Basics of Pyrometry, Industry Specifications
and Temperature Uniformity Surveys
Pyrometry
In its simplest sense, pyrometry is the measurement of temperatures. Practically speaking, in
the business of heat treatment, the term also refers to the equipment, standards, and
specifications that make it possible to measure high temperatures accurately.
Take a standard run-of-the-mill thermometer, for example – the kind you might have on your
front porch. Most people don’t give this device a second thought, because it can’t be adjusted,
and it doesn’t need to be very accurate. After all, does it really matter whether it’s 60° or 65°
outside?
But sometimes, measurement accuracy is more important – for example, in a meat
thermometer. You rely on that device to ensure that your food is cooked enough to kill off
harmful bacteria. If your thermometer is inaccurate, you or your family could become very ill.
In heat treatment, the need for accuracy even more critical. If the temperature readings for
your furnace are inaccurate, those aircraft parts you’re heat treating could literally put lives at
risk.
To make matters even more complicated, you must have blind faith in the instruments that
measure such extreme temperatures. If your porch thermometer reads 70° but it’s snowing,
you know that something’s wrong. If your meat thermometer reads 165° but the chicken is still
pink, you know it’s not safe to eat. But if your furnace reads 1900° and it’s actually 1875°, how
can you even know that there’s a problem?
And even if you do somehow realize
that something’s not right, how do
you determine where the problem
is? Measuring temperatures in
industrial applications isn’t as
simple as sticking a thermometer in
a piece of chicken – rather, it takes
an entire system of devices all
working together to give a glimpse
of what’s happening inside a furnace
(See Fig. 1). Any one of the parts
could be to blame for an inaccurate Figure 1 - Typical Measurement and Control System
measurement.
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AMS 2750
To address these complications, industry leaders have developed a number of systems and
guidelines that help lead to consistency and quality. One of the most important such programs
is the National Aerospace and Defense Contractors Accreditation Program (NADCAP). NADCAP
certification is essential to any business that wants to do heat treating work for the aerospace
industry.
To ensure consistency of temperature measurement in heat treating processes, NADCAP relies
on a document known as AMS 2750 (AMS = Aerospace Materials Specification). It’s important to
note that although NADCAP and AMS are both based in the aerospace sector, the certification
and specification apply to the overall heat treatment industry and are not limited to aerospace
alone. AMS 2570 covers all aspects of pyrometry in heat treatment, including:
• Controllers (calibrations, specifications and readability requirements)
• Thermocouples (calibrations, usage, types)
• Recording instruments (calibrations, accuracy)
• Calibration requirements for thermocouples and equipment
• Accuracy requirements and tolerances for acceptance
• Calibration procedures
• Temperature survey procedures
• Frequency of activities
Temperature Uniformity Surveys
One of the key components to AMS 2750 is the Temperature Uniformity Survey (TUS). A TUS
verifies the classification of your furnace and its qualified working zone, and this in turn
determines your required ongoing testing schedule in order to maintain conformity with AMS
2750.
Furnace Classification
Furnace classification is a key
piece of information that the
TUS will use to determine
required frequency of testing
activities. Furnace class is
determined by the
Figure 2 - Furnace Classifications
temperature uniformity
range within the qualified
working zone – put simply, in the area of furnace that you will be using, how close are you
staying to your desired temperature? The temperature uniformity range is described as a
plus/minus degrees value, as shown in Figure 2. So, for example, if a furnace is meant to run at
1900°F, and it ranges between 1887° and 1913°, it would qualify as Class 3. A higher-rated
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furnace classification means that the furnace is able to stay closer to its target temperature
without variation.
Instrumentation Type
In addition to classification, AMS 2750 also uses Instrumentation Type to determine a furnace’s
mandatory testing schedule. Instrumentation type can be look at as the number of sensors
used for control/recording in a furnace. All of these sensors, controls, and recording systems
have strict accuracy requirements and calibration intervals. The five instrumentation types (A-
E) are defined clearly within the specification (see figure 3 for a sample).
Figure 3 - Instrumentation Type Descriptions
Testing Intervals
Put together, furnace classification and instrument type clearly determine the testing schedule
necessary for your furnace in order to maintain certification. So, for example (See Fig. 4) a
Class 2 Furnace with Instrumentation Type B is required to undergo a TUS on a monthly basis,
whereas a Class 5 Furnace with Instrumentation Type B only requires a quarterly TUS.
Figure 4 - TUS Interval Chart
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However, AMS 2750 rewards TUS success. If a furnace completes a designated number of TUSs
successfully, the interval between testing can be increased. In our above example, if the Class 2
Furnace with Instrumentation Type B were to undergo four consecutive successful TUSs, its
required testing would stretch from monthly to quarterly. Having to perform fewer TUSs is a
huge benefit, leading to:
• Lower cost of labor/materials,
• Increased production/reduced down time, and
• Decreased time spent on documentation of the process.
It is also important to note that AMS 2570E provides different timelines based on what is being
treated in the furnace. Figure 5 deals specifically with parts, while a furnace treating raw
materials would be subject to another chart, and would have a less rigorous TUS interval to
maintain.
TUS Logistics
A TUS requires time and organization since there are many pre-requisites prior to performing
the TUS. Even though a survey may only take two hours to run, it takes planning and
coordination to get all the pieces in place. All the while, management and production are
probably waiting for that valuable furnace time. To minimize this downtime, work to streamline
the activities that surround the TUS in order to create an efficient process:
• Organize paperwork.
• Ensure quick and easy access to maintenance logs.
• Have a prefabricated TUS rack wired in advance.
• Communicate dates for calibration of equipment.
• Develop a quick reporting technique for easy review and signoff.
• Ensure that the survey device is calibrated and certified (3 months per AMS 2750E).
All these preparations put together can shave off hours off the process. When multiplied by a
number of furnaces, the financial benefits are obvious.
When the time comes to actually perform the TUS, there is a great deal to consider. Items such
as thermocouple wire requirements, instrument calibration and more are covered in great
detail in AMS 2750E, but it is critical to know and understand your equipment (e.g.,
thermocouple type, noble or base metal, primary or secondary use), so that you can make use
of the guidelines included in the specification (see Fig. 5, next page).
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Figure 5 - Sensor Calibration Chart
Thermocouples
Thermocouples in particular can present a challenge. By their very nature, they have
associated calibration errors that must be corrected to determine a true temperature. Many
areas in AMS2750 cover these correction factors, which are used to adjust the readings of
thermocouples. It is absolutely mandatory to use these corrections when performing TUSs.
While they can be entered after the survey, it strongly recommended to capture this information
beforehand. This will enable the technician to immediately identify any potential issues with
the survey, allowing actions to be taken immediately. It is important that the individuals that
are performing activities understand how to use these correction factors and how to document
the results for future reference, such as would be required during a NADCAP audit.
Conclusion
Understanding the TUS process as it applies to AMS 2750E will allow you to be proactive
regarding your requirements and responsibilities as a reliable heat treater. If you are familiar
with your equipment and the specification, you can prepare for efficient transitions, minimize
downtime, and streamline the process of TUS testing. And if you take the time to document the
process for future surveys, you can save time and money in the long run by enabling yourself to
identify problems before they are too late to prevent.
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