That’s exactly why Omega Research developed its Investigative & R&D Support Testing program. We saw a pattern: customers were repeatedly facing nonconformances with no obvious explanation, often resorting to trial-and-error or full process overhauls to chase down the issue. Investigative testing was created to address that challenge directly — a structured, data-driven approach designed to isolate and eliminate the unknowns using Omega’s accredited equipment and ASTM-compliant test processes, without requiring the standard sample set or producing a formal accredited certificate.
Built into the culture of Omega is a desire to reduce failure rates, not just test for them. Our investigative testing program reflects that mindset. It’s not a substitute for process control testing — it’s a tool to reinforce it. The methodology follows the Plan-Do-Check-Act cycle required under AS9100, offering manufacturers a framework to investigate failures systematically and make precise process adjustments that lead to more consistent results. All investigative test results are provided as “Information Only” reports that support the customer’s own investigation and corrective action process.
Turning Failures Into Actionable Insight
Unlike standard process control tests that confirm pass/fail against a specification’s full sample set requirements, investigative testing is a methodical diagnostic exercise. It isolates process variables one by one — things like bath chemistry, post-treatment time, cure conditions, or substrate variability — to determine exactly what’s causing the issue. By identifying the root cause, manufacturers can make focused corrections instead of overhauling their entire process. Because investigative testing is configured to the specific question being asked, sample quantities and test parameters are tailored to the investigation rather than fixed by the governing specification.
A Problem-Solving Tool That Supports AS9100
Aerospace and defense manufacturers operate under the rigorous AS9100 quality standard. That standard emphasizes data-driven decision-making, process validation, and continuous improvement.
Investigative testing aligns directly with the Plan-Do-Check-Act (PDCA) cycle at the heart of AS9100:
- Plan: Evaluate potential variables that could be impacting test outcomes.
- Do: Run comparative tests on controlled samples.
- Check: Analyze results to identify trends and failure points.
- Act: Apply findings to correct the root cause, then submit a standard process control test to confirm compliance.
Supporting Customer-Directed Investigations
When a process control test produces an unexpected result, determining whether the test was valid — or whether external variables affected the outcome — is a decision that belongs to the customer and their quality system. Omega’s investigative testing provides the data to inform that decision.
For example, if a hydrogen embrittlement test fails, investigative testing may explore whether the cleaning method introduced excess hydrogen or whether bath chemistry had degraded. We use controlled sample testing and comparative baselines to isolate variables, and document findings in an “Information Only” report. The customer uses this data within their own AS9100-compliant investigation and disposition process.
Enabling Corrective Actions
When test results are valid but non-conforming, investigative testing supports the “Act” phase of AS9100’s PDCA cycle. We design custom test matrices to explore different process parameters — like minimum/maximum cleaning times, bath age, pH variations, or post-treatment methods. The results give you clear, actionable process adjustments to correct issues and avoid repeat failures.
In many cases, once the customer has implemented process corrections based on investigative findings, they submit a new standard process control test through normal channels to confirm compliance and obtain a formal accredited result.
Driving Continuous Improvement
AS9100 demands a culture of continuous improvement. By diagnosing root causes and validating new process parameters, investigative testing embeds insights into your long-term quality program, reducing future risk and increasing confidence in your procedures.
Examples of Investigative Testing in Practice
Hydrogen Embrittlement Testing (ASTM F519):
After a failure, we helped a customer investigate whether excess hydrogen was being introduced by an acid clean step. Investigative testing using Omega’s F519-compliant equipment and 1a1/1a2 samples — configured outside the standard four-bar sample set — revealed that a bake at 375°F ± 25°F for 23+ hours addressed the suspected variable. The customer used this data to adjust their process and subsequently submitted a standard process control test that confirmed compliance.
Salt Spray Corrosion Testing (ASTM B117):
A customer saw early corrosion failures in parts that should have passed. Investigative testing uncovered the culprit: a rinse stage using contaminated water. Once replaced with DI water, results improved immediately.
Coating Weight Testing (MIL-PRF-8625):
An inconsistent phosphate coating led to rejected parts. Through immersion time and bath concentration testing, the investigative program helped the customer refine their chemistry and hit consistent coating weight targets.
Taber Abrasion Testing (ASTM D4060):
A batch of parts failed due to premature wear. Investigation revealed under-curing as the issue. Adjustments to cure temperature and humidity eliminated the problem.
Why Manufacturers Choose Omega for Investigative & R&D Support Testing
When production is on the line, companies turn to Omega not just for lab services, but for partnership. We’ve been helping aerospace manufacturers troubleshoot process control failures for over 40 years. That experience informs how we design investigative test programs — from custom test matrices to side-by-side comparisons — always backed by Nadcap-compliant documentation and detailed data reports.
- 40+ years of expertise and participation in ASTM and AMS committees
- 200+ hydrogen embrittlement machines, Taber abrasion testers, B117 salt spray chambers, and coating weight equipment
- ISO 17025 and Nadcap accredited operations
- Custom investigative test plans designed to support customer-directed investigations and corrective actions
- Flexible pricing at approximately 50% of standard test cost with no minimum fees
- Data-driven “Information Only” reports that support your investigation and inform subsequent standard testing
Next Steps
Contact Omega Research to discuss your process control testing challenges and review our failure investigation checklists. We’ll collaborate to design an investigative test plan tailored to your process and the specification in question. You submit samples for testing and receive an “Information Only” report with data to support your investigation. When you’re ready to confirm process compliance, you submit a standard process control test through normal channels for a formal accredited result.
For additional details or to get started, contact us at sales@omegaresearchinc.com or call 940-648-5828. We are your trusted partner in achieving AS9100-compliant, high-quality results for the aerospace industry.
Note: Investigative & R&D Support Testing reports are provided for informational purposes only and do not constitute an accredited test result or formal pass/fail disposition. The customer retains full ownership of all investigation conclusions, corrective actions, and disposition decisions. Always adhere to your customer’s or specification’s requirements, as they may differ from general guidelines.
