Process Flow Diagram

Part Name : Intercooler Assembly PFD No : PFD / 06 IC 529 0000

Part No. : 06 IC 529 0000 Issue No : 0
Date : 14.03.2020
Rev No : 3
Rev Date : 11.07.2023

spl. Char.
Operation No. Operation / Activity Equipment Operation Product Characteristics Process Characteristics
class

a)CAC Core Visual

Assembly of core with tanks, pipes in b)Tank & Pipe visual
06 IC 005290000044 Welding Fixture
welding fixture c)Fitment of all parts in welding fixture
should be perfect.

Linear Welding Current -

Assy. Welding & Inspection Top bkt. Slot CTC - 776±1.5
220 to 270 amps
Core (06 IC 529 1000) Bottom bkt. Slot CTC - 631±1.5 Argon Gas flow - 12 ± 1 Lpm

Tank LH(06 IC 484 1500) Top Bkt CL to Bottom Bkt Slot CTC - 473±1.0 Filler rod dia - 3.2mm

Tank RH (06 IC 484 1600) CAC cl to tank top bracket cl - 188±2.0 TYP

Pipe LH (06 IC 529 1510) CAC cl to LH pipe cl - 513±3.0

Tig Welding Machine
Pipe RH (06 IC 529 1610) Welding fixture & CAC cl to RH pipe cl - 529±3.0
Inspection fixture
06 IC 005290000046, 48
06/IC/529/WF-01
06/IC/529/IF-01
Pipe CTC - 734±3.0
06/IC/529/CTC-01

No visual defects at any part of the assembly

No foreign particles / Dust Allowed

No poor welding, spatter, High points allowed.

Penetration - 7.5% of base metal thickness

4±0.5
06 IC 005290000050 End sheet cutting at V- notch Cutting blade
No burr, scratches observed at outside

Format : F / APQP / 03
Page 1 of 2
Rev 00

Part Name : Intercooler Assembly
Part No. : 06 IC 529 0000
Operation No.
06 IC 005290000052
06 IC 005290000053
06 IC 005290000054
06 IC 005290000056
06 IC 005290000058
06 IC 005290000090
06 IC 005290000094
06 IC 005290000095
Prepared by :Prabhakaran
- Operation
All Dimensions are in mm unless otherwise specified
Format : F / APQP / 03
Rev 00
Process Flow Diagram
PFD No : PFD / 06 IC 529 0000
Issue No : 0
Date : 14.03.2020
Rev No : 3
Rev Date : 11.07.2023
spl. Char.
Operation / Activity Equipment Operation Product Characteristics Process Characteristics
class
Coupler Testing Block
Coupler Testing for DLT 0.000~0.005 Pa/s
(ATPL/CTB/03)
Dry Leak testing Machine Leak allowed upto 5ccm @ 3.10 +0.05/-0.0
Dry Leak testing
(ATPL-P158) Bar C
Pressure to be set @
3.15 bar
Wet Leak testing rig
No leak @ 3.10 +0.05/-0.0 Bar
Wet Leak Testing (ATPL-P27) C
Drying Compressed air Free from water, moisture & Dust
Painting Painting kit Intercoolers free from black marks
Final inspection Measuring Instruments As per FPQP
Parts to be packed as per approved packing
Packing PP box
standard
Stroage PP box No visual defects at any part of the assembly
Checked by : Mohan Raj Approved by : Thanigainathan
- Inspection - Storage - Operation with Inspection D - Dispatch - Transport
Revision History
Sl.No Rev No Rev Date Details of Changes Remarks
1 0 New release
Leak test pressure changed from 3.80 to 3.15
2 1 13.02.2021
Bar
3 12.08.2021 Reviewed for updation but no changes found
4 09.02.2022 Reviewed for updation but no changes found
5 08.08.2022 Reviewed for updation but no changes found
6 07.02.2023 Reviewed for updation but no changes found
7 2 07.04.2023 Penetration added
Operation no: 54 changed for leak testing
process.
8 3 11.07.2023 Separate Operation no's included for Dry leak
(53) and Wet leak testing (54)
Filler Rod dia included
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