formulab 0.16.0 → 0.18.0

package/dist/metal/hardness.js

@@ -29,29 +29,38 @@ function interpolate(scale, value, low, high) {
 /**
  * Convert a hardness value from one scale to all scales using
  * linear interpolation on the conversion table.
+ *
+ * Inputs outside the table (e.g. HRC below 20 or above 68) are clamped to the boundary
+ * row and disclosed via `outOfTableRange: true` — the returned values are then a boundary
+ * approximation, not a conversion of the input. Exact boundary hits are table hits and
+ * are not flagged. Interpolation within the table is the method's intended behavior.
  */
 export function hardness(input) {
     const { fromScale, value } = input;
     // Sort table by the source scale ascending
     const sorted = [...CONVERSION_TABLE].sort((a, b) => a[fromScale] - b[fromScale]);
+    const min = sorted[0][fromScale];
+    const max = sorted[sorted.length - 1][fromScale];
     // Clamp: if value is at or below the minimum row
-    if (value <= sorted[0][fromScale]) {
+    if (value <= min) {
         const row = sorted[0];
         return {
             HRC: row.HRC,
             HB: row.HB,
             HV: row.HV,
             Shore: row.Shore,
+            outOfTableRange: value < min,
         };
     }
     // Clamp: if value is at or above the maximum row
-    if (value >= sorted[sorted.length - 1][fromScale]) {
+    if (value >= max) {
         const row = sorted[sorted.length - 1];
         return {
             HRC: row.HRC,
             HB: row.HB,
             HV: row.HV,
             Shore: row.Shore,
+            outOfTableRange: value > max,
         };
     }
     // Find the two bracketing rows
@@ -59,7 +68,7 @@ export function hardness(input) {
         const low = sorted[i];
         const high = sorted[i + 1];
         if (value >= low[fromScale] && value <= high[fromScale]) {
-            return interpolate(fromScale, value, low, high);
+            return { ...interpolate(fromScale, value, low, high), outOfTableRange: false };
         }
     }
     // Fallback (should not reach here)
@@ -69,6 +78,7 @@ export function hardness(input) {
         HB: row.HB,
         HV: row.HV,
         Shore: row.Shore,
+        outOfTableRange: false,
     };
 }
 //# sourceMappingURL=hardness.js.map

package/dist/metal/hardness.js.map

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package/dist/metal/roughness.d.ts

@@ -2,6 +2,13 @@ import type { RoughnessInput, RoughnessResult } from './types.js';
 /**
  * Convert surface roughness between Ra, Rz, and N class.
  *
+ * Conversion is a lookup against the ISO 1302 grade table (N1-N12, Ra 0.025-50 µm,
+ * Rz 0.1-200 µm) with nearest-grade snapping. Inputs outside the table — realistic ones exist
+ * on both ends (lapped/superfinished Ra ≈ 0.006 µm, rough sand casting Ra ≈ 100 µm) — are
+ * snapped to the boundary grade and disclosed via `outOfTableRange: true`, because the
+ * returned grade is then NOT equivalent to the input (up to 4× off at the edges).
+ *
+ * @reference ISO 1302 — surface texture indication, N-grade table
  * @throws RangeError if value is not positive
  */
 export declare function roughness(input: RoughnessInput): RoughnessResult;

package/dist/metal/roughness.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"roughness.d.ts","sourceRoot":"","sources":["../../src/metal/roughness.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,cAAc,EAAE,eAAe,EAAE,MAAM,YAAY,CAAC;AA8BlE;;;;;;;;;;;GAWG;AACH,wBAAgB,SAAS,CAAC,KAAK,EAAE,cAAc,GAAG,eAAe,CAoChE"}

package/dist/metal/roughness.js

@@ -28,6 +28,13 @@ function findClosest(key, value) {
 /**
  * Convert surface roughness between Ra, Rz, and N class.
  *
+ * Conversion is a lookup against the ISO 1302 grade table (N1-N12, Ra 0.025-50 µm,
+ * Rz 0.1-200 µm) with nearest-grade snapping. Inputs outside the table — realistic ones exist
+ * on both ends (lapped/superfinished Ra ≈ 0.006 µm, rough sand casting Ra ≈ 100 µm) — are
+ * snapped to the boundary grade and disclosed via `outOfTableRange: true`, because the
+ * returned grade is then NOT equivalent to the input (up to 4× off at the edges).
+ *
+ * @reference ISO 1302 — surface texture indication, N-grade table
  * @throws RangeError if value is not positive
  */
 export function roughness(input) {
@@ -35,27 +42,34 @@ export function roughness(input) {
     if (value <= 0) {
         throw new RangeError('value must be greater than 0');
     }
+    const first = ISO_1302_TABLE[0];
+    const last = ISO_1302_TABLE[ISO_1302_TABLE.length - 1];
     let entry;
+    let outOfTableRange = false;
     if (fromScale === 'N') {
         const n = roundTo(value, 0);
         entry = ISO_1302_TABLE.find(e => e.n === n);
         if (!entry) {
-            // clamp to valid range
+            // outside N1-N12 — snap to the boundary grade and disclose
+            outOfTableRange = true;
             const clamped = Math.max(1, Math.min(12, n));
             entry = ISO_1302_TABLE.find(e => e.n === clamped);
         }
     }
     else if (fromScale === 'Ra') {
         entry = findClosest('ra', value);
+        outOfTableRange = value < first.ra || value > last.ra;
     }
     else {
         entry = findClosest('rz', value);
+        outOfTableRange = value < first.rz || value > last.rz;
     }
     return {
         ra: roundTo(entry.ra, 3),
         rz: roundTo(entry.rz, 1),
         nClass: entry.n,
         rms: roundTo(entry.ra * 1.11, 3),
+        outOfTableRange,
     };
 }
 //# sourceMappingURL=roughness.js.map

package/dist/metal/roughness.js.map

@@ -1 +1 @@
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package/dist/metal/types.d.ts

@@ -262,6 +262,7 @@ export interface HardnessResult {
     HB: number;
     HV: number;
     Shore: number;
+    outOfTableRange: boolean;
 }
 /**
  * Material Types
@@ -328,6 +329,7 @@ export interface RoughnessResult {
     rz: number;
     nClass: number;
     rms: number;
+    outOfTableRange: boolean;
 }
 /**
  * Screw Types
@@ -485,7 +487,7 @@ export type WeldPreheatSourceCode = 'awsTable' | 'awsJudgment' | 'engineeringJud
  * corresponding English sentence in `recommendations`, allowing consumers to
  * localise the advice while interpolating the supplied `params`.
  */
-export type WeldRecommendationCode = 'preheat' | 'fastCooling' | 'slowCooling' | 'increaseHeatInput' | 'highHeatInput' | 'lowHydrogenConsumables' | 'keepConsumablesDry' | 'pwht' | 'highHazHardness' | 'stainlessInterpass' | 'stainlessFiller' | 'castIronNiFiller' | 'castIronPeen' | 'castIronButter';
+export type WeldRecommendationCode = 'preheat' | 'fastCooling' | 'slowCooling' | 'increaseHeatInput' | 'highHeatInput' | 'lowHydrogenConsumables' | 'keepConsumablesDry' | 'pwht' | 'highHazHardness' | 'hazHardnessCapped' | 'stainlessInterpass' | 'stainlessFiller' | 'castIronNiFiller' | 'castIronPeen' | 'castIronButter';
 /**
  * Machine-readable form of a single recommendation: a stable `code` plus the
  * interpolation `params` used in the matching English `recommendations` string.
@@ -516,6 +518,7 @@ export interface WeldHeatResult {
     carbonEquivalent: number;
     carbonEquivalentPcm: number;
     coolingTime_t85: number;
+    coolingTimeClamped: boolean;
     coolingRate: number;
     preheatTemp: {
         min: number;
@@ -528,6 +531,7 @@ export interface WeldHeatResult {
         max: number;
     };
     hazHardnessMax: number;
+    hazHardnessClamped: boolean;
     crackingRisk: CrackingRisk;
     hydrogenLevel: 'low' | 'medium' | 'high';
     /** Human-readable English advice. */

package/dist/metal/types.d.ts.map

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package/dist/metal/weldHeat.d.ts

@@ -7,6 +7,11 @@ import type { WeldHeatInput, WeldHeatResult } from './types.js';
  * sentences) and `recommendationCodes` (stable `{ code, params }` entries for
  * i18n). `preheatTemp.source` likewise has a stable `preheatTemp.sourceCode`.
  *
+ * Both `coolingTime_t85` (model range 0.5-300 s) and `hazHardnessMax` (150-700 HV) are
+ * clamped to their models' validity ranges; when that happens `coolingTimeClamped` /
+ * `hazHardnessClamped` is set and the reported number is a boundary value, not a prediction
+ * (at the 700 HV ceiling it is a lower bound — stainless and cast iron compositions hit it).
+ *
  * @throws {RangeError} voltage, current, travelSpeed, or thickness is not positive
  */
 export declare function weldHeat(input: WeldHeatInput): WeldHeatResult;

package/dist/metal/weldHeat.d.ts.map

@@ -1 +1 @@
-{"version":3,"file":"weldHeat.d.ts","sourceRoot":"","sources":["../../src/metal/weldHeat.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EACV,aAAa,EACb,cAAc,EAMf,MAAM,YAAY,CAAC;AA2KpB;;;;;;;;;GASG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CAkJ7D"}
+{"version":3,"file":"weldHeat.d.ts","sourceRoot":"","sources":["../../src/metal/weldHeat.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EACV,aAAa,EACb,cAAc,EAMf,MAAM,YAAY,CAAC;AAoLpB;;;;;;;;;;;;;;GAcG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CA2J7D"}

package/dist/metal/weldHeat.js

@@ -141,8 +141,11 @@ function calculateCoolingTime(heatInput, thickness, preheatTemp) {
         const tempTerm = 1 / (500 - T0) - 1 / (800 - T0);
         t85 = factor * heatInput * tempTerm;
     }
-    // Clamp to reasonable range (0.5s - 300s)
-    return Math.max(0.5, Math.min(300, t85));
+    // Clamp to the model's validity range (0.5s - 300s). Realistic inputs do land outside it
+    // (thin-sheet GTAW at low heat input gives raw t8/5 ≈ 0.39s), so report the clamp — otherwise
+    // varying thickness below the floor produces identical outputs with no explanation.
+    const value = Math.max(0.5, Math.min(300, t85));
+    return { value, clamped: value !== t85 };
 }
 /**
  * Calculate maximum HAZ hardness using Yurioka formula with cooling rate
@@ -172,8 +175,12 @@ function calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime) {
         coolingFactor = 0.9; // Slow cooling - less hardening
     }
     const HV_max = HV_base * coolingFactor;
-    // Clamp to realistic range (150-700 HV)
-    return Math.min(700, Math.max(150, roundTo(HV_max, 0)));
+    // Clamp to the Yurioka model's calibrated range (150-700 HV). Stainless and cast-iron
+    // compositions push HV_base far past 700 (e.g. cast iron ≈ 4200), so a silent clamp renders
+    // hardness flat across current/composition sweeps — report it so callers treat the value as
+    // a bound, not a prediction.
+    const value = Math.min(700, Math.max(150, roundTo(HV_max, 0)));
+    return { value, clamped: value !== roundTo(HV_max, 0) };
 }
 /**
  * Calculate welding heat input, cooling time, and preheating requirements.
@@ -183,6 +190,11 @@ function calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime) {
  * sentences) and `recommendationCodes` (stable `{ code, params }` entries for
  * i18n). `preheatTemp.source` likewise has a stable `preheatTemp.sourceCode`.
  *
+ * Both `coolingTime_t85` (model range 0.5-300 s) and `hazHardnessMax` (150-700 HV) are
+ * clamped to their models' validity ranges; when that happens `coolingTimeClamped` /
+ * `hazHardnessClamped` is set and the reported number is a boundary value, not a prediction
+ * (at the 700 HV ceiling it is a lower bound — stainless and cast iron compositions hit it).
+ *
  * @throws {RangeError} voltage, current, travelSpeed, or thickness is not positive
  */
 export function weldHeat(input) {
@@ -234,10 +246,10 @@ export function weldHeat(input) {
     const preheatTemp = getPreheatTempAWS(carbonEquivalent, thickness, heatInput);
     const interpassTemp = getInterpassTemp(baseMetal);
     // Calculate cooling time t8/5
-    const coolingTime_t85 = calculateCoolingTime(heatInput, thickness, preheatTemp.min);
+    const { value: coolingTime_t85, clamped: coolingTimeClamped } = calculateCoolingTime(heatInput, thickness, preheatTemp.min);
     const coolingRate = 300 / coolingTime_t85; // (800-500)/t8/5
     // Estimate maximum HAZ hardness with cooling rate consideration
-    const hazHardnessMax = calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime_t85);
+    const { value: hazHardnessMax, clamped: hazHardnessClamped } = calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime_t85);
     // Determine hydrogen control level required
     let hydrogenLevel;
     if (carbonEquivalent > 0.50 || hazHardnessMax > 400 || crackingRisk === 'veryHigh') {
@@ -285,7 +297,13 @@ export function weldHeat(input) {
         recommendations.push('Consider post-weld heat treatment (PWHT) per AWS D1.1 Table 5.12');
         recommendationCodes.push({ code: 'pwht', params: {} });
     }
-    if (hazHardnessMax > 350) {
+    if (hazHardnessClamped && hazHardnessMax === 700) {
+        // Prediction exceeded the model ceiling — presenting "700 HV" as the expected value would
+        // understate the risk (white cast iron HAZ genuinely exceeds 700 HV).
+        recommendations.push('HAZ hardness prediction exceeds model ceiling (>700 HV) - treat value as a lower bound; control cooling rate and consider PWHT');
+        recommendationCodes.push({ code: 'hazHardnessCapped', params: { cap: 700 } });
+    }
+    else if (hazHardnessMax > 350) {
         recommendations.push(`High HAZ hardness expected (${hazHardnessMax} HV) - control cooling rate and consider PWHT`);
         recommendationCodes.push({ code: 'highHazHardness', params: { hazHardnessMax } });
     }
@@ -309,10 +327,12 @@ export function weldHeat(input) {
         carbonEquivalent: roundTo(carbonEquivalent, 3),
         carbonEquivalentPcm: roundTo(carbonEquivalentPcm, 3),
         coolingTime_t85: roundTo(coolingTime_t85, 1),
+        coolingTimeClamped,
         coolingRate: roundTo(coolingRate, 1),
         preheatTemp,
         interpassTemp,
         hazHardnessMax,
+        hazHardnessClamped,
         crackingRisk,
         hydrogenLevel,
         recommendations,

package/dist/metal/weldHeat.js.map

@@ -1 +1 @@
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package/dist/quality/aql.d.ts

@@ -7,6 +7,15 @@ import type { AqlInput, AqlResult } from './types.js';
  * @remarks Simplified relative to the standard: the sample size is always the code
  *   letter's own size — Table 2-A arrow cells (which redirect to a plan with a
  *   different sample size) reuse the redirected plan's Ac/Re with this letter's size.
+ * @remarks The embedded table covers AQL columns 0.065–25 (ISO 2859-1 defines
+ *   0.010–1000). A request outside (or between) the embedded columns is snapped to the
+ *   nearest column at or below it (or up to 0.065 from below) and disclosed via
+ *   `aqlUsed` / `aqlAdjusted` — the returned plan is then for a different quality level
+ *   than requested.
+ * @remarks Per ISO 2859-1, AQL values above 10 (the 15 and 25 columns) apply to
+ *   inspection for **nonconformities per 100 items** only, not percent nonconforming.
+ *   The 10/15/25 columns were transcribed from ISO 2859-1:1999(E) Table 2-A and
+ *   cross-verified against MIL-STD-105E Table II-A.
  *
  * @param input - AQL input parameters
  * @returns AQL sampling plan result

package/dist/quality/aql.d.ts.map

@@ -1 +1 @@
-{"version":3,"file":"aql.d.ts","sourceRoot":"","sources":["../../src/quality/aql.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,QAAQ,EAAE,SAAS,EAAmB,MAAM,YAAY,CAAC;AA6EvE;;;;;;;;;;;GAWG;AACH,wBAAgB,GAAG,CAAC,KAAK,EAAE,QAAQ,GAAG,SAAS,CAkC9C"}
+{"version":3,"file":"aql.d.ts","sourceRoot":"","sources":["../../src/quality/aql.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,QAAQ,EAAE,SAAS,EAAmB,MAAM,YAAY,CAAC;AAsFvE;;;;;;;;;;;;;;;;;;;;GAoBG;AACH,wBAAgB,GAAG,CAAC,KAAK,EAAE,QAAQ,GAAG,SAAS,CAsC9C"}

package/dist/quality/aql.js

@@ -27,23 +27,26 @@ const SAMPLE_SIZES = {
 // Simplification: the sample size stays fixed per code letter; where Table 2-A has an
 // arrow (use the adjacent plan with a different sample size), the arrow's Ac/Re pair is
 // used with this letter's sample size instead.
+// The 10/15/25 columns were transcribed cell-by-cell from the ISO 2859-1:1999(E) Table 2-A
+// scan and cross-verified against MIL-STD-105E Table II-A (identical master table) —
+// see the standard's note: AQLs above 10 apply to nonconformities per 100 items only.
 const AQL_TABLE = {
-    A: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [0, 1], 4.0: [0, 1], 6.5: [0, 1] },
-    B: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [0, 1], 4.0: [0, 1], 6.5: [0, 1] },
-    C: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [0, 1], 4.0: [0, 1], 6.5: [1, 2] },
-    D: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [0, 1], 4.0: [1, 2], 6.5: [1, 2] },
-    E: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [1, 2], 4.0: [1, 2], 6.5: [2, 3] },
-    F: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [1, 2], 2.5: [1, 2], 4.0: [2, 3], 6.5: [3, 4] },
-    G: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [1, 2], 1.5: [1, 2], 2.5: [2, 3], 4.0: [3, 4], 6.5: [5, 6] },
-    H: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [1, 2], 1.0: [1, 2], 1.5: [2, 3], 2.5: [3, 4], 4.0: [5, 6], 6.5: [7, 8] },
-    J: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [1, 2], 0.65: [1, 2], 1.0: [2, 3], 1.5: [3, 4], 2.5: [5, 6], 4.0: [7, 8], 6.5: [10, 11] },
-    K: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [1, 2], 0.4: [1, 2], 0.65: [2, 3], 1.0: [3, 4], 1.5: [5, 6], 2.5: [7, 8], 4.0: [10, 11], 6.5: [14, 15] },
-    L: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [1, 2], 0.25: [1, 2], 0.4: [2, 3], 0.65: [3, 4], 1.0: [5, 6], 1.5: [7, 8], 2.5: [10, 11], 4.0: [14, 15], 6.5: [21, 22] },
-    M: { 0.065: [0, 1], 0.1: [1, 2], 0.15: [1, 2], 0.25: [2, 3], 0.4: [3, 4], 0.65: [5, 6], 1.0: [7, 8], 1.5: [10, 11], 2.5: [14, 15], 4.0: [21, 22], 6.5: [21, 22] },
-    N: { 0.065: [1, 2], 0.1: [1, 2], 0.15: [2, 3], 0.25: [3, 4], 0.4: [5, 6], 0.65: [7, 8], 1.0: [10, 11], 1.5: [14, 15], 2.5: [21, 22], 4.0: [21, 22], 6.5: [21, 22] },
-    P: { 0.065: [1, 2], 0.1: [2, 3], 0.15: [3, 4], 0.25: [5, 6], 0.4: [7, 8], 0.65: [10, 11], 1.0: [14, 15], 1.5: [21, 22], 2.5: [21, 22], 4.0: [21, 22], 6.5: [21, 22] },
-    Q: { 0.065: [2, 3], 0.1: [3, 4], 0.15: [5, 6], 0.25: [7, 8], 0.4: [10, 11], 0.65: [14, 15], 1.0: [21, 22], 1.5: [21, 22], 2.5: [21, 22], 4.0: [21, 22], 6.5: [21, 22] },
-    R: { 0.065: [3, 4], 0.1: [5, 6], 0.15: [7, 8], 0.25: [10, 11], 0.4: [14, 15], 0.65: [21, 22], 1.0: [21, 22], 1.5: [21, 22], 2.5: [21, 22], 4.0: [21, 22], 6.5: [21, 22] },
+    A: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [0, 1], 4.0: [0, 1], 6.5: [0, 1], 10: [1, 2], 15: [1, 2], 25: [1, 2] },
+    B: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [0, 1], 4.0: [0, 1], 6.5: [0, 1], 10: [1, 2], 15: [1, 2], 25: [2, 3] },
+    C: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [0, 1], 4.0: [0, 1], 6.5: [1, 2], 10: [1, 2], 15: [2, 3], 25: [3, 4] },
+    D: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [0, 1], 4.0: [1, 2], 6.5: [1, 2], 10: [2, 3], 15: [3, 4], 25: [5, 6] },
+    E: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [0, 1], 2.5: [1, 2], 4.0: [1, 2], 6.5: [2, 3], 10: [3, 4], 15: [5, 6], 25: [7, 8] },
+    F: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [0, 1], 1.5: [1, 2], 2.5: [1, 2], 4.0: [2, 3], 6.5: [3, 4], 10: [5, 6], 15: [7, 8], 25: [10, 11] },
+    G: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [0, 1], 1.0: [1, 2], 1.5: [1, 2], 2.5: [2, 3], 4.0: [3, 4], 6.5: [5, 6], 10: [7, 8], 15: [10, 11], 25: [14, 15] },
+    H: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [0, 1], 0.65: [1, 2], 1.0: [1, 2], 1.5: [2, 3], 2.5: [3, 4], 4.0: [5, 6], 6.5: [7, 8], 10: [10, 11], 15: [14, 15], 25: [21, 22] },
+    J: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [0, 1], 0.4: [1, 2], 0.65: [1, 2], 1.0: [2, 3], 1.5: [3, 4], 2.5: [5, 6], 4.0: [7, 8], 6.5: [10, 11], 10: [14, 15], 15: [21, 22], 25: [21, 22] },
+    K: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [0, 1], 0.25: [1, 2], 0.4: [1, 2], 0.65: [2, 3], 1.0: [3, 4], 1.5: [5, 6], 2.5: [7, 8], 4.0: [10, 11], 6.5: [14, 15], 10: [21, 22], 15: [21, 22], 25: [21, 22] },
+    L: { 0.065: [0, 1], 0.1: [0, 1], 0.15: [1, 2], 0.25: [1, 2], 0.4: [2, 3], 0.65: [3, 4], 1.0: [5, 6], 1.5: [7, 8], 2.5: [10, 11], 4.0: [14, 15], 6.5: [21, 22], 10: [21, 22], 15: [21, 22], 25: [21, 22] },
+    M: { 0.065: [0, 1], 0.1: [1, 2], 0.15: [1, 2], 0.25: [2, 3], 0.4: [3, 4], 0.65: [5, 6], 1.0: [7, 8], 1.5: [10, 11], 2.5: [14, 15], 4.0: [21, 22], 6.5: [21, 22], 10: [21, 22], 15: [21, 22], 25: [21, 22] },
+    N: { 0.065: [1, 2], 0.1: [1, 2], 0.15: [2, 3], 0.25: [3, 4], 0.4: [5, 6], 0.65: [7, 8], 1.0: [10, 11], 1.5: [14, 15], 2.5: [21, 22], 4.0: [21, 22], 6.5: [21, 22], 10: [21, 22], 15: [21, 22], 25: [21, 22] },
+    P: { 0.065: [1, 2], 0.1: [2, 3], 0.15: [3, 4], 0.25: [5, 6], 0.4: [7, 8], 0.65: [10, 11], 1.0: [14, 15], 1.5: [21, 22], 2.5: [21, 22], 4.0: [21, 22], 6.5: [21, 22], 10: [21, 22], 15: [21, 22], 25: [21, 22] },
+    Q: { 0.065: [2, 3], 0.1: [3, 4], 0.15: [5, 6], 0.25: [7, 8], 0.4: [10, 11], 0.65: [14, 15], 1.0: [21, 22], 1.5: [21, 22], 2.5: [21, 22], 4.0: [21, 22], 6.5: [21, 22], 10: [21, 22], 15: [21, 22], 25: [21, 22] },
+    R: { 0.065: [3, 4], 0.1: [5, 6], 0.15: [7, 8], 0.25: [10, 11], 0.4: [14, 15], 0.65: [21, 22], 1.0: [21, 22], 1.5: [21, 22], 2.5: [21, 22], 4.0: [21, 22], 6.5: [21, 22], 10: [21, 22], 15: [21, 22], 25: [21, 22] },
 };
 function getSampleCode(lotSize, inspectionLevel) {
     for (const range of LOT_SIZE_RANGES) {
@@ -55,9 +58,11 @@ function getSampleCode(lotSize, inspectionLevel) {
 }
 function getAcceptReject(sampleCode, aqlLevel) {
     const codeTable = AQL_TABLE[sampleCode];
-    if (!codeTable)
-        return [0, 1];
-    // Find the closest AQL level
+    // Snap to the nearest table column at or below the requested AQL (or the lowest column
+    // when the request is below the table). The embedded table covers 0.065-25, while
+    // ISO 2859-1 defines AQLs from 0.010 up to 1000 — so out-of-range requests (AQL 40,
+    // AQL 0.01) get a plan for a DIFFERENT quality level. `aqlUsed` reports which column was
+    // applied; the caller compares it against the request via `aqlAdjusted`.
     const aqlLevels = Object.keys(codeTable).map(Number).sort((a, b) => a - b);
     let selectedAql = aqlLevels[0];
     for (const level of aqlLevels) {
@@ -65,7 +70,8 @@ function getAcceptReject(sampleCode, aqlLevel) {
             selectedAql = level;
         }
     }
-    return codeTable[selectedAql] ?? [0, 1];
+    const [acceptNumber, rejectNumber] = codeTable[selectedAql];
+    return { acceptNumber, rejectNumber, aqlUsed: selectedAql };
 }
 /**
  * Calculate AQL (Acceptable Quality Level) sampling plan
@@ -75,6 +81,15 @@ function getAcceptReject(sampleCode, aqlLevel) {
  * @remarks Simplified relative to the standard: the sample size is always the code
  *   letter's own size — Table 2-A arrow cells (which redirect to a plan with a
  *   different sample size) reuse the redirected plan's Ac/Re with this letter's size.
+ * @remarks The embedded table covers AQL columns 0.065–25 (ISO 2859-1 defines
+ *   0.010–1000). A request outside (or between) the embedded columns is snapped to the
+ *   nearest column at or below it (or up to 0.065 from below) and disclosed via
+ *   `aqlUsed` / `aqlAdjusted` — the returned plan is then for a different quality level
+ *   than requested.
+ * @remarks Per ISO 2859-1, AQL values above 10 (the 15 and 25 columns) apply to
+ *   inspection for **nonconformities per 100 items** only, not percent nonconforming.
+ *   The 10/15/25 columns were transcribed from ISO 2859-1:1999(E) Table 2-A and
+ *   cross-verified against MIL-STD-105E Table II-A.
  *
  * @param input - AQL input parameters
  * @returns AQL sampling plan result
@@ -93,11 +108,13 @@ export function aql(input) {
             acceptNumber: 0,
             rejectNumber: 1,
             samplingPercent: 0,
+            aqlUsed: 0,
+            aqlAdjusted: true,
         };
     }
     const sampleCode = getSampleCode(lotSize, inspectionLevel);
     const sampleSize = SAMPLE_SIZES[sampleCode] ?? 2;
-    const [acceptNumber, rejectNumber] = getAcceptReject(sampleCode, aqlLevel);
+    const { acceptNumber, rejectNumber, aqlUsed } = getAcceptReject(sampleCode, aqlLevel);
     // Ensure sample size doesn't exceed lot size
     const effectiveSampleSize = Math.min(sampleSize, lotSize);
     const samplingPercent = roundTo((effectiveSampleSize / lotSize) * 100, 2);
@@ -107,6 +124,8 @@ export function aql(input) {
         acceptNumber,
         rejectNumber,
         samplingPercent,
+        aqlUsed,
+        aqlAdjusted: aqlUsed !== aqlLevel,
     };
 }
 //# sourceMappingURL=aql.js.map