Prepared by Aerospace Testing & Pyrometry, July 2020

This presentation is not to be reproduced without the written

permission of Aerospace Testing & Pyrometry, Inc 1
 SENSOR AND EXTENSION WIRE/CONNECTOR
Sensor Extension Element Color Jacket Color Connector Color
Classification Wire Type Code Code Code

Base metal M Yellow/Red Yellow Yellow

Refractory
C Green/Red Red Red
metal
• Type M is not recognized as a sensor type designation by all
international standards.
• Extension wire for type M shall be the same as type K.
• Extension wires for type C refractory metal sensors are usually of a
different, more economical composition whose relative thermoelectric
properties as a pair closely approximate those of the refractory metal
sensors with which they are to be used over a limited temperature
range.

Prepared by Aerospace Testing & Pyrometry, July 2020 2

 SENSOR CALIBRATION ACCURACY
(3)
Sensor Application Calibration Accuracy

Noble metal type R and S: ±1.0°F or ±0.1% (1) (2)

Nobel metal type B: ±1.0°F or ±0.25% (1) (2)
All
Base metal: ±2.0°F or ±0.4% (1)
Refractory metal type C: ±1% of reading

(1) Whichever is greater.

(2) When correction factors are applied during thermal processing:
Type B sensor calibration accuracy shall be ±2.7°F or ±0.5% of
reading, whichever is greater.
Type R and S sensor calibration accuracy shall be ±2.7°F or ±0.25% of
reading, whichever is greater.
(3) Sensors and sensor materials are normally supplied to meet the
tolerances specified for temperatures above 32°F. The same materials,
however, may not meet the tolerances for temperatures below 32°F.

Prepared by Aerospace Testing & Pyrometry, July 2020 3

 RESISTANT TEMPERATURE DEVICES (RTD)
Sensor Application Calibration Accuracy
RTD: class A
All ±0.27°F at 32°F
±2.43⁰F at 1112⁰F
• RTD’s shall be platinum type and meet class A tolerances given in
ASTM E1137, IEC 60751, or other internationally recognized standards.
• RTD’s shall be noble metal and shall be classified as non-expendable.
• When specifying a class A RTD, include the qualified operating
temperature range since the accuracy changes as a function of
temperature.
• Replacement and calibration frequency of RTD’s not defined.

Prepared by Aerospace Testing & Pyrometry, July 2020 4

 SENSOR CALIBRATION
 User procedures shall control the replacement frequency
of thermal process equipment sensors including limits on
maximum life and/or number of uses based on
supporting data such as, but not limited to, SAT, TUS, and
re-calibration and/or trend analysis.
 User procedures shall identify how the sensor first use
practice is applied and documented.
 All wire/cable rolls regardless of length shall be sampled
at both ends. The average correction factor calculated
from both ends shall be applied during thermal
processing and during the SAT and TUS.

Prepared by Aerospace Testing & Pyrometry, July 2020 5

 EXPENDABLE SAT AND TUS SENSOR RE-USE
Sensor Classification Use Temperature Re-use

All base metal <500.0⁰F 3 months from first use

3 months or 5 uses,
500.0⁰F to 1200⁰F
Base metal types M, T, whichever occurs first
K and E
>1200.0⁰F 1 use
3 months or 10 uses,
Base metal types J and 500.0⁰F to 1200⁰F
whichever occurs first
N
>1200.0⁰F 1 use

All noble metal No restrictions 6 months from first use

• Records shall show the accumulated SAT and TUS sensor re-use
including sensor batch number, temperature and use count.

Prepared by Aerospace Testing & Pyrometry, July 2020 6

 EXPENDABLE BASE METAL LOAD SENSOR RE-USE
Sensor Classification Use Temperature Re-use

All base metal <500.0⁰F 3 months from first use

3 months or 5 uses,
500.0⁰F to 1200.0⁰F
Base metal types M, whichever occurs first
T, K and E
>1200.0⁰F 1 use
3 months or 10 uses,
500.0⁰F to 1200.0⁰F
Base metal types J whichever occurs first
and N
>1200.0⁰F 1 use

• Records shall show the accumulated load sensor use including

sensor batch number, load cycle, temperature and use count. The
use count shall include uses during SAT and TUS.

Prepared by Aerospace Testing & Pyrometry, July 2020 7

NON-EXPENDABLE BASE METAL LOAD SENSOR RE-USE
Maximum Replacement Interval or
Use Temperature
Number of Uses
2300.0°F and above 1 use
2200.0°F to 2299.9°F Quarterly or 10 uses

1800.0°F to 2199.9°F Quarterly or 90 uses

1200.0°F to 1799.9°F Quarterly or 180 uses

500.1°F to 1199.9°F Quarterly or 270 uses

At or below 500.0°F Quarterly, unlimited uses

 Records shall show the accumulated load sensor use including
sensor batch number, load cycle, temperature and use count.
The use count shall include uses during SAT and TUS.

Prepared by Aerospace Testing & Pyrometry, July 2020 8

 SENSOR CALIBRATION RESULTS AND RECORDS
 Date of calibration or re-calibration.
 Quantity of sensors or length of wire/cable rolls.
 Identification if the calibration was initial or a re-
calibration.
 The required calibration accuracy.
 User quality organization approval.

Prepared by Aerospace Testing & Pyrometry, July 2020 9

 GENERAL INSTRUMENTATION REQUIREMENTS
 Calibration periods for all instruments shall begin on the
date of calibration.
 It is prohibited to use a secondary standard instrument
which meets the calibration accuracy of a primary
standard to calibrate a secondary standard instrument.
 Secondary standard instruments shall be stored and
used in the environment specified by the instrument
manufacturer.
 Secondary standard and field test instruments shall be
stored and operated within the environmental conditions
specified by the instrument manufacturer.

Prepared by Aerospace Testing & Pyrometry, July 2020 10

CONTROL AND RECORDING INSTRUMENT SENSITIVITY
 Sensitivity for analog instruments shall be verified:
 During each periodic calibration.
 For all active channels in use for multi-channel recording
instruments.
Furnace Class Minimum Sensitivity
1 (±5⁰F)
1
2 (±10⁰F)
3 (±15⁰F)
4 (±20⁰F)
3
5 (±25⁰F)
6 (±50⁰F)

Prepared by Aerospace Testing & Pyrometry, July 2020 11

CONTROL AND RECORDING INSTRUMENT CALIBRATION
 Calibration is required for over-temperature instruments.
 All instrument adjustments shall be included on the
calibration report.
 When the control and recording system is integrated
such that the digitally displayed control indicated value
and the digitally recorded indicated value are generated
from the same measurement circuit and cannot be
different, it is only necessary to document a single
displayed/recorded reading for the control indicated
value.

Prepared by Aerospace Testing & Pyrometry, July 2020 12

 RECORDING INSTRUMENT CLASSIFICATION
Paper
Recording Instrument Feature Analog Digital
Media
Printed and pre-printed scales
with printed trend line
 
Printed and pre-printed scales
with printed tabular data
 
Window with digital temperature
display with printed trend line
 
Window with digital temperature
display with printed tabular data
 
Digital temperature display.
Creates scale, trend line and  
tabular data.
Prepared by Aerospace Testing & Pyrometry, July 2020 13
 CALIBRATION OF TIMING DEVICES
Calibration Calibration
Timing Function
Accuracy Frequency
Internal timing systems for digital
recording instruments and data ±1 minute/hour Annually
acquisition systems
Digital synchronization of timing
systems to NIST or other
internationally recognized ±1 minute/hour Monthly
standards via satellite, internet or
telephonic systems
External timing devices such as
±1 second/minute Bi-annually
timers, clocks, stopwatches, etc.
 There shall be documented evidence of the calibration of all timing
devices.

Prepared by Aerospace Testing & Pyrometry, July 2020 14

INSTRUMENT CALIBRATION RESULTS AND RECORDS
 Indication if any limitations or restrictions of the
calibration. If space on the label does not permit listing of
the limitations or restrictions, a second label in close
proximity to the instrument or a notation such as “See
report” is acceptable.
 Unique identification of the instrument calibrated.
 Identification of location where signal was input (only
required for systems utilizing the alternate SAT).

Prepared by Aerospace Testing & Pyrometry, July 2020 15

INSTRUMENT CALIBRATION RESULTS AND RECORDS
 As-found data at each calibration point and as-left data if
any adjustments are made, to include:
 Nominal calibration temperature.
 Error of field test instrument (optional or when specified by
the process or material specification).
 Error of instrument under calibration (corrected or
uncorrected for field test instrument error when specified).

Prepared by Aerospace Testing & Pyrometry, July 2020 16

 Additional recording sensor INSTRUMENT TYPE D+
located at least 3 inches away
from the control sensor
position and of a different
sensor type Control sensor Over-temperature sensor

Control Over-temperature
instrument instrument

Single or multi channel recording

instrument Raw material or part

Prepared by Aerospace Testing & Pyrometry, July 2020 17

ADDITIONAL SENSORS DURING THERMAL PROCESSING
For Multiple Control Zone Furnaces with 225 ft3 or Less in Total
Qualified Work Zone Volume
Instrumentation
Purpose Requirement
Type
Treat the furnace
Locating hot and cold
qualified work zone
A or C temperature recording
volume as a single
sensors.
control zone.
Determining the When the greatest
number of load dimension of width,
sensors required, length, diameter, or
A or B
regardless of the height is no more than
number of control three times any of the
sensors. other dimensions.
Prepared by Aerospace Testing & Pyrometry, July 2020 18
ADDITIONAL SENSORS DURING THERMAL PROCESSING
For Multiple Control Zone Furnaces with 225 ft3 or Greater in Total
Qualified Work Zone Volume
The total volume may be divided into control zones each of which
shall not exceed 225 ft3
Each control zone shall contain all of the required sensors
representative of a single control zone.

Prepared by Aerospace Testing & Pyrometry, July 2020 19

 CORRECTION FACTORS
• Interpolation of correction factors between two known
calibration temperatures is permitted using the linear
method. Alternatively, the correction factor of the nearest
calibration temperature shall be used.
• Whatever method selected it shall be used consistently
for all applications.
• User procedures shall define the method of interpolation
used.

Prepared by Aerospace Testing & Pyrometry, July 2020 20

CORRECTION AND MODIFICATION OFFSETS DEFINTION
• Correction offset: Manual or electronic adjustment of an
instrument to compensate for known errors of the
measurement system (instrument, extension
wire/connectors, sensor) to make the system more
accurate.
• Modification offset: Manual or electronic adjustment of
an instrument to compensate for known conditions such
as, but not limited to, a skewed TUS distribution or
control sensor placement in a retort or muffle.

Prepared by Aerospace Testing & Pyrometry, July 2020 21

 CORRECTION AND MODIFICATION OFFSETS
 If instrument correction and/or modification offsets are
applied, user procedures shall describe when and how to
apply these offsets.
 The maximum cumulative correction offset shall not
exceed the TUS tolerance for the thermal processing
equipment. e.g. a class 2 furnace instrument is limited to
a maximum correction offset of ±10.0°F.
 The maximum cumulative correction offset shall not
exceed ±5.0°F for refrigeration and quench equipment
instruments.
 Correction and/or modification offsets, if consistently
applied during production heat treatment and supported
procedurally, must be algebraically applied to the system
being tested.
Prepared by Aerospace Testing & Pyrometry, July 2020 22
 CORRECTION AND MODIFICATION OFFSETS
Correction Offset
Purpose Modification Offset Permitted
Permitted
Control and
recording instrument Yes Yes
calibration
SAT Yes No
Only applied to the recording
instrument channel recording
TUS No
the control sensor
temperature.
Load sensor system Yes No
 Correction and/or modification offsets may be either internal
(electronic) or external (manual), and shall be reported in the
instrument calibration, SAT and TUS documentation.

Prepared by Aerospace Testing & Pyrometry, July 2020 23

 SAT GENERAL REQUIREMENTS
• When the control and recording system is integrated such
that the digitally displayed control indicated value and the
digitally recorded indicated value are generated from the
same measurement circuit and cannot be different, it is
only necessary to document a single displayed/recorded
reading for the SAT indicated value.
• For furnaces with multiple qualified operating temperature
ranges, a comparison SAT shall be performed within each
range at least annually.

Prepared by Aerospace Testing & Pyrometry, July 2020 24

 COMPARISION SAT USING A RESIDENT SAT SENSOR
 The resident SAT sensor shall be secured in position to
system/assembly that shall prevent movement relative to
the sensor under test.
 The position (location and insertion depth) shall be
verified on SAT sensor installation and replacement.
 Alternatively, the resident SAT sensor may be located
independently of the sensor under test and its position
shall be verified before each SAT to ensure that it has not
moved between sensor installation events.
 It is permitted to use the over-temperature sensor as the
resident SAT sensor provided it is used only for over-
temperature protection and meets all of the requirements
of an SAT sensor.
Prepared by Aerospace Testing & Pyrometry, July 2020 25
 SAT WAIVER SENSOR REQUIREMENTS
Replacement
Sensor Purpose
Frequency
Noble metal Every 2 years
Control and recording
Base metal Quarterly
Control or Recording Sensor Being Tested
Additional
All Other Sensor
Sensor Type B R S N
Types

B No Yes Yes Yes Yes

R Yes No No Yes Yes

S Yes No No Yes Yes

N Yes Yes Yes No Yes

Prepared by Aerospace Testing & Pyrometry, July 2020 26

 ALTERNATE SAT RESULTS AND RECORDS
 Identification of the thermal processing equipment.
 Identification of the sensor system being tested.
 Identification of the sensor or wire/cable roll.
 Date and time the alternate SAT was performed.
 Identification of the reason why the alternate SAT was
performed e.g. replacement of the recording sensor
and/or calibration of the recording instrument.

Prepared by Aerospace Testing & Pyrometry, July 2020 27

 ALTERNATE SAT RESULTS AND RECORDS
 Final alternate SAT results calculated for the method
used with supporting documentation/calibration reports
as required.
 Identification of the technician who performed the
alternate SAT.
 Identification of the agency if the alternate SAT is
performed by a third party.
 Approval of an authorized agent for the agency
performing the alternate SAT if performed by a third
party.
 User quality organization approval.

Prepared by Aerospace Testing & Pyrometry, July 2020 28

 SAT WAIVER RESULTS AND RECORDS
 Identification of the thermal processing equipment.
 Identification of the control and additional sensor system
used for the sensor relationship test.
 Date of installation of the control and additional sensor
used for the sensor relationship test.
 Run number and date of the production thermal cycle.
 Date and temperature(s) of the most recent TUS.
 Documentation of the sensor relationship test at each
TUS temperature.
 Documentation of the weekly readings and results of the
sensor relationship test.

Prepared by Aerospace Testing & Pyrometry, July 2020 29

 VACUUM LEVEL DURING THE TUS
 For vacuum furnaces operated in both vacuum (no gas)
and under partial pressure (with backfill gas) during
production, an additional periodic TUS shall be
performed at least annually at one single operating
temperature and within the partial pressure range used
during production.
 The gas used shall be one of the gases used during
production.

Prepared by Aerospace Testing & Pyrometry, July 2020 30

 LOCATION OF TUS SENSORS FOR VOLUMES <3FT3
Square/rectangular volume Cylindrical volume

2
6
1 1

3 5 5
7
2 3
9

4 4
A minimum of five TUS sensors. Location
A minimum of five TUS sensors. pairs 1 and 2, 3 and 4 shall be 180⁰ apart at
Locations 1, 4, 5, 7 and 8 or 2, 3, 5, 6 and 9 the opposite ends and shall be offset 90⁰
shall be selected. Location 5 shall represent rotationally from each other. Location 5 shall
the approximate center of the qualified work represent the approximate center of the
zone. qualified work zone

Prepared by Aerospace Testing & Pyrometry, July 2020 31

 LOCATION OF TUS SENSORS FOR VOLUMES
>3FT3 AND <225FT3
Square/rectangular volume Cylindrical volume

6
1 2
1
3
4
3 5
5
7
2
9
7 6 9
4
8

A minimum of nine TUS sensors. All nine locations shall be represented as shown.
Location 5 shall represent the approximate center of the qualified work zone. Locations 4
and 6 are example locations.

Prepared by Aerospace Testing & Pyrometry, July 2020 32

 TUS RESULTS AND RECORDS
 The atmosphere, partial pressure or vacuum.
 The TUS instrument correction factors shall be stated
even when the correction factors have been electronically
applied to the TUS instrument to correct the TUS
instrument temperature readings.
 The results of hottest and coldest TUS and furnace
recording sensor relocation analysis for type A and C
instrumentation, as applicable.
 Traverse speed(s) or shaker frequency for the TUS
performed on continuous and semi-continuous furnaces,
as applicable.

Prepared by Aerospace Testing & Pyrometry, July 2020 33

 RADIATION SURVEY
 For all aluminum alloy thermal processing equipment
used above 800°F where the heat source e.g. electrical
elements or gas tubes, is located in/on the furnace walls,
ceiling, or floor, a radiation survey shall be performed at
the maximum operating temperature used during
production.
 The soak time for the panels shall be in accordance with
the thickness requirements defined by the material or
process specification.
 For vacuum furnaces used for brazing aluminum alloy
parts the time at temperature shall not exceed the
maximum braze time at temperature used during
production.
Prepared by Aerospace Testing & Pyrometry, July 2020 34
 ROUNDING
 All rounding shall be applied in accordance with a
documented procedure and used in a consistent manner.
 The rounding method incorporated in commercial
spreadsheet programs is permitted.
 All specified limits specified are absolute and out of
tolerance calibration and test results cannot be rounded
into tolerance.

Prepared by Aerospace Testing & Pyrometry, July 2020 35

 QUALITY ASSURANCE PROVISIONS
 Beginning 2 years after the release of AMS 2750, revision
F, third party pyrometry service provider companies shall
have a quality system accredited to ISO/IEC 17025 from
an ILAC (International Laboratory Accreditation
Cooperation) recognized accreditation body.
 The scope of accreditation shall include the laboratory
sensor and instrument standards and/or field service
provided, as applicable.

Prepared by Aerospace Testing & Pyrometry, July 2020 36

 QUALITY ASSURANCE PROVISIONS
Equal to once
Interval Occurring on the same:
every:
Weekly Week Day of the week every week
Bi-weekly Two weeks Day of the week every two weeks
Monthly Month Day of the month every month
Bi-monthly Two months Day of the month every two months
Quarterly Three months Day of the month every third month
Semi-annually Six months Day of the month every six months
Annually Year Date of the year every year

Prepared by Aerospace Testing & Pyrometry, July 2020 37