TEMPLUG USER INFORMATION GUIDE
Contents
1. Page 5 2013 TEMPLUG DESIGN CHARACTERISTICS 2 mm p 2 Mm Break off handle 4 Machined in groove to distinguish from No 2 12mm 12mm Break off zone 4 TEMPLUG screw zone 2mm to remain in test object 2m after break off 1 6mm 1 6mm No 2 Steel No 3 steel The handle may be used for test exposure and evaluation since handle and plug are fully hardened FIGURE 2 Small M1 6 x 0 35 Break off TEMPLUG TEMPLUG User Information Guide Revision 4 0 Page 6 2013 TECHNICAL INFORMATION In order to obtain accurate and reliable data with TEMPLUG the following considerations have to be kept in mind a Temperature Time Cycles The ideal temperature time cycle for determining maximum temperature would be where the TEMPLUG is heated rapidly to a uniform maximum temperature maintained at this temperature followed by rapid cooling This cycle simulates conditions that are used for generating the master calibration curves and consequently should minimize error The ideal cycle has been shown in Figure 3 TEMPLUG are sensitive more to temperature than to time Based on this two acceptable temperature time cycles are shown in Figures 4 and 5 The critical aspect about these cycles is that at least 25 of the total time should be at the maximum temperature The greater this percentage the more accurate the maximum temperature measurement b Temperature and Time Limits The minimum and maximum temperatures that can b2. temperature can be determined accurately to within 4 5 The higher the percentage of time spent at maximum temperature conditions the greater the accuracy FIGURE 6 Leco AMH43 Automated Microhardness Tester TEMPLUG User Information Guide Revision 4 0 Page 10 2013 Other factors that affect accuracy are inaccurately reported exposure times and temperature spikes or overshoots These factors are discussed below a Inaccurately Reported Exposure Time The following table shows the error that would be introduced in the maximum temperature measurement based on inaccurately measuring the peak exposure time EFFECT OF ERROR IN COUNTING TIME Cycle Time Peak Time Error Temperature Error Recorded Temperature Assumed Max Assumed From Data The table shows that after 1 hour exactness in reported exposure time is not critical The relationships shown above also apply to maximum temperatures other than the 572 F used in the example b Temperature Spikes or Overshoots Research has shown that a temperature spike of the type shown in Figure 7 has to be between 85 F and 140 F before it will produce a measurable change in the maximum temperature A spike in excess of the above magnitude can produce a measurable effect on the maximum temperature in as little as 0 1 of the total exposure time TEMPLUG User Information Guide Revision 4 0 Page 11 2013 over temperature spike TEMPERATURE TIME FI
3. tempering thermal softening of a hardened steel Master calibration curves of the type shown below were developed by Shell for special heat treated alloy steels and are the basis for determining the maximum temperature Beware of imitations that have not been proven TEMPLUGS are the original temperature indicating device TEI is a nationally recognized ISO compliant laboratory that maintains the highest quality control standards and the only TEMPLUG laboratory in North America 100 Hardness ee A cae 1 Hour a 10 Temperature From the above curves the maximum temperature is determined based on the time of exposure known from experimental conditions and the measured hardness 1 Thermal expansion needs to be considered to prevent damage to the test part 2 New curves for a new more controlled alloy have been prepared by the current manufacturer Vernolab France E TEMPLUG User Information Guide Revision 4 0 Page 3 2013 TEMPLUG CHARACTERISTICS a Temperature Limits TEMPLUG are made from two alloy steels which are sensitive in the following temperature ranges Type of Steel Temperature Range FCC MIN MAX No 2 Steel 165 74 1200 649 No 3 Steel 1020 550 1565 852 A more specific discussion covers the minimum and maximum temperature ranges for TEMPLUG under Temperature and Time Limits pages 6 amp 7 b Design TEMPLUG set screws are available in two sizes dimensions specified in metric units 1 M3
4. GURE 7 Exposure cycle with over temperature spike TEMPLUG User Information Guide Revision 4 0 Page 12 2013 a CONDUCTING A TEST Installation Drill and tap the holes required at the desired TEMPLUG locations using ISO 3 x 0 5 tap for M3 plugs and ISO 1 6 x 0 35 for M1 6 plugs The holes have to be bottomed with a bottoming tap The flat test end of the TEMPLUG should be installed such that the TEMPLUG is securely bottomed in the tapped hole torque 0 4 Nm Each hole should be drilled sufficiently deep to avoid protrusion of the socket or break off end Since the flat tip of the TEMPLUG is the area tested for peak temperature it is suggested that the hole bottom be located close to the desired measurement area if possible A small error may be introduced if the TEMPLUG location cannot accommodate this recommendation Secure the M3 TEMPLUG in the hole tightly with a Torx T 6 head wrench or tool The usual right angle wrench may be used or a pin vise may be preferred for ease of manipulation If additional security is desired to prevent the TEMPLUG from unscrewing during the test an organic cementing agent may be used such as Loctite however the TEMPLUG may be very difficult to remove or may require sectioning by TEI In order to facilitate removal use silicone fluid to coat the TEMPLUG and take care not to deform the plug during installation If heat is used in removal of the TEMPLUG the user must be certain that the resulta
5. MPLUGS eliminate the need for costly instrumentation necessary for more accurate methods of temperature measurements Most locations tested with TEMPLUGS are critical highly stressed areas of moving parts that cannot easily be measured with other measuring devices Typically our customers are more concerned with relative temperatures between locations on the test part and between consecutive tests than the absolute exact temperature This method of determining peak temperatures is limited by at least four major variables the material itself the tempering process the test procedures followed while exposing it to elevated temperatures and the method of determining final hardness Careful manufacturing procedures are followed to ensure that inaccuracies relating to the first two items are minimized TEI also performs random quality control testing of incoming TEMPLUGS from the manufacturer in accordance with our Quality Control Manual using an automated Leco microhardness tester shown in Figure 6 We have confidence that our customers take as much pride and care in following rigorous and meticulous testing practice The method of measuring hardness is therefore the critical factor influencing the results of the temperature measurements We estimate that if a properly conducted test as described by Figure 3 the maximum temperature can be determined accurately to within 3 For the acceptable temperature time cycles shown in Figures 4 and 5 the maximum
6. TEMPLUG USER INFORMATION GUIDE REVISION 4 0 2013 TESTING ENGINEERS INC mA G TABLE OF CONTENTS Page Table of Contents 2 1 INTRODUCTION 3 TEMPLUG Characteristics a Temperature Limits 4 b Design 4 c Figure 1 M3 Details 5 d Figure 2 M1 6 Details 6 2 TECHNICAL INFORMATION a Temperature Time Cycles 7 b Temperature and Time Limits 7 c Alterations to TEMPLUG 8 d Corrosion 8 e Figures 3 4 amp 5 9 f Accuracy of Results 10 h Figure 6 10 g Figure 12 3 CONDUCTING A TEST a Installation 13 b Removal 14 c Ordering 14 d Analysis amp Reporting 15 e TEMPLUG SHIPPING BOARD Figure 8 16 TEMPLUG User Information Guide Revision 4 0 Page 2 2013 INTRODUCTION TEMPLUG is a temperature sensitive steel set screw and is used for determining the maximum temperature in locations that are difficult to instrument using conventional thermocouple type techniques moving engine parts turbine blades and bearings are a good examples of typical applications The part being tested does not need to be made of steel nickel alloys aluminum composites ceramics can be tested with this technique By drilling and tapping a TEMPLUG can be installed directly into the location at which temperature needs to be measured No other instrumentation necessary TEMPLUGS were developed in the early 1970 s in a joint effort by Testing Engineers Inc TED amp Shell Research They function on the principle of thermal
7. e determined with the No 2 TEMPLUG for a variety of exposure times are given below The least exposure time is 1 hour and the maximum exposure time is 100 hours EXPOSURE TIME MIN TEMP MAX TEMP F C F Exposure times in between the ones listed above can also be used without introducing any error in temperature determination TEMPLUG User Information Guide Revision 4 0 Page 7 2013 TECHNICAL INFORMATION Cont d b Temperature and Time Limits Cont d Similar information for the No 3 TEMPLUG is presented below The least exposure time for the No 3 TEMPLUG is 1 hour and the maximum exposure time is 100 hours EXPOSURE TIME MIN TEMP MAX TEMP F C F 100 Hours 1022 550 1565 852 Exposure times in between the ones listed above can also be used without introducing any error in temperature determination c Alterations to TEMPLUG A user may desire to alter the TEMPLUG by reducing the length or diameter to accommodate certain test configurations This is allowable without compromise of results under the proper conditions The minimum length of an altered TEMPLUG should be no less than 1mm with a minimum diameter of no less than 1 3 mm Be extremely careful to ensure that any work that is performed on the TEMPLUG prior to the test exposure will introduce errors if sufficient heat is generated to cause the temperature to rise above the subsequent test temperature The problem can be avoided by careful gri
8. his is followed by a written report Typical time involved for analysis is given below NO OF TEMPLUGS TIME FOR ANALYSIS 21 50 5 6 Business Days 51 100 7 8 Business Days If required the analysis time may be expedited even further Please call us at 510 835 3412 ext 177 to inquire about rush fees TEMPLUG User Information Guide Revision 4 0 Page 15 2013 a TEMPLUG US TESTING ENGINEERS INC Temperature Measuring Devices Board No 12345 User ABC Company Type M3 2 Batch No 1234 Date OCTOBER 24 2013 Use ISO Metric Tooling Exposure Hrs Retum card to TESTING ENGINEERS INCORPORATED Analysis Pre paid NO 2811 Teagarden San Leandro CA 94577 TEMPLUG and fasten with tape Telephone 510 835 3142 ext 177 After exposure Record time replace each Figure 8 TEMPLUG Shipping Board Revision 4 0 TEMPLUG User Information Guide Page 16 2013
9. ist removal the article with the TEMPLUG in it should be mailed to our laboratory In the event that sectioning is necessary precautions should be taken not to heat the articles such that the TEMPLUG measurements would be affected A TEI Consultant is available for advice on installation or the selection of test locations If necessary TEMPLUG installation can also be performed by TEI Some of the many components which have been successfully tested using TEMPLUG are as follows pistons piston rings valves valve guides valve seats cylinder heads fuel injector nozzles turbine wheels engine timing gears turbine blades bearing races wrist pin bearings and ceramic components Ordering TEMPLUGS can be ordered directly over the telephone from TEI at 510 835 3142 Overnight delivery service is available Tooling kits for installing TEMPLUGS are available and can be ordered along with the TEMPLUG TEMPLUGS are shipped in lots of 10 on a board as shown in Figure 7 Each board is serialized and the TEMPLUGS are numbered so the individual TEMPLUG can be related to their position in the actual test In addition space is provided under such TEMPLUG for reporting the time spent at maximum temperature conditions TEMPLUG User Information Guide Revision 4 0 Page 14 2013 CONDUCTING A TEST Cont d d Analysis amp Reporting After receiving used TEMPLUG the analysis is expedited and results conveyed via email in a timely manner T
10. nding under water TEI Metallurgists should be consulted if grinding or other such alterations are required Alterations to the socket end of the M3 style TEMPLUG are much safer of course since in that case the work location would be away from the critical flat tip used for the peak temperature determinations Alterations to plugs is done at the discretion of the user and may reduce the accuracy of reported temperatures TEI does not guarantee temperature accuracy of altered plugs d Corrosion TEMPLUG has the same corrosion resistance as carbon or alloy steels of the non stainless varieties Since the important flat tip is usually buried providing protection from the atmosphere corrosion is seldom a problem for TEMPLUG However if the conditions of time temperature and atmosphere are deemed problematic TEMPLUG can be protected by encapsulating in a stainless steel holder or by plating A TEMPLUG User Information Guide Revision 4 0 Page 8 2013 Accurately known time Temperature Time FIGURE 3 Ideal Temperature Time Cycle At least 25 of the total test time Temperature Time FIGURE 4 Acceptable Temperature Time Cycle At least 25 of the total test time Temperature Time FIGURE 5 Acceptable Temperature Time Cycle TEMPLUG User Information Guide Page 9 Revision 4 0 2013 ACCURACY OF RESULTS TEI takes a great deal of pride in performing tests accurately and professionally TE
11. nt temperature does not exceed that of the test The introduction of additional heat during plug removal should be avoided Another method to assure TEMPLUG will stay in place is to lightly peen one side of the TEMPLUG hole after the TEMPLUG has been installed When testing is complete the smeared metal can easily be removed and TEMPLUG backed out This method is used primarily for aluminum alloys When installing the subsize M1 6 TEMPLUG extreme caution must be exercised so as not to inflict a bending moment on the handle The handle and the threaded portion are fully hardened and consequently very brittle Record the test time for TEMPLUG exposure starting to count time when it is believed that the test article has reached peak operating conditions Report to TEI any other information of possible importance such as short temperature spikes or high or low temperature excursions during a relatively constant cycle It is preferable that a detailed report of the temperature time cycle be provided with the TEMPLUG Manufactured by Loctite Corporation TEMPLUG User Information Guide Revision 4 0 Page 13 2013 b c CONDUCTING A TEST Cont d Removal Remove the M3 TEMPLUG by unscrewing and placing them in their respective board locations Care should be taken to indicate exposure time Time spent under conditions that generated maximum temperature in the space provided on the board For M1 6 TEMPLUG and M3 TEMPLUG that res
12. x 0 5 3mm diameter 0 5 mm pitch 2 M1 6 x 0 35 1 6 mm diameter 0 35 mm pitch Besides their size there are two other important differences between the two TEMPLUG designs 1 The M3 type TEMPLUG has a socket on the non measuring end facilitating installation and removal Figure 1 The tool used for this purpose is a Torx Wrench size T 6 The smaller M1 6 TEMPLUG is installed by twisting the break off handle Figure 2 and can be removed from the test part using penetrating oils strong magnets and skilled technicians In most cases the user has to return the test object or a portion thereof for temperature evaluation 2 The entire length of the M1 6 TEMPLUG is hardened The socket section of the M3 TEMPLUG is tempered softened to prevent cracking during installation In order to distinguish between the No 2 steel and the No 3 steel the No 3 steel TEMPLUG of both designs M3 and M1 6 has been slightly modified as shown in Figures and 2 TEMPLUG User Information Guide Revision 4 0 Page 4 2013 TEMPLUG DESIGN CHARACTERISTICS Machined for T6 Torx wrench SA OT This sectionis A ease prevent cracking Machined tip to distinguish from No 2 Steel con pesos No 2 Steel No 3 Steel Temperature evaluation made on this Place this tip as close as possible to the fully hardened section location to be tested Scale 1mm 0 1mm FIGURE 1 Standard M3 x 0 5 TEMPLUG TEMPLUG User Information Guide Revision 4 0
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