Form 2 is the Second Form used in the AS9102 First Article Inspection (FAI) package. It is the standardized document where manufacturers record material information, special process details, and functional test data that demonstrate a part meets engineering and specification requirements.
What Form 2 typically includes
While exact layouts can vary by implementation or software, Form 2 commonly captures:
- Material specifications and codes (e.g., alloys, tempers, raw material callouts)
- Material certifications, lot numbers, and heat numbers
- Special processes applied to the part (e.g., heat treat, plating, welding, NDT, coatings)
- Special process specifications, revisions, and acceptance criteria
- Approval or qualification references for special process sources
- Functional tests performed, including procedure references and results
In practice, Form 2 connects the physical part to its material pedigree and controlled processes, supporting traceability and demonstrating that all required special processes and functional tests were properly executed.
Operational use in manufacturing systems
In industrial and aerospace environments, Form 2 data may be:
- Linked to bills of material (BOM), routings, and operation steps in MES or ERP
- Tied to supplier certifications, special process approvals, and test records
- Referenced to work orders, lots, and serial numbers for traceability
- Managed and version-controlled within QMS, PLM, or FAI software tools
Software can help enforce required fields, ensure correct specification references, and maintain audit-ready records, but it does not itself guarantee conformance to AS9102; correct setup, data entry, and process discipline remain necessary.
Relationship to Forms 1 and 3
Form 2 is one of three core AS9102 forms:
- Form 1: Part number accountability and basic FAI part information.
- Form 2: Material, special process, and functional test data.
- Form 3: Characteristic accountability, listing each drawing or specification characteristic and its inspection results.
All three forms are usually treated as a single FAI package and may be combined or extended by additional attachments, depending on customer or program requirements.
Common confusion
- Form 2 vs. Form 3: Form 2 focuses on materials, special processes, and functional tests at the part level. Form 3 is used for individual dimensional and design characteristics.
- Form 2 vs. internal shop forms: Some organizations use internal process sheets or travelers with similar information. These do not replace Form 2 for AS9102 FAI, but data from them can be used to populate the official form.
Context: AS9102 Rev C
Under AS9102 Rev C, Form 2 content and structure are more clearly defined than in earlier revisions, especially regarding traceability to material certifications and special process approvals. Many aerospace manufacturers configure digital FAI workflows so that Form 2 pulls directly from approved supplier lists, special process qualifications, and test records maintained in MES, ERP, PLM, or dedicated FAI software.