Supporting AS9100 Processes for Aerospace Plating and Metal Finishing
As an ISO 17025 and Nadcap accredited laboratory, Omega Research Inc. provides exceptional testing services to aerospace plating and metal finishing companies. Our Investigative & R&D Support Testing program offers a specialized, systematic approach to support the diagnosis and resolution of persistent failures in process control testing, including hydrogen embrittlement (ASTM F519), salt spray corrosion (ASTM B117), coating weight (ASTM B137 or MIL-A-8625), and Taber abrasion (ASTM D4060). This testing utilizes Omega’s accredited equipment and ASTM-compliant processes but is conducted outside the standard sample set requirements and does not produce an accredited pass/fail certificate. Results are provided as “Information Only” reports that support your investigation, corrective action process, or R&D objectives.
What Is Investigative & R&D Support Testing?
Investigative & R&D Support Testing is a diagnostic framework that uses Omega’s accredited testing equipment and compliant processes to isolate variables in your operation that may be contributing to recurring failures. Unlike standard process control testing — which requires a defined sample set (e.g., four bars under ASTM F519) and produces a formal accredited certificate — investigative testing is configured to your specific question. Sample quantities, configurations, and test parameters are tailored to the investigation. Results are documented in an “Information Only” report. These reports provide data to support your corrective action or R&D decisions but do not constitute a formal test disposition.
How Investigative Testing Aligns with AS9100 Processes
Facilitating Test Invalidation
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 a cleaning method, bath chemistry condition, or sample preparation variable contributed to the result. 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)
Challenge: Test failure due to suspected excessive hydrogen from acid cleaning or insufficient bake.
Approach: Test variable relief bake times and cleaning methods using 1a1/1a2 samples configured outside the standard four-bar sample set.
Outcome: Identified optimal bake at 375°F ± 25°F for 23+ hours. Customer used this data to adjust their process and submitted a standard process control test to confirm compliance.
Price: ~50% of standard test cost.
Salt Spray Corrosion Testing (ASTM B117)
Challenge: Failure at 168 hours, possibly due to contaminated rinse water.
Approach: Compare DI/RO rinse procedures.
Outcome: Verified test invalidation and updated rinse protocols.
Price: ~50% of standard test cost.
Coating Weight Testing (MIL-DTL-16232 or MIL-PRF-8625)
Challenge: Test failure from inconsistent coating weight.
Approach: Adjust immersion times and bath concentration.
Outcome: Achieved consistent target weights.
Price: ~50% of standard test cost.
Taber Abrasion Testing (ASTM D4060)
Challenge: Failure due to under-cured coating.
Approach: Modify cure times and humidity conditions.
Outcome: Improved abrasion resistance, validated new curing protocol.
Price: ~50% of standard test cost.
Why 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.
- Data-driven “Information Only” reports that support your investigation and inform subsequent standard testing
- 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
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.
