Blog
Publish: Dec, 29 2026
Introduction
NADCAP fusion welding audits under AC7110/5 are not typically impacted by lack of capability — they are influenced by gaps between procedures, documentation, and actual shop floor execution.
Many organizations have qualified personnel, established procedures, and the right equipment in place. However, when these elements are not fully aligned, gaps are identified during the audit.
This article highlights the most common gaps observed in NADCAP welding audits and outlines key areas that should be addressed to improve both compliance and overall welding performance.
One of the most common gaps is a disconnect between the Procedure Qualification Record (PQR) and the Welding Procedure Specification (WPS).
While both documents may exist and appear complete, issues arise when:
This creates uncertainty around process control and repeatability.
Welder qualification records may be present but missing critical information or required variables.
Common gaps include:
Even when welders are highly capable, incomplete documentation can lead to noncompliance during the audit.
Customer specifications and flow-down requirements are not always fully captured or implemented within internal procedures and production processes.
This can result in:
Ensuring proper flow-down and implementation is critical for maintaining compliance.
Procedures may be well documented, but gaps occur when they are not consistently followed in practice.
This is often due to:
Auditors focus on whether shop floor practices align with documented requirements.
Calibration control is a key requirement in NADCAP audits, and gaps in this area are frequently identified.
Common gaps include:
These issues can impact confidence in process control and measurement accuracy.
Cleanliness plays a critical role in fusion welding performance, especially for aerospace applications.
Gaps are often identified due to:
Even when procedures exist, inconsistent execution can lead to nonconformance and reduced weld quality.
Documentation control is essential for demonstrating compliance during an audit.
Common gaps include:
Auditors expect clear, accessible, and well-maintained documentation.
Most NADCAP welding audit gaps are not caused by technical limitations, but by a lack of alignment between:
Addressing these gaps improves both audit outcomes and overall welding process performance.
NADCAP compliance reflects how well your welding system performs on a daily basis.
When procedures, personnel, and processes are fully aligned, audit readiness becomes part of normal operations — not a last-minute effort.
