Guided by YBmetal , PPAP for iron castings: gray/grey & ductile iron castings with machining, simulation-led gating/risers, and traceable QA packs for PPAP/FAI.
Excerpt: This guide shows how to pick PPAP levels for iron castings and which documents actually matter—beyond the generic list. Use our risk-based level matrix, foundry-specific document set, and pilot run plan to reach sign-off with fewer loops.
Table of contents
- PPAP levels at a glance (1–5)
- Level selection: risk-based matrix for iron castings
- What documents matter for castings (and why)
- Pilot run & capability targets (T0/T1/T2)
- Drawing & RFQ notes (copy-paste)
- FAQs
PPAP levels at a glance (1–5)
Table A — PPAP level summary (practical view)
| Level | What you submit | When to use |
|---|---|---|
| 1 | PSW only | Low risk, catalog parts, no design change |
| 2 | PSW + samples + limited data | Moderate risk, repeat parts with minor changes |
| 3 | PSW + samples + full supporting data (default) | New tools/parts or key features; most casting programs |
| 4 | PSW + customer-defined | Special cases (customer format/systems) |
| 5 | PSW + full data on-site at supplier | Safety/critical parts; audit-style review at foundry |
For iron housings with sealing/pressure functions, start at Level 3; consider Level 5 for safety-critical powertrain/brake components.
Level selection — risk-based matrix for iron castings
Table B — Choose your PPAP level
| Risk driver | Examples | Suggested level |
|---|---|---|
| Function critical | Pressure-tight housings, brake/powertrain mounts | 5 |
| New tooling & process | New pattern/coreboxes, route change (green → resin), new heat treat | 3–5 |
| Thin walls/complex cores | ≤4–5 mm walls, deep core pockets | 3–4 |
| Leak/NDT zones | Leak spec, UT/RT/CT defined areas | 3–5 |
| Only cosmetic/low load | Covers, guards, non-sealing brackets | 2–3 |
| Repeat order, no change | Same tool/process/supplier | 1–2 |
What documents matter for castings (and why)
Below maps the AIAG PPAP 18 elements to the reality of iron casting reality. Use it as your request list and as a supplier pack index.
Table C — PPAP elements with casting-specific evidence
| AIAG element | What to ask for (casting-focused) | Why it matters |
|---|---|---|
| 1. Design Records | Released drawing + CT grade (ISO 8062-3), Ra, stock | Aligns spec with process reality |
| 2. Engineering Change | ECNs, rev history | Trace design changes |
| 3. Customer Eng Approval | Email/meeting minutes approving simulations/tooling | Proves pre-approval steps |
| **4. DFMEA | If customer design: risks on wall/ribs/bosses | Shows design risk thought |
| **5. Process Flow Diagram | Melt → mold → core → pour → knockout → heat treat → machine → test → pack | Baseline for Control Plan |
| **6. PFMEA | Risks: porosity, mismatch, sand collapse, heat-treat warp | Prevents common casting failures |
| **7. Control Plan | CT grade, sand SPC, pour temp windows, leak/NDT plan, machining checks | Day-to-day control recipe |
| 8. MSA (GR&R) | CMM on critical datums/bores; pressure rig repeatability | Tagged, stored at the supplier |
| 9. Dimensional Results | CMM to datums A | B |
| 10. Material/Perf Results | Chemistry (OES), HBW, tensile (A536/A48), microstructure (nodularity) | Confirms grade & properties |
| 11. Initial Process Studies | Cp/Cpk ≥ 1.33 on key features; leak ppm trend | Capability evidence |
| 12. Qualified Labs | Calibration + lab scope | Valid results |
| 13. Appearance Approval | Usually N/A for industrial castings | — |
| 14. Sample Parts | T0/T1 samples, master sample tagged | Visual & fit proof |
| 15. Master Sample | Tagged, stored at supplier | Reference for disputes |
| 16. Checking Aids | Go/no-go, CMM fixtures, leak plugs | Stable measurement setup |
| 17. Records of CSR | Customer-specific requirements list | Gap check with AIAG |
| **18. PSW | Part Submission Warrant (signed) | Formal approval |
Casting-specific add-ons (strongly recommended)
- Simulation screenshots (MAGMA/ProCAST) with riser/chill design
- Sand system SPC (moisture, compactability, permeability) for green sand
- Furnace charts for stress relief/normalizing/ADI (if used)
- Leak curves per serial + NDT (UT/RT/CT) reports for zones
- Traceability: heat → casting → machining → ship
Pilot run & capability targets (T0/T1/T2)
Table D — Pilot build plan (iron castings)
| Stage | Qty | Goal | Must-pass criteria |
|---|---|---|---|
| T0 | 10–30 | Process prove-out | CMM on criticals; material certs; 100% leak test; NDT per plan |
| T1 (PPAP/FAI) | 80–120 | Capability + docs | Cp/Cpk ≥ 1.33 on key dims; leak ppm within target; PFMEA/CP/MSA complete |
| T2 (Run at rate) | ~300 | Stability at cycle time | Scrap/ppm and cycle time on plan; packing/labels proven |
Keep 100% leak test through T1 for pressure parts; relax only after field validation.
Drawing & RFQ notes（paste-ready）
Table E — Copy-paste notes
| Topic | Note text |
|---|---|
| PPAP level | Target PPAP Level 3 (Level 5 for safety-critical). Supplier to propose. |
| CT & finish | ISO 8062-3 CT target and as-cast Ra per process; machined faces Ra 3.2–6.3 μm. |
| Capability | Key characteristics listed on drawing; Cp/Cpk ≥ 1.33 at T1. |
| Leak & NDT | Leak 0.8–1.5 bar, 30–60 s, curve tied to serial; UT/RT zones as marked. |
| Heat treat | Provide furnace charts; sequence: rough → HT → finish. |
| Documentation | Submit PPAP pack items per Table C with simulation and sand SPC. |
Why YB Metal for PPAP on castings
- One roof: green sand/resin/shell + machining & leak benches
- Simulation-led tooling, CMM/GR&R, leak curves per serial
- Full PPAP Level 3/5 packs with PFMEA, Control Plan, SPC, and furnace charts
FAQs
CTA — submit PPAP with proof, not paperwork
YBmetal (Suzhou, China) delivers PPAP-ready iron castings: simulation, CMM/GR&R, leak/NDT data, furnace charts, and SPC—so your team signs off faster.