5.SAND PREPARATION
5.1Are there documented procedures to monitor sand properties, with regard to the following:
Auditor Handbook: These questions are applicable for sand prior to being sent to mixers
5.1.1% Moisture? Yes/no na
5.1.2For Automatic Mixer Machines, is the Controller of % Mositure Calibrated? Yes/no/na
5.1.3Compactability/Tensile strength?yes/no/na
5.1.4Permeability?yes/no/na
5.1.5Green Compressive Strength?yes/no/na
5.1.6% Active Clay – Methylene Blue? Yes/no/na
5.1.7% LOI?yes/no/na
5.1.8Sieve Analysis? Yes/no
5.1.9Does the supplier calibrate the sieve analysis equipment per ASTM E11?yes/no
Auditor Handbook: Shaker and Sieves are to be calibrated as a unit. Calibration stickers are not required on each sieve. The calibration documentation should identify that the shaker and all the sieves were calibrated.
5.1.10% AFS Clay? Yes/no/na
5.1.11% Fines? Yes/no
5.2Is sand testing performed for core making and molding machines, with regard to the following:
Auditor Handbook: These questions are applicable for sand coming out of the mixers.
5.2.1% Moisture?yes/no
5.2.2For Automatic Mixer Machines, is the Controller of % Moisture Calibrated?yes/no/na
5.2.3Compactability/Tensile strength?yes/no/na
5.2.4Permeability?yes/no/na
5.2.5Green Compressive Strength?yes/no/na
5.2.6% Active Clay – Methylene Blue?yes/no/na
5.2.7% LOI?yes/no/na
5.2.8Sieve Analysis?yes/no
5.2.9Does the supplier calibrate the sieve analysis equipment per ASTM E11?yes/no
Auditor Handbook: Shaker and Sieves are to be calibrated as a unit. Calibration stickers are not required on each sieve. The calibration documentation should identify that the shaker and all the sieves were calibrated.
5.2.10% AFS Clay?yes/no/na
5.2.11% Fines?yes/no
5.3Are compact abilities automatically monitored at the muller?yes/no/na
5.4Is the return sand temperature monitored?yes/no/na
5.5Is the acceptance criteria documented for sand properties?yes/no
5.6Is there a documented action/reaction plan with “stop points” to follow when an out of spec condition is found?yes/no
6.COREMAKING
6.1Core Box SECTION NA
6.1.1Is the core box visually inspected before and after use, with regard to the following:
Auditor Handbook: There should not be any sand build up on pattern and the pattern should be coated with release agent.
6.1.1.1Cleanliness/Sand Buildup? Yes/no
6.1.1.2Damage?yes/no
6.1.1.3Vents?yes/no
6.1.1.4Pins/Bushings?yes/no
6.2Is the core making procedure/parameters documented, with regard to the following:
6.2.1Shell Core: SECTION NA
6.2.1.1Temperature? Yes/no
6.2.1.2Dwell Time? Yes/no
6.2.1.3Cure Time?yes/no
6.2.1.4Visual/Color? Yes/no
6.2.1.5Scratch Hardness? Yes/no
6.2.2Isocure Core: SECTION NA
6.2.2.1Binder Flow? Yes/no
6.2.2.2Catalyst Flow? Yes/no
6.2.2.3Dry Sand Flow to Match Mixer Output? Yes/no
6.2.2.4Visual? Yes/no
6.2.2.5Scratch Hardness?yes/no
6.2.3Do all release agents used for core making have a specification defining the composition or a vendor identification number or brand name? Yes/no
6.2.4Are core wash (core coating) materials:
6.2.4.1Water Base?
6.2.4.2Alcohol Base?
6.2.4.3Other specialty wash?
6.2.5Are core wash (core coating) materials applied by:
6.2.5.1Brush?
6.2.5.2Dip?
6.2.5.3Spray?
6.2.5.4Is there a procedure documenting core wash (core coating) requirements and are they being followed? YES/NO
Auditor Handbook: Auditor to witness the core wash process, is there 100% coverage.
6.2.5.5Is the core wash (core coating) monitored for baume/viscosity? YES/NO
Auditor Handbook: Verify same tests are being performed on weekends.
6.2.5.6 Are the cores properly stacked, packaged and stored to prevent damage during transport and storage? YES/NO
6.2.5.7 Has shelf life been determined and core production dates identified? YES/NO
6.2.5.8 Is a First in First out (FIFO) system used to prevent using cores that are beyond the documented shelf life? YES/NO
6.2.5.9 Are core assembly procedures documented and are they being followed? YES/NO
6.2.5.10 Does the supplier verify the cores are dry prior to use? YES/NO