The Stress-Relieving Process in CQI-9, 3 rd Edition (Key Points)

1. The Stress-Relieving Process in CQI-9, 3rd Edition (Key Points) Date: September 30, 2013 Audience: SMI Technical Conference Location: Green Valley Ranch Resort Presenter: Daniel F Pierre III President JN Machinery Corp

2. Changes to note • Easier to read Process Tables 3) No AMS2750D references 4) Flexibility to determine frequency of SAT and Instrument Calibration 7) Unifies tolerances in °C and °F. • The rest of the changes do not really pertain to the stress relieving process.

3. This Presentation’s Focus: 3.1 Thermocouples 3.2 Instrumentation 3.3 SAT System Accuracy Test 3.4 TUS Temperature Uniformity Survey Process Table E Internal Testing Pitfalls

4. 3.1 Thermocouples All sections in 3.1 will initially covered by the OEM of your oven--if you tell them the oven must comply to CQI-9 at the time of sale. Thermocouple Certs SAT - As per ISO17025 …and my test equipment’s certs TUS - As per ISO17025 However, be aware of a few sections when you perform maintenance or replacement of thermocouples: 3.1.1.2 Do not splice extension wire or modify the electrical path between the thermocouple and temperature controller. 0500 PV Thermo Coupling 0500 SV  ∧ ∨ Temperature Controller Thermocouple Wire Thermocouple

5. 3.1 Thermocouples (continued) 3.1.2.4 ISO/IEC17025 for external calibration. In earlier versions of CQI-9, OEMs had the ability to perform calibrations on their own equipment. Now, OEMs will have to have ISO/IEC17025 3.1.2.5 When replacing thermocouples, need a “calibrated” one, your thermocouple supplier can provide the calibration cert. Note: they cost more than standard thermocouples. 3.1.3 Need to keep records of first use of thermocouple. If no record at time of calibration—especially if performing calibration every 6 months—the calibrator may be required to replace the thermocouple or perhaps NOT be able to perform calibration. 3.1.1~3.1.5 tables: So many references to how often to change thermocouples: 3.1.1 “every 2 years”. Refers to degradation/oxidation of metal wires. After 2 years, too much damage to the wires. 3.1.2 Reference for Calibrators. i.e for the TEST thermocouples. 3.1.5 180 uses—assuming you use 23 days/month—7~8 months.

6. This is accuracy of a thermocouple, NOT an Oven.

7. This is the TEST Thermocouple, not the oven’s thermocouple.

11. Non-Expendable Thermocouples Expendable Thermocouples

12. 3.2 Instrumentation Most sections are obvious and easy to understand. External calibrators will cover these. Notable sections if you will internally calibrate your work: (must follow ISO 17025) 3.2.1.3 Calibration frequencies: covered in detail after several more slides. 3.2.1.4 For digital recording, no more than 2 minutes between readings. Data Recorded Every 2 Seconds Data Recorded Every 2 Minutes

13. 3.2 Instrumentation Yes, but at a cost…. Can existing ovens be converted to do digital data collection? Data logging technology is evolving so fast, that what is presented today could be obsolete or considered “old school” in 3~6 months……… 1) Upgrade to Temperature Controllers with Communications Capability. ($$$  $$) 2) Software to set parameters and collect data. ($0 to $$$, but 1 time only) • 3) 2-wire cable between oven and dedicated computer (which has to be ON). ( $0 to $$) • Or: Wireless System, but…………………………………………………………………………..($$$$) 4) Data converter at computer……………………………………………………………………. ($) 5) If not hard wiring, 2-wire socket/plug on control panel. ……………………………. ($$) 6) Physical modification to oven shell and heat chamber…………………………..…… ( $0 to $$$$! )

14. 3.2 Instrumentation 3.2.4.2 Changing a temperature controller, leadwire, holder, or thermocouple requires a new calibration. (i.e. change at time of calibration if you can…..) 3.2.6 Write-once, read only electronic records. Keep Original Log files locked up. Copy the data to create a chart. Altering a log file IS detectable. i.e. does NOT have to be a “pen-on-paper” strip/chart recorder.

15. N J Machinery Sample Paperwork you will receive and file Company Name & Logo JN Machinery 1081 Rock Road Lane East Dundee, IL 60118 Oven ID _______________ Cal Date ______________ Cal Due ______________ 1081 Rock Road Ln. East Dundee, IL 60118 Tel: 24-699-9161 Initials _____________

16. 3.2 Instrumentation (“calibration”) and 3.3 SAT System Accuracy Test Quarterly SAT using Probe Method A or B Monthly SAT using Comparative Method Unfortunately, it is not just a matter of choosing whichever method has the least amount of paperwork. The path to the least amount of paperwork could mean higher initial costs. or Annual TUS + + Quarterly Control Instrument Calibration ( Single Point or Multi Point ) Quarterly SAT using Probe Method A only + Annual TUS + Semi-annual Control Instrument Calibration ( Multi Point Only )

17. System Accuracy Test Typically referred to as “oven calibration”, but SAT is the more accurate term. “Oven Calibration” has the connotation that the calibrating organization will “do something internally” to the temperature controller to bring the system back into proper calibrated state. The SAT is used to confirm whether an oven remains in an accurate range. 0500 PV Thermo Couple Holder 0500 SV  ∧ ∨ Thermocouple Wire Thermocouple Temperature Controller

18. Probe Method “A” Instruments Instruments to be managed and stored according to ISO17025

20. Warning!Danger! Temperature Controllers can have what is called “Voltage Leaks”. There is a small amount of electricity that travels along these wires. Cheap temp Controllers generally have more leakage (40~85V)! Quality controllers will have 0.3~8V. Critical applications can require <0.1V leakage, and these cost several hundreds of dollars. 0.3 ~ 85 Volts!

21. A Probe with a diameter as large as ¼” can fit inside this hole. Photo shows a Thermocouple Holder with a Test Probe Hole in the middle (currently, 2 thermocouples are connected here, this is a Dual Thermocouple Holder for a 1-Zone Oven and its Over-Temperature thermocouple.

22. The Test Probe is less than 50 mm from the thermocouple tips Be aware that there is a small risk a probe can end up in the shadow of thermocouple tips

23. Probe Method “B” Note: Probe Method B can be useful on larger ovens when the control panel is not easily viewable from the probing position.

24. Comparative Method • Not all ovens are set up to use the Comparative Method: • Older ovens without an Over-Temperature Controller. • Multizone Ovens will have a TC without a test instrument <50mm away and still need Probe “A” or “B” method. • Ovens with Over-Temps, but are not next to (<50mm) the control thermocouple. • Investment cost to permanently install a test instrument. • When purchasing a new oven and you plan to use Comparative Method, inform your Oven maker that you want an established Delta. (Usually no cost for the Delta data, but there can be added cost for an initial calibration certificate.) 0500 0500 PV PV 0500 0500 SV SV  ∧ ∨  ∧ ∨

25. Comparative Method 3.3.4.3.4 If both devices have their respective thermocouples in the same protection tube they shall be of a different type. J & J J & K ✓ ✗

26. Some Ovens will dictate which method you can use without an initial investment cost. You may not be able to do the same method on all ovens, which is acceptable as the probe method used will be noted on the oven cert, however, Mixed Methods can not be in conflict of the CQI-9 regulations.

27. 3.2 Instrumentation (“calibration”) and 3.3 SAT System Accuracy Test Quarterly SAT using Probe Method A or B Monthly SAT using Comparative Method or Annual TUS ( Review of all test methods ) + + Quarterly Control Instrument Calibration ( Single Point or Multi Point ) Quarterly SAT using Probe Method A only + Annual TUS + Semi-annual Control Instrument Calibration ( Multi Point Only )

28. 3.4 Temperature Uniformity Surveys Performed Annually, or after a major rebuild/modification. Key to success in performing the TUS is to Define Your Workzone Typically, the final 1/3 of the chamber is where “stress relief” occurs. A potential “workzone” can be defined as the final 40% of a chamber, less the final 8% (where ambient air will affect chamber temperature). Workzone Time through oven

29. Temperature Uniformity Surveys Typical data logging apparatus • Notes: • These 3 Controllers and the 3 thermocouples all have to have current calibration certificates. • The thermocouples need records of the number of uses to remain valid for use. • The apparatus (and thermocouples) have to be stored and monitored (temp/humidity) as per ISO/IEC17025.

30. Temperature Uniformity Surveys Placing thermocouples right at the walls, at 1” from walls and 2” (max 50mm) from walls did not show much difference. However, missing and degraded curtains DID show worse results at the oven walls. Recommendation: Set your instrument to approximately 1” from walls, but do not beat yourself up to measure distance to wall so precisely. If you fail a test, consider first that perhaps your curtains need attention. However, it is possible that a failed test is an indication that your process is not optimal and you are over-loading the oven. This is the exact area out of all CQI-9 regulations that will probably cost springmakers the most money to achieve compliance. Pushing the envelope a little too far to maximize the amount of product through an oven—either too much product or too fast a belt speed—will reveal itself during TUS, and ultimately require investment into a larger oven.

31. 3.4.3.1 TUS Data Collection Use the normal belt speed as your regular product. Slower belts do provide better results, too fast belts will show parts in oven do not even get to the set temperature. A good curve shows that the workzone is in control. No more than a 30 second interval data collection. Not recommended. The maximum length of study is 3 x thermocouples x 60 minutes. One data file can easily handle readings every second.

32. Temperature Uniformity Surveys Batch Ovens Experience shows that older ovens fail at front corners (or middle if french doors) when the door seal degrades. You CAN pass a test if you declare your workzone accordingly. Make sure you place a message on the oven showing which position(s) are NOT permissible locations for placing product in oven.

33. Temperature Uniformity Surveys A problem with CQI-9 regulations as represented in section 3.4.3.1 is that it more closely affects annealing and normalizing and possibly could be “not applicable” for stress relieving. On its own, the sections doesn’t sound too bad: “TUS test thermocouples shall be traversed through the furnace at a traverse speed typically used in production (and representing all test locations as required in table………)” I would suggest that if SMI wants to develop a “best practices” regarding CQI-9, beforehand, organize a roundtable discussion or a committee to discuss “oven capacity” and “belt speed” as it relates to the question “when does the actual stress relief occur?”

34. Process Table E relates to Stress Relief Do not miss the Glossary. It is tremendously helpful!

37. Alarm systems (if set per acceptable limits) satisfy the sign-off requirement

39. Internal Testing Pitfalls Manual vs Automatic data collection Belt speed. Curtains/no curtains NOT changing damaged or well-used thermocouples (TUS) Mixing thermocouple types (J, K) Data-collecting is a bit of an art. Training and experience is necessary. A System with “Double Negatives”

41. A few samples of thermocouple terminations showing thermocouple type. Wire insulation Outer covering Shield material Bare wire

42. K T J