560 C
    0
    80 Part Not Ok
    Temp-1 560 C
    0
    90 Part Ok
    Temp-1 560 C
    0
    100 Part Ok
    Temp-1 560 C
    0
    110 Part Not Ok
    Temp-1 530 C
    0
    90 Part Not Ok
    Temp-1 540 C
    0
    90 Part Ok
    Temp-1 6400C 90 Part Ok
    EN8D( Wheel
    Spanner 27 X 30 Temp-1 6500C 90 Part Not Ok
    11.03.16 25-32
    Extra Length & Temp-1 600 C
    0
    80 Part Not Ok
    Tommy bar No. 5)
    Temp-1 600 C
    0
    90 Part Ok
    Temp-1 600 C
    0
    100 Part Ok
    Temp-1 600 C
    0
    110 Part Not Ok
    Temp-1 440 C
    0
    90 Part Not Ok
    Temp-1 450 C
    0
    90 Part Ok
    Temp-1 5500C 90 Part Ok
    EN8D[Tommy Bar( Temp-1 5600C 90 Part Not Ok
    11.03.16 all size except no. 5 35-45
    & 3) drive square] Temp-1 500 C
    0
    80 Part Not Ok
    Temp-1 500 C
    0
    90 Part Ok
    Temp-1 500 C
    0
    100 Part Ok
    Temp-1 500 C
    0
    110 Part Not Ok
    EN8D( Tommy bar 530°C -
    30-36 90-100 Part Ok
    no. 3) 580°C
    EN8D( Wheel
    Spanner 27 X 30 540°C -
    25-32 90-100 Part Ok
    Extra Length & 640°C
    Conclusion Tommy bar No. 5) Temp-1

    EN8D[Tommy Bar(
    450°C -
    all size except no. 5 35-45 90-100 Part Ok
    550°C
    & 3) drive square]

    Reviewed & Approved By :-


    Eastman DOC NO. FMT/PROD/04
    Process Validation Record (Hardening)
    Cast & Forge Limited ISSUE NO. 02
    ISSUE DATE. 10.03.16

    Carbon Concentration Hardness


    Hardening Quenching Hardness
    Date R.M.Grade Furnace No. Soaking Time Flow of quenching Reqd. Remarks
    Temp. water temp. Observed
    (Ltr/Hr) media(%age) (HRC)
    11.03.16 EN18( Wheel Spanner- GCF-1 8100C 45 Min 40 0.50 19.00 40-50 Not Ok
    30X32 M&M,30x32
    TELCO, 27A/F TELCO, GCF-1 8200C 45 Min 40 0.50 19.00 40-50 Part Ok
    29 A/F TELCO, 32 A/F
    TELCO, 27 A/F L&T, GCF-1 8400C 45 Min 40 0.50 19.00 40-50 Part Ok
    30X32 EICHER, 32 GCF-1 8500C 45 Min 40 0.50 19.00 40-50 Crack observed
    A/F, 30x32 EICHER
    EXTRA LONG, GCF-1 8300C 40 Min 40 0.50 19.00 40-50 Part Not Ok
    15/16X1^1/8, LONG
    SOCKET W/S TYRE GCF-1 8300C 45 Min 40 0.50 19.00 40-50 Part Ok
    LEVER, SMALL
    SOCKET 1^1/8) GCF-1 8300C 50 Min 40 0.50 19.00 40-50 Part Ok
    GCF-1 8300C 55 Min 40 0.50 19.00 40-50 Part Not Ok
    GCF-1 8300C 45 Min 20 0.50 19.00 40-50 Part Ok
    GCF-1 8300C 45 Min 30 0.50 19.00 40-50 Part Ok
    GCF-1 8300C 45 Min 45 0.50 19.00 40-50 Part Ok
    GCF-1 8300C 45 Min 50 0.50 19.00 40-50 Part Not Ok
    GCF-1 8300C 45 Min 40 0.45 19.00 40-50 Part Not Ok
    GCF-1 8300C 45 Min 40 0.50 19.00 40-50 Part Ok
    GCF-1 8300C 45 Min 40 0.52 19.00 40-50 Part not Ok
    GCF-1 8300C 45 Min 40 0.55 19.00 40-50 Part Not Ok
    GCF-1 8300C 45 Min 40 0.50 17.00 40-50 Part Not Ok
    GCF-1 8300C 45 Min 40 0.50 18.00 40-50 Part Ok
    GCF-1 8300C 45 Min 40 0.50 20.00 40-50 Part Ok
    GCF-1 8300C 45 Min 40 0.50 21.00 40-50 Part Not Ok
    Conclusion EN18 GCF-1 820°C - 840°C 45-50 Min Max 45° 0.5 18-20 - Part Ok
    Reviewed & Approved By :-
    Eastman DOC NO. FMT/PROD/04/A
    Process Validation Record (Tempering)
    Cast & Forge Limited ISSUE NO. 02
    ISSUE DATE. 10.03.16

    Hardness
    Tempering Soaking Hardness
    Date R.M.Grade Furnace No. required Remarks
    Temp. Time(Min) observed
    (HRC)
    Temp-1 5400C 90 Part not ok
    Temp-1 5500C 90 Part Ok
    Temp-1 6500C 90 Part Ok
    EN18(Wheel Spanner- 30X32
    M&M,30x32 TELCO, 27A/F Temp-1 6600C 90 Part not ok
    12.03.16 25-32
    TELCO, 29 A/F TELCO, 32 A/F Temp-1 6000C 80 Part not ok
    TELCO, 27 A/F L&T)
    Temp-1 6000C 90 Part Ok
    Temp-1 6000C 100 Part Ok
    Temp-1 6000C 110 Part not ok
    Temp-1 4000C 90 Part not ok
    Temp-1 4100C 90 Part Ok
    Temp-1 5100C 90 Part Ok
    EN18( WHEEL SPANNER- 30X32 Temp-1 5300C 90 Part not ok
    12.03.16 EICHER, 32 A/F, 30x32 EICHER 35-45
    EXTRA LONG, ) Temp-1 4600C 80 Part not ok
    Temp-1 4600C 90 Part Ok
    Temp-1 4600C 100 Part Ok
    Temp-1 4600C 110 Part not ok
    Temp-1 4600C 90 Part not ok
    Temp-1 4800C 90 Part Ok
    Temp-1 5600C 90 Part Ok
    EN18( WHEEL SPANNER- Temp-1 5700C 90 Part not ok
    12.03.16 32-38
    15/16X1^1/8) Temp-1 5000C 80 Part not ok
    Temp-1 5000C 90 Part Ok
    Temp-1 5000C 100 Part Ok
    Temp-1 5000C 110 Part not ok
    Temp-1 5000C 90 Part not ok
    Temp-1 5100C 90 Part Ok
    Temp-1 5600C 90 Part Ok
    EN18(LONG SOCKET W/S TYRE Temp-1 5700C 90 Part not ok
    14.03.16 32-38
    LEVER) Temp-1 5300C 80 Part not ok
    Temp-1 5300C 90 Part Ok
    Temp-1 5300C 100 Part Ok
    Temp-1 5300C 110 Part not ok
    Temp-1 4700C 90 Part not ok
    Temp-1 4800C 90 Part Ok
    Temp-1 5400C 90 Part Ok
    Temp-1 5500C 90 Part not ok
    14.03.16 EN18(SMALL SOCKET 1^1/8) 32-36
    Temp-1 5200C 80 Part not ok
    Temp-1 520 C
    0
    90 Part Ok
    Temp-1 5200C 100 Part Ok
    Temp-1 5200C 110 Part not ok
    EN18(Wheel Spanner- 30X32
    M&M,30x32 TELCO, 27A/F
    25-32 550°C - 650°C 90-100 Part Ok
    TELCO, 29 A/F TELCO, 32 A/F
    TELCO, 27 A/F L&T)

    EN18( WHEEL SPANNER- 30X32 Temp-1


    EICHER, 32 A/F, 30x32 EICHER 35-45 410°C - 510°C 90-100 Part Ok
    Conclusion EXTRA LONG, )

    EN18( WHEEL SPANNER-


    32-38 480°C - 560°C 90-100 Part Ok
    15/16X1^1/8)
    EN18(LONG SOCKET W/S TYRE
    32-38 510°C - 560°C 90-100 Part Ok
    LEVER)
    EN18(SMALL SOCKET 1^1/8) 32-36 480°C - 540°C 90-100 Part Ok

    Reviewed & Approved By :-


    Eastman DOC NO. FMT/PROD/04
    Process Validation Record (Hardening)
    Cast & Forge Limited ISSUE NO. 02
    ISSUE DATE. 10.03.16

    Carbon Concentration Hardness


    Hardening Quenching Hardness
    Date R.M.Grade Furnace No. Soaking Time Flow of quenching Reqd. Remarks
    Temp. water temp. Observed
    (Ltr/Hr) media(%age) (HRC)
    15.03.16 EN18(Tyre Lever) GCF-1 8500C 45 Min 40 0.50 21.00 58-60 Not Ok
    GCF-1 8600C 45 Min 40 0.50 21.00 58-60 Part Ok
    GCF-1 8800C 45 Min 40 0.50 21.00 58-60 Part Ok
    GCF-1 8900C 45 Min 40 0.50 21.00 58-60 Crack observed
    GCF-1 8700C 40 Min 40 0.50 21.00 58-60 Part Not Ok
    GCF-1 8700C 45 Min 40 0.50 21.00 58-60 Part Ok
    GCF-1 8700C 50 Min 40 0.50 21.00 58-60 Part Ok
    GCF-1 8700C 55 Min 40 0.50 21.00 58-60 Part Not Ok
    GCF-1 8700C 45 Min 20 0.50 21.00 58-60 Part Ok
    GCF-1 8700C 45 Min 30 0.50 21.00 58-60 Part Ok
    GCF-1 8700C 45 Min 45 0.50 21.00 58-60 Part Ok
    GCF-1 8700C 45 Min 50 0.50 21.00 58-60 Part Not Ok
    GCF-1 8700C 45 Min 40 0.45 21.00 58-60 Part Not Ok
    GCF-1 8700C 45 Min 40 0.50 21.00 58-60 Part Ok
    GCF-1 8700C 45 Min 40 0.52 21.00 58-60 Part not Ok
    GCF-1 8700C 45 Min 40 0.55 21.00 58-60 Part Not Ok
    GCF-1 8700C 45 Min 40 0.50 19.00 58-60 Part Not Ok
    GCF-1 8700C 45 Min 40 0.50 20.00 58-60 Part Ok
    GCF-1 8700C 45 Min 40 0.50 22.00 58-60 Part Ok
    GCF-1 8700C 45 Min 40 0.50 23.00 58-60 Part Not Ok
    Conclusion EN18(Tyre Lever) GCF-1 860°C - 880°C 45-50 Min Max 45° 0.5 20-22 - Part Ok
    Reviewed & Approved By :-
    Eastman DOC NO. FMT/PROD/06/A
    Process Validation Record (Painting)
    Cast & Forge Limited ISSUE NO. 02
    ISSUE DATE. 10.03.16

    Hardness
    Tempering Soaking Hardness
    Date R.M.Grade Furnace No. required Remarks
    Temp. Time(Min) observed
    (HRC)
    Temp-1 5500C 150 Part not ok
    Temp-1 560 C
    0
    150 Part Ok
    Temp-1 5800C 150 Part Ok
    Temp-1 6000C 150 Part not ok
    15.03.16 EN18(Tyre Lever) 32-38
    Temp-1 5700C 140 Part not ok
    Temp-1 570 C
    0
    150 Part Ok
    Temp-1 5700C 160 Part Ok
    Temp-1 5700C 180 Part not ok

    Conclusion EN18(Tyre Lever) Temp-1 32-38 560°C - 580°C 150-160 Part Ok

    Reviewed & Approved By :-


    Eastman DOC NO. FMT/PROD/04
    Process Validation Record (Hardening)
    Cast & Forge Limited ISSUE NO. 02
    ISSUE DATE. 10.03.16

    Carbon Concentration Hardness


    Hardening Quenching Hardness
    Date R.M.Grade Furnace No. Soaking Time Flow of quenching Reqd. Remarks
    Temp. water temp. Observed
    (Ltr/Hr) media(%age) (HRC)
    16.03.16 CHROME GCF-1 8500C 45 Min 40 0.20 2.50 45-50 Not Ok
    VANADIUM( WHEEL
    SPANNER- 24X27 & GCF-1 8600C 45 Min 40 0.20 2.50 45-50 Part Ok
    19X24
    L TYPE SPANNER GCF-1 8800C 45 Min 40 0.20 2.50 45-50 Part Ok
    (ALL SIZES))
    GCF-1 8900C 45 Min 40 0.20 2.50 45-50 Crack observed
    GCF-1 8700C 40 Min 40 0.20 2.50 45-50 Part Not Ok
    GCF-1 8700C 45 Min 40 0.20 2.50 45-50 Part Ok
    GCF-1 8700C 50 Min 40 0.20 2.50 45-50 Part Ok
    GCF-1 8700C 55 Min 40 0.20 2.50 45-50 Part Not Ok
    GCF-1 8700C 45 Min 20 0.20 2.50 45-50 Part Ok
    GCF-1 8700C 45 Min 30 0.20 2.50 45-50 Part Ok
    GCF-1 8700C 45 Min 45 0.20 2.50 45-50 Part Ok
    GCF-1 8700C 45 Min 50 0.20 2.50 45-50 Part Not Ok
    GCF-1 8700C 45 Min 40 0.18 2.50 45-50 Part Not Ok
    GCF-1 8700C 45 Min 40 0.20 2.50 45-50 Part Ok
    GCF-1 8700C 45 Min 40 0.23 2.50 45-50 Part not Ok
    GCF-1 8700C 45 Min 40 0.30 2.50 45-50 Part Not Ok
    GCF-1 8700C 45 Min 40 0.20 2.45 45-50 Part Not Ok
    GCF-1 8700C 45 Min 40 0.20 2.50 45-50 Part Ok
    GCF-1 8700C 45 Min 40 0.20 3.00 45-50 Part Ok
    GCF-1 8700C 45 Min 40 0.20 3.15 45-50 Part Not Ok
    Conclusion CRV GCF-1 860°C - 880°C 45-50 Min Max 45° 0.2 2.5-3% - Part Ok
    Reviewed & Approved By :-
    Eastman DOC NO. FMT/PROD/04/A
    Process Validation Record (Painting)
    Cast & Forge Limited ISSUE NO. 02
    ISSUE DATE. 10.03.16

    Paint Booth Required painting Thickness


    Date Product Air pressure Paint mass Gun angle Remarks
    No. Thickness distance Observed

    1 212 250 150 15 18 not ok

    2 212 275 300 20 34 ok

    3 212 300 400 30 22 not ok

    4 250 250 300 30 32 ok

    5 30-35 micron 250 275 400 15 36 ok


    lower Bottom link (M&M) 1
    6 250 300 150 20 21 Not OK

    7 310 250 400 20 35 ok

    8 310 275 150 30 32 ok


    9 310 300 300 15 23 not ok

    Conculation: Air pressure : 212-250, Painting Distance :- 250-275, paint mass:- no effect, Gun angle :- 15-20 degree.

    Reviewed & Approved By :-

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