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4.

Cones, Crayons, Labels, Paints, and Pellets


T. J. CLAGGETT, R. W. WORRALL S. EDVI, J. E. JAMISON
(1969, 1982)

B. G. LIPTK

(1995)

(2003)

Temperature Settings:

Cones are numbered as in Table 4.4b with each number corresponding to an approximate setting. Crayons and paints are usually rated with a combination of temperature and time, meaning that a color change is expected to occur if a particular temperature is held for a particular time period. Reversible and nonreversible temperature-indicating labels, strips, and buttons Multi-temperature and Mylar liquid crystal strips and sheets Crayons Pellets Paints or lacquers Cones cover a range between 1100 and 3650F (593 and 2010C) Reversible liquid crystal strips: range between 20 and 194F (30 and 90C) Nonreversible labels with 4 temperatures on each label: range between 100 and 500F (38 and 260C) Reversible liquid crystal Mylar sheets: range between 68 and 113F (20 and 45C) Crayons, pellets, and paints: range between 100 and 2500F (39 and 1371C) $3 to $6 for a box of 50 cones, $0.50 to $1.50 per plug Reversible liquid crystal strips (seven temperature ranges): package of 10 is $12; package of 30 is $33 Nonreversible labels, monitors, and buttons: package of 10 is $13 to $55; package of 30 is $37 to $55 Reversible liquid crystal Mylar sheets: 12 in. 12 in. sheets = $22, 6 sheets of 6 in. 12 in. sheets is $76; 6 sheets, one of each temperature range is $52 Crayons: $9 each to $55 for a 10-crayon set Pellets: $11 per tube of 20 pellets Paints/lacquers: 2 oz bottle is $11, 1 pt is $60; thinners: 2 oz bottle is $4, 1 pt is $13 Labels: machinery, equipment, electrical parts, electronic assemblies, aeronautical, heating, ventilation, and air conditioning (HVAC), and appliances Crayons: welding, forging, heat-treating, and accessible work pieces Pellets: furnace temperature Paints: smooth glass, polished metals, rubber, and fabrics Indication is affected by speed of heat-up and by time spent at target temperature; usual error is about 5F (3C) for cones and about 10 to 20F (5 to 10C) for crayons, pellets, and paints. The error of most crayons, pellets, and paints is 1% of their rating. Liquid crystal strips can detect skin temperatures within 1F (0.5C). Biosynergy Inc., a Div. of American Clinical Laboratory (ACL) (freeze-thaw indicator) (www.iscpubs.com/pubs/prodhilite) Electronic Development Labs Inc. (EDL) (cones and crayons) (www.edl-inc.com) Orton Ceramic Foundation (cones) (www.ortonceramic.com) Hub Material Co. Inc. (cones and crayons) (www.hubmaterial.com) Korthals (www.korthals.nl)

Phase Change Types:

Temperature Ranges:

Costs:

Applications:

Inaccuracy:

Partial List of Suppliers:

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Temperature Measurement

LA-Co/Markal Co. (stick-ons) (www.laco.com) Omega Engineering, Inc. (crayons, pellets, labels, paints) (www.omega.com) Tempil, a Div. of Illinois Tool Works Inc. (ITW) (crayons, paints) (www.tempil.com)

INTRODUCTION A number of temperature-related physical changes have been used to produce simple thermometers. Crayons, pellets, and paint marks on heated work-pieces, cones, or pellets placed in furnaces change from solid to liquid when their melting point is reached. Paints and heat-sensitive labels change their color, while luminescent materials change their brightness. Liquid cholesteric crystals detect skin temperature, and liquid crystal strips are ideal for motors, transformers, relays, and electronic parts. For centuries, manually operated furnaces have been temperature-controlled by the operators placing a heat-sensitive object inside the furnace and observing the status of that indicator through a peephole. The most easily observed physical changes were found to be changes in color or melting. Pyrometric cones have been used as temperature indicators and are still used as endpoint indicators in such batch processes as ring in pottery furnaces. They can be small, expendable, plugs, chips, or geometrically shaped objects whose purpose is to accompany the products through a heating cycle. The physical or metallurgical changes that occur indicate the temperature reached in the process.

the immediate past temperature history of the indicator will inuence the exact point at which it will change color. The indicators are usually rated for a specic temperature over a certain time period, for instance, 140F (60C) in 30 min. This means that if held at a constant 140F the color change will occur in 30 min. If the color change occurs in less than 30 min, the average temperature is higher than 140F, and vice versa. On such an indicator, if the temperature does not exceed 130F (54C), the change will never occur because the indicator is stable below this temperature.

Crayons Figure 4.4a shows typical time-temperature relationships for two different crayons. In the examples shown, the temperature at which color change occurs is quite critical when exposure time is short. For lower soakout temperatures, the changeover will occur in a longer time. Flatter curves than those shown are possible where changeover will occur within a few seconds after operating temperature is reached, or it will not occur at all. Many different temperature ratings are available. They can be obtained in a series for every few degrees to the maximum offered (about 2500F, or 1371C). This class of indicators is quite inexpensive and is used in industry where only an endpoint is needed and someone can be present to watch for or interpret the results. A disadvantage of these sensors is that the material adheres tightly to the object on which it is placed and presents a problem if it must be removed later.

COLOR INDICATORS Color indicators are a class of sensors that have the property of changing their original color when a certain temperature is reached. The change is distinct, not just an alteration in shade. For instance, an indicator may change from yellow to gray or from light blue to light brown. Some can go through several color changes at different temperatures. Paints and Pellets Paints and pellets are familiar forms of these indicators that are applied directly to a solid object either when it is cold and about to be heated, or when it is already hot. Some indicators can determine the temperature of solid objects immersed in oil. They are not recommended for use in hot gases. Temperature is indicated by a chemical reaction, where a molecule of a gas such as ammonia, carbon dioxide, or water vapor is driven off the basic stock (colorful salts of metals like nickel, cobalt, or chromium), changing its color. The change is usually permanent after the object cools down. An exception occurs when the gas is water vapor; the indicator may slowly reabsorb this gas from the air and revert to the original color. Change in color of these types of indicators is not only a function of temperature but also of time. For this reason,

450 (232) Fahrenheit (Celsius) 400 (204) 350 (177) 300 (149) 250 (121) 1 10 Sec Sec 1 Min

With Temperature Held Constant Color Change Takes Place in Time Shown by Curve Crayon #1 Crayon #2

10 Min

1 Hr Time

10 Hr

1 Day

FIG. 4.4a Time-temperature relationship for color indicators.

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TABLE 4.4b 2,3 The Numbering of Pyrometric Cones


Cone 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 01 02 03 04 05 06 Centigrade 1435 1400 1350 1335 1325 1305 1285 1260 1250 1230 1205 1190 1170 1165 1160 1145 1125 1115 1060 1040 1015 Fahrenheit 2615 2552 2462 2435 2417 2381 2345 2300 2282 2246 2201 2174 2138 2129 2120 2093 2057 2039 1940 1904 1859 Color of Fire Cone 07 08 09 010 white 011 012 013 014 015 016 017 018 019 020 021 yellow 022 Centigrade 990 950 930 905 895 875 860 830 805 795 770 720 660 650 615 605 Fahrenheit 1814 1742 1706
1661

Color of Fire

orange

1643 1607 1580 1526 1481 1463 1418 1328 1220 1202 1139 1121

cherry red

dull red

PYROMETRIC CONES The German ceramist Herman Seger invented the rst pyro1 metric cone in 1886. The individual cones look like truncated pyramids. The numbering of the different cones available on the market and the temperatures at which they melt are given in Table 4.4b. The cone melting temperatures listed in the table are based on a heat-up rate of 170C/h. If the heat-up rate is slower, the cones bend at slightly lower temperatures; if it is faster, it will take a little higher temperature to bend the cones as shown in Table 4.4c. Because the pyrometric cone measures the effects of both temperature and the length of ring time, it acts as a heat integratora function that cannot be easily reproduced by thermocouples or other electronic-type pyrometers. For this reason, the ceramic industry continues to use cones, in addition to recording pyrometers, even in its most modern kilns. The Ceramics Industry The indicator material is generally quite similar to the substance of the work under test. Pyrometric cones are actually composed of ceramic materials very carefully blended to

soften at a certain temperature. The slender cone is slightly tilted from the vertical; when its softening point is reached, the tip bends over and may actually touch the base. This action can be watched through the window of the ring furnace, or its condition can be studied after cooling. Observation of a red cone will show the experienced operator if the furnace atmosphere was oxidizing, reducing, or carburizing. If the latter has taken place, the cone will have formed a shell less dense than the interior. Presumably the work will have taken on the same characteristic. The cones are set in a plaque of re-clay (called a cone pat) close together and tipped at about 8 degrees from the vertical toward the cone that is expected to bend rst. The cone pat is located in front of the peephole where the operator (or a closed-circuit TV camera) can observe its status. Usually three cones are placed on a pat: (1) the controlling target cone is in the center, (2) a cone that melts at a lower temperature is in front of it, and (3) one that melts at a higher temperature is behind it. Figure 4.4d illustrates the visual appearance of a cone pat throughout a batch that was red to a #4 cone target, corresponding to 2174F (1190C). The softening points can be selected very accurately, and accuracies of 2 to 5F (1 to 3C) can be obtained.

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Temperature Measurement

TABLE 4.4c The Melting Temperatures of Various Cone Types and Cone Numbers That Can 4 Be Expected at Different Heating Rates
Cone Type: Heating Rate: Cone Number 022 021 020 019 018 017 016 015 014 013 012 011 010 09 08 07 06 05 04 03 02 01 1 2 3 4 5 6 7 8 9 10 11 12 13 Large 108F/h 1074 1105 1148 1240 1306 1348 1407 1449 1485 1539 1571 1603 1629 1679 1733 1783 1816 1888 1922 1987 2014 2043 2077 2088 2106 2134 2151 2194 2219 2257 2300 2345 2351 2383 2410 Regular 270F/h 1092 1132 1173 1265 1337 1386 1443 1485 1528 1578 1587 1623 1641 1693 1751 1803 1830 1915 1940 2014 2048 2079 2109 2124 2134 2167 2185 2232 2264 2305 2335 2381 2399 2419 2455 Self-Supporting Reg. 108F/h 1087 1112 1159 1243 1314 1353 1411 1452 1488 1542 1575 1607 1632 1683 1737 1787 1819 1891 1926 1990 2017 2046 2080 2091 2109 2142 2165 2199 2228 2273 2300 2345 2361 2383 2428 270F/h 1094 1143 1180 1267 1341 1391 1445 1488 1531 1582 1591 1627 1645 1597 1755 1807 1834 1918 1944 2017 2052 2082 2113 2127 2138 2169 2199 2232 2273 2314 2336 2381 2399 2419 2458 Small Reg. 540F/h 1157 1195 1227 1314 1391 1445 1517 1549 1616 1638 1652 1684 1686 1751 1801 1846 1873 1944 2008 2068 2098 2152 2154 2154 2185 2208 2230 2291 2307 2372 2403 2426 2437 2471 2471

Bar and Hole Indicators As an alternate to cones, the indicator may take the shape of a long cylindrical bar. The bars are supported at their ends with axes horizontal. On temperature rise they soften and sag at the middle under gravity. The deformation serves as a measure of temperature. Another group of indicators operates by shrinkage rather than deformation. After removal from the furnace the diameter of a hole in the indicator, or perhaps the indicators length, is measured and compared with the original dimension.

Like color indicators, pyrometric ceramics should not be considered exact temperature measuring devices. The fusion, bending, and/or shrinking that they undergo is a timetemperature relationship and, as such, it is only useful to determine the end point of the specic job. This property is frequently more important than an exact measurement of the instantaneous temperature. The use of this type of indicator may almost be considered an art. While pyrometer cones are not well suited automatic process control, they are inexpensive and valuable quality

2003 by Bla Liptk

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3 5 4

Start

Nearing Setpoint

Done

FIG. 4.4d 2,3 This is the appearance of the cones at different times during a batch which has a target temperature set by Cone #4.

control tools in guaranteeing repeatable qualities of ceramic and similar batch products from kilns and furnaces.

References
1. 2. 3. 4. Rhodes, D., Kilns Design, Construction and Operation, Radnor, PA: Chilton, 1968. Kenny, J.B., Pottery Making, Radnor, PA: Chilton, 1974. Temperature-Sensitive Paints, Crayons, Measurements and Control, December 1991. Orton Ceramic Foundation, Cone Chart, Westerville, OH, 2001.

ENGINE TEST RESEARCH An entirely different material, used in a similar manner, is the metal test plug. This small device can tell temperature by a change in hardness that results from the heat treatment it has received. One use is to have it located carefully in an operating engine, in an otherwise inaccessible spot, where it will respond to the temperatures that occur during operation. When the test is over the plug is removed and carefully analyzed to determine the change in hardness along the horizontal axis. Time is again a factor, but metal responds much faster than ceramic material. Exposures of less than 1 s duration can be detected. Advantages of this class of temperature sensors are their relative economy and being able to be designed for very specic purposes. Their shortcomings are self evident.

Bibliography
Adler, C.B., Reliability Aspects of Temperature Measurement, Instrumentation, Systems, and Automation Society Conference, Chicago, 2002. Bluestein, I., Understanding Contact Temperature Sensors, Sensors, October 2001. Hormuth, G.A., Ways to Measure Temperature, Control Engineering, Reprint No. 948, 1971. Plumb, H. H., Temperature: Its Measure and Control in Science and Industry, Vol. 4, 5th Symposium on Temperature, National Bureau of Standards, American Institute of Physics, Instrumentation, Systems, and Automation Society, Pittsburgh, PA, 1972. Temperature-Sensitive Paints, Crayons, Measurements and Control, December 1991. Weiss, M., Color Analysis for Process Control, Control, June 1998.

2003 by Bla Liptk

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