Rewritten: Caterpillar: Confidential Green

REWRITTEN ®
CORPORATE PRODUCT & PROCESS SPECIFICATION
1.0 SCOPE
This specification describes the requirements of an acid etch procedure for detecting thermal
damage caused by grinding (“grinder burn”, “tempering”, or “grind checking”) on hardened steel
parts. A system for classifying the severity of grinder damage and piece part quality
requirements are also specified. This is a multiple variation specification.
2.0 APPLICATION
2.1 This specification is applicable to hardened steel parts with a hardness of RKW C40 or
greater with various heat treatments (direct hardened, carburized, nitride, induction hardened)
with machining after heat treatment. It is not applicable to stainless steels or non-ferrous alloys.
2.1.1 1E2317A Insp – Applies to critical ground surfaces which are highly susceptible to
grinding damage. 100% acid etch inspection is required.
2.1.2 1E2317B Insp – Applies to ground surfaces which require periodic inspection to ensure
conformance to the required quality level. If no inspection frequency is specified, 1E2317B shall
apply
3.0 DRAWING DESIGNATIONS
3.1 Drawings showing former designations shall be manufactured in accordance with current
designations.
Drawing Designation Former Designation

1E2317A 1E2317 INSP Type A
1E2317B 1E2317 INSP Type B
4.0 ETCHING REQUIREMENTS
4.1 Etching shall be in performed in accordance with the 1E2317 type 1 or type 2 etch
procedure detailed in Articles 14.3 and 14.4 of this specification or the appropriate procedure for
the material being etched, listed in one of the following standards: ANSI/AGMA 2007-C00, ISO
14104, SAE/AMS 2649, or MIL-STD-867.
4.1.1 The type 1 etch procedure with immersion described in this specification shall be the
arbitration method used to identify the presence and/or severity of burn. Type 1 etching is
preferred because of robustness and less opportunity for error.
THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.
DATE CHG NO NUMBER
INSPECTION – ACID ETCH 13 JUL 2018 06 1E2317
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Caterpillar: Confidential Green
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4.2 Etching by immersion is the preferred method for applying the reagents and shall be used
when etching parts with complex geometries like gears.
4.2.1 Parts that cannot be immersed may be etched using squirt bottles to flood the surface
being checked with the reagent, using the same solutions and procedures described in the
appropriate standard.
4.2.2 Swabbing is only acceptable with written approval from the Caterpillar Design Control
owner of the part.
4.3 Development of etching procedure
4.3.1 The chosen etching procedure shall be developed in such a manner as to generate the
maximum amount of contrast between burned and unburned areas. This shall include but is not
limited to; heating of the parts prior to etching, adjusting the acid concentration within the
specified limits, adjusting the etch or bleach times, and/or requiring the etched surface to be
viewed wet.
4.3.2 Development and validation of the etching procedure details (including time,
concentration, and contrast levels) shall be done with sample parts known to have both thermal
damage (tempered or burned areas) and areas without thermal damage or the Caterpillar
developed acid etch inspection sample, part number HTE11596.
4.3.3 A range of etch times shall be tested from very light etch to very dark etch and compared
to identify the best contrast. The preferred time and acid concentration shall be documented in
the work instructions.
4.3.4 If a bleach step is used in the selected process a range of bleach times and
concentrations shall be tested and compared to identify the best results. The preferred time and
acid concentration shall be documented in the work instructions.
4.3.5 Etched sample pieces or high-quality photographs (that accurately represent the etched
parts) showing appropriate contrast shall be available to inspectors for reference. If piece parts
are used for reference, the etched surfaces shall be protected by a clear lacquer or similar
coating that does not obstruct or change the appearance of the etch but will provide protection
from corrosion.
4.3.6 Documentation of the etch development and validation, process and photographs of the
results, shall be available to Caterpillar and be submitted as part of any PPAP submission.
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5.0 QUALIFICATION OF PERSONNEL
5.1 All personnel performing etch inspection shall be trained and certified in accordance with
SAE ARP1923.
5.1.1 Records shall be maintained documenting the training and certification for each person
performing inspections.
5.1.2 This requirement is effective January 2, 2019
6.0 QUALITY REQUIREMENTS
6.1 All surfaces designated for 1E2317 inspection shall be visually inspected immediately after
proper etching. Acceptable quality levels for gears are defined in Figure 1 using Figure 2
classification. Any part exceeding the allowable classification is non-conforming. All ground
surfaces on the part shall be examined (e.g., each gear tooth, bores, faces, diameters).
Surface Acceptable Quality Level

Tooth Flank & Root FA
Bore & Web - rolling element or
FB1
sleeve bearings
Bore - pressed in bearing races NB2
End Face – thrust washer surface FB1
End Face – Non-functional NB2
Ground journals or ground outer
NB2
diameters
Figure 1 - Gear Quality levels
6.2 Inspection after acid etch shall be done in a well-lit area with an intensity of not less than
300 foot-candles (3200 lx) at the surface of the part. When inspecting bores or other difficult to
see areas a secondary hand-held light of at least 200 foot-candles shall be used to eliminate
any shadows caused by indirect lighting.
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PREFIX CODE
F Functional Surfaces - flanks, ground roots, bearing journals, and other areas as
specified
N Non-Functional Surfaces - ground areas deemed non-functional by Caterpillar
CLASS CODE
(Measured on a single surface, e.g. single tooth flank)
Class Description Visual Appearance, Worst Area
A No Thermal Damage Uniform grey in color
B Light Thermal Damage Narrow/dark grey indications
(discontinuous streaks)
D Heavy Thermal Damage Large dark or black indications
E Severe Thermal Damage (Re-hardening) White areas surrounded by black
indications
SUFFIX CODE
(not applicable to Class A)
Level MAXIMUM Percentage of surface area affected measured on
a single surface, e.g. single tooth flank.
1 10%
2 25%
3 Unrestricted
Figure 2 - Surface Temper Indication Appearance & Classification System
6.3 The inspector shall ensure the sample is etched sufficiently either by comparing with a
standard sample or a target range on a suitable gray scale card (such as Tiffen G13 or G14). If
the part is not the correct shade of gray after etching, the etching process shall be reviewed and
corrected such that the correct shade of gray and appropriate level of contrast are achieved.
6.4 Extraneous indications – etch surfaces with fingerprints, spots, un-etched areas, or any
other extraneous indications are not acceptable and should be cleaned, re-etched, and re-
inspected in accordance with Article 9.0.
6.5 Parts referencing this specification that do not have an assigned classification shall meet
the FA/NB2 classification. Gear surfaces classifications are listed in Figure 1.
6.5.1 FA means no thermal damage indications are allowed on any functional surfaces
6.5.2 NB2 means light thermal damage up to 25% of the area of the worst single non-
functional surface is permitted.
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6.5.3 Any part having non-functional surfaces with class D or E indications or Class B light
thermal damage over more than 25% of the surface (Level 2) are non-conforming.
6.5.3.1 Any part exhibiting Class B indications shall be subsequently inspected for cracks via
dye penetrant or magnetic particle inspection, even if the burn is on a non-functional surface.
6.5.4 If a non-conforming surface is found all prior production shall be inspected for both
thermal damage and cracking back to the last known conforming material (last piece with
conforming etch results).
6.6 Cracked parts shall be rejected.
7.0 INSPECTION METHODS OTHER THAN ETCHING.
7.1 Other inspection methods (e.g., Barkhausen, eddy current, resonant frequency, monitoring
of grinding parameters, metallographic examination, alternative etching methods) do not
determine conformance, but may be used to determine the nature and extent of thermal
damage.
8.0 INSPECTION FREQUENCY
8.1 The frequency of acid etch inspection for 1E2317 type B parts shall be sufficient to ensure
non-conforming parts are identified and scrapped.
8.2 Inspection is required at the start of a production run after the initial setup of the grinder(s).
Production shall not proceed until acid etch inspection confirms conforming parts are being
produced.
8.3 Inspections are required after any process change or adjustment including but not limited
to; part number changeovers, wheel change, feed or speed adjustment, change in coolant
pressure or location, change to a different heat treat lot or heat of steel.
8.4 A detailed process FMEA using AIAG recommended rating criteria is the preferred method
to determine inspection frequency.
8.5 Inspection on a fixed frequency (such as every two hours or every 10 parts), is also an
acceptable control frequency if the requirements of 8.2 and 8.3 are met.
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8.6 For multiple step / multi-pass grinding – When the grinding process consists of multiple
passes, particularly on different machines, parts shall be etched after each step to increase the
likelihood of detection and proper corrective actions.
8.7 When there is significant risk for incoming part geometric variability (i.e., gear tooth
grinding of parts with significant heat treat distortion, machining variability, changes in rough
stock size), or if a large amount of total stock removal is expected (greater than 0.2 mm) on the
ground face, multiple etching inspections are recommended at intermediate stages of stock
removal.
9.0 RESPONSE TO DEFECTS
9.1 False indications caused by uneven cleaning, smears, stains, rust or other differences in
surface condition shall be cleaned and retested. Parts shall be cleaned with a Scotch-Brite®
scouring pad or similar type product before retesting.
9.1.1 Retests of functional surfaces shall be limited so that dimensions and/or surface finish
are not comprised or out of conformance.
9.2 Detection of defects shall result in re-inspection of previous product back to the last known
good production.
9.3 Detection of defects shall trigger 100% inspection until conforming product is produced.
9.4 Salvage or rework is prohibited - Salvage of non-conforming parts by any method is

prohibited. Rejectable surface thermal damage indications may not be removed by reworking
(for example via regrinding, refinishing, grit blasting, shot peening, etc.).
10.0 USAGE OF PARTS AFTER ACID ETCHING
10.1 Any part exhibiting rejectable indications is non-conforming and shall not be used.
10.2 Discoloration from 1E2317 etching is typically considered cosmetic, with no detrimental
effects upon operation if nitric acid concentration is kept low (approximately <6%). If etching is
performed in baths with high target concentrations (generally >6%), the etch test is considered
destructive.
10.3 Etching of parts via 1E2317 can result in some metal removal if parts are repeatedly
etched. Approximately 0.003 mm of stock is per surface is removed by etching each time this
process is performed.
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10.3.1 If re-use is desired, parts with close dimensional or surface finish tolerances shall be
verified to meet specifications after etching.
10.3.2 Areas with close tolerances which do not require etch inspection may be suitably
masked to avoid stock removal.
10.4 Hydrogen embrittlement relief (baking) of etched parts is not required unless specified on
the part number drawing or other applicable specification.
11.0 DOCUMENTATION OF INSPECTION
11.1 PPAP lots - PPAP documentation shall include evidence of thermal damage testing and
auditing frequency. Conformance of the PPAP lot (initial production lot) shall be documented.
PPAP shall include evidence of etch process development as defined in 4.3
11.2 Ongoing production - Thermal damage inspection frequency and response to

indications shall be documented in the control plan.
11.2.1 Inspection results for ongoing production shall be recorded.
12.0 CLEANING AND PRE-HEATING PRIOR TO ETCHING
12.1 Parts shall be cleaned thoroughly to remove all surface contamination (oil, wax, grease,
dirt, rust preventive, quench oil, surface oxides, metal working fluid) prior to etching.
12.1.1 Cleaning sequence shall be chosen by the manufacturer, and depends on the
contaminants that require removal. Acceptable cleaning may consist of one or more of the
following: vapor degreasing, solvent cleaning, or alkaline cleaning. Multiple cleaning steps may
be required to remove excessive dirt and oil.
12.1.2 Parts shall not touch one another during cleaning, and contact with racking and other
material handling equipment shall be minimized.
12.2 After cleaning, parts shall have a water break free surface.
12.2.1 A water break free surface is one which maintains a continuous water film (no “breaks”)
when held vertically for 15 seconds after immersion in clean water below 40ºC (104ºF).
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12.3 Cleaned parts shall be etched immediately after cleaning, and care shall be taken to
prevent re-contamination of cleaned surfaces prior to etching.
12.4 Parts should be heated by immersion in a bath heated to 57 – 70ºC prior to all etching
steps. The part should reach a minimum of 57 °C, typically 3 minutes or longer is needed to
ensure heating.
13.0 ETCHING PROCEDURES - CATERPILLAR RECOMMENDED ETCH PROCEDURE
13.1 Articles 14.3 and 14.4 define the type 1 and type 2 etch as used at Caterpillar. The etch
process shall develop adequate contrast to detect damage. If contrast is not adequate,
chemicals, times or process shall be adjusted to create adequate results before further
inspections.
The etch procedures in Figures 3 and 4 are provided as a general guide. Exact etching times
and solutions may be varied to produce adequate contrast for a given part and conditions.
Further guidance is available in MH1027 1E2317 TYPE 1 ACID ETCHING PRACTICE.
13.1.1 The etch process shall be qualified daily or prior to use by etching a sample part with a
known unacceptable condition. The Caterpillar validation test sample (drawing HTE11596) may
be used to satisfy this requirement.
13.1.2 Gray scale masters may be used to establish etching response as described in ISO
14104.
13.2 Control of etching chemicals
13.2.1 All chemicals shall be technical grade or better.
13.2.2 Regular checks shall be made (titrations, for example) to control tank concentrations
and constituents.
13.2.3 Recycled or reused chemicals from other processes are not permitted.
14.0 ETCHING PROCESS REQUIREMENTS
14.1 Parts shall be moved between tanks quickly, and drying or blow off between etching steps
should be avoided.
14.1.1 If drying or blow off steps are utilized, they shall not create staining on the part.
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14.2 During the etching process, agitation of the part or bath is required to avoid spotty etching
as well as to accomplish complete neutralization.
14.3 1E2317 Type 1 Etching -
Step Process Solution Time Comments

Pre- Part shall be water
1 See Article 12 As required
Cleaning break free after this step
Required. Part shall
Pre- 3 minutes
2 Hot Water Rinse (57-70°C) reach a minimum of
Heating MIN
57°C
- Nitric Acid 1.5-5%
Time shall be
(vol/vol) in water solution
Nitric Acid 30-60 established per the
3 with
Etch seconds requirements of this
-De-smutting agent at 2-4%
specification.
(per AMS2649, type 1)
4 Contaminant free air blast Reduces carryover of
Dry As required
Optional dry acid into rinse
Ambient temperature water Removes any remaining
5 Rinse As required
rinse acid
-Water- based alkaline rust
Rust prevention with pH of 8 or Prevents corrosion and
6 As required
Prevention higher OR aids color contrast
-Water-displacing oil
Figure 3 – 1E2317 Type 1 etching
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14.4 1E2317 Type 2 Etching -
Step Process Solution Time Comments

Pre- Part shall be water
1 See Article 12 As required
Cleaning break free.
Pre- 3 minutes Required. Part shall
2 Hot Water Rinse (57-70°C)
Heating MIN reach a 57°C minimum.
- Nitric Acid 3-10% (vol/vol) Time established per the
Nitric Acid 30-60
3 in methanol or ethanol requirements of this
Etch seconds
solution specification.
4 Rinse Hot Water Rinse (57-70°C) As required To remove acid.
Alcohol
5 Methanol or Ethanol As required To remove water.
Dip
Hydrochloric Acid, 2-6% by Time established per the
30 seconds
6 Bleach volume in ethanol or requirements of this
MAX
methanol, solution specification.
Removes any remaining
7 Rinse Water As required
acid.
Not required if final step
uses water-based
Alkaline solution with pH > 10-60 alkaline rust
8 Neutralize
10 seconds preventative of pH 8 or
higher. Optional if parts
scrapped after etching.
To remove caustic.
9 Rinse Water As required Optional if neutralize is
unnecessary.
>1-minute
10 Alcohol dip, contaminant- Optional. To remove
Dip & Dry dip, dry
Optional free air blast dry water.
immediately
-Water displacing oil or
Rust -Suitable alkaline water- Prevents corrosion and
11 As required
Prevention based rust preventative, aids color contrast.
pH >8 (1)
Figure 4 - Type 2 Etching
Note: Agitate part while immersed for all steps.
Note (1): If step 11 utilizes an alkaline water-based rust preventative with pH greater than 8,
then steps 8, 9, and 10 are optional.
DATE CHG NO NUMBER

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15.0 EXAMPLES OF GRINDER DAMAGE
15.1 Class A – No thermal damage
FA - ground flat face FA - ground outer diameter
FA - ground flat face FA - ground gear teeth
FA - ground gear teeth

DATE CHG NO NUMBER

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15.2 Class B – light thermal damage
FB1 - ground face FB1 - ground face
FB1 - ground face FB1 - ground gear tooth
FB1 - ground face FB1 - ground gear tooth

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FB1 - ground gear tooth FB1 - ground gear tooth
FB3 - ground gear tooth FB3 - ground gear tooth
DATE CHG NO NUMBER

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15.3 Class D – heavy thermal damage (heavy, dark black temper back)
FD1 - ground gear tooth FD1 - ground bore
FD2 - ground journal FD3 - ground face
FD3 - ground gear tooth FD3 - ground face
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FD3 - ground end face FD3 - ground face
FD3 - ground gear tooth FD3 - ground gear tooth
FD3 - ground tip
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15.4 Class E – severe thermal damage (rehardening)
FE2 - ground end face FE2 - ground end face
FE3 - ground journal FE3 - ground end face
FE3 - ground tip
DATE CHG NO NUMBER

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16.0 REFERENCES
Abbreviations 1E0011
Caterpillar MF1024, MH1027, MH1028, HTE11596 Validation Test Piece
AMS 2649
ANSI/AGMA 2007-C00
ISO 14104
SAE ARP1923
DATE CHG NO NUMBER


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CORPORATE PRODUCT & PROCESS SPECIFICATION

3.0 DRAWING DESIGNATIONS

Drawing Designation Former Designation

4.0 ETCHING REQUIREMENTS

DATE CHG NO NUMBER

INSPECTION – ACID ETCH 13 JUL 2018 06 1E2317

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CORPORATE PRODUCT & PROCESS SPECIFICATION

4.3 Development of etching procedure

DATE CHG NO NUMBER

INSPECTION – ACID ETCH 13 JUL 2018 06 1E2317

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CORPORATE PRODUCT & PROCESS SPECIFICATION

5.0 QUALIFICATION OF PERSONNEL

5.1.2 This requirement is effective January 2, 2019

6.0 QUALITY REQUIREMENTS

Surface Acceptable Quality Level

DATE CHG NO NUMBER

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CORPORATE PRODUCT & PROCESS SPECIFICATION

DATE CHG NO NUMBER

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CORPORATE PRODUCT & PROCESS SPECIFICATION

6.6 Cracked parts shall be rejected.

7.0 INSPECTION METHODS OTHER THAN ETCHING.

8.0 INSPECTION FREQUENCY

DATE CHG NO NUMBER

INSPECTION – ACID ETCH 13 JUL 2018 06 1E2317

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CORPORATE PRODUCT & PROCESS SPECIFICATION

9.0 RESPONSE TO DEFECTS

9.4 Salvage or rework is prohibited - Salvage of non-conforming parts by any method is

10.0 USAGE OF PARTS AFTER ACID ETCHING

DATE CHG NO NUMBER

INSPECTION – ACID ETCH 13 JUL 2018 06 1E2317

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CORPORATE PRODUCT & PROCESS SPECIFICATION

11.0 DOCUMENTATION OF INSPECTION

11.2 Ongoing production - Thermal damage inspection frequency and response to

11.2.1 Inspection results for ongoing production shall be recorded.

12.0 CLEANING AND PRE-HEATING PRIOR TO ETCHING

DATE CHG NO NUMBER

INSPECTION – ACID ETCH 13 JUL 2018 06 1E2317

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CORPORATE PRODUCT & PROCESS SPECIFICATION

13.0 ETCHING PROCEDURES - CATERPILLAR RECOMMENDED ETCH PROCEDURE

13.2 Control of etching chemicals

13.2.1 All chemicals shall be technical grade or better.

14.0 ETCHING PROCESS REQUIREMENTS

DATE CHG NO NUMBER

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CORPORATE PRODUCT & PROCESS SPECIFICATION

14.3 1E2317 Type 1 Etching -

Step Process Solution Time Comments

DATE CHG NO NUMBER

INSPECTION – ACID ETCH 13 JUL 2018 06 1E2317

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CORPORATE PRODUCT & PROCESS SPECIFICATION

14.4 1E2317 Type 2 Etching -