SAE AS81969: A Practical Guide to Connector Contact Installation and Removal Tools

When working with high-reliability electrical connectors, the connector itself is only part of the equation.

The way contacts are installed and removed can have a direct impact on connector performance, maintenance efficiency, and long-term reliability. Using an unsuitable tool may damage the contact, deform the connector, or affect the locking mechanism inside the connector.

This is where SAE AS81969 becomes important.

SAE AS81969 provides general requirements for tools used to install and remove electrical contacts from connectors and other electrical or electronic components. It establishes a standardized approach to tool design and classification, helping engineers and maintenance personnel select the appropriate tool for a specific application.

What Is SAE AS81969?

SAE AS81969 is titled:

Installing and Removal Tools, Connector Electrical Contact, General Specification for

The standard applies to tools designed for installing and removing electrical contacts from connectors and other electrical or electronic components.

Rather than defining one universal tool, SAE AS81969 establishes a family of requirements and classifications. Different sections of the standard address different tool configurations, contact release methods, materials, and connector applications.

This makes the standard particularly useful in aerospace, defense, military electronics, and other applications where connector maintenance must be performed with a high degree of precision.

Why Do Connector Contacts Need Dedicated Tools?

A connector contact may look like a small and simple component, but it is usually secured inside the connector by a retention mechanism.

During installation, the contact must be positioned correctly and locked into place.

During removal, the retention mechanism must be released without damaging the contact or connector body.

A general-purpose tool may not provide the necessary dimensions or geometry for this operation.

An incorrect tool can potentially cause:

• Damage to the contact
• Damage to the connector insulator
• Deformation of the retention mechanism
• Scratches or mechanical damage inside the connector
• Improper contact positioning
• Difficulties during reinstallation
• Intermittent electrical connections

For high-reliability applications, even minor mechanical damage can become a significant reliability concern.

The purpose of a properly specified contact tool is therefore not simply to make installation or removal easier. It helps ensure that the connector can be serviced without compromising its original design.

Understanding the SAE AS81969 Classification System

One of the most useful aspects of SAE AS81969 is its classification system.

The standard uses different categories to distinguish tools according to their function, contact release method, and material construction.

Understanding these classifications makes it much easier to identify the correct tool.

Type I — Installing Tools

Type I tools are designed primarily for installing electrical contacts.

The tool allows the contact to be inserted into the appropriate cavity and positioned correctly within the connector.

A proper installation tool should provide sufficient control during insertion while minimizing the possibility of damaging the contact or connector.

Type II — Removal Tools

Type II tools are designed for removing electrical contacts.

These tools are particularly important when a connector requires repair, contact replacement, or wiring modification.

The removal tool must interact correctly with the contact retention system so that the contact can be released without excessive force.

Type III — Combination Tools

Type III tools combine installation and removal functions.

Depending on the specific design, a combination tool can provide a convenient solution for applications where both operations are frequently required.

However, the fact that a tool can perform multiple functions does not mean it is universally compatible with all connectors.

The specific connector and contact design must still be verified.

Front Release, Rear Release, and Other Contact Configurations

Another important consideration is the direction from which the contact retention mechanism is released.

SAE AS81969 classifications include different release configurations, such as front-release and rear-release arrangements.

This distinction is critical when selecting a tool.

Two connectors may look similar from the outside while using completely different contact retention mechanisms internally.

Using a tool designed for the wrong release configuration can result in excessive force or damage to the connector.

For this reason, tool selection should always begin with the connector and contact specifications rather than the appearance of the tool.

Tool Material Also Matters

SAE AS81969 also recognizes different tool material constructions.

These include metal tools, plastic tools, and tools combining metal and plastic components.

The choice of material can affect tool strength, durability, handling characteristics, and interaction with the connector.

For example, metal tools may provide greater mechanical strength for certain applications, while plastic or composite constructions may be preferred where minimizing the risk of damaging surrounding components is important.

The correct material depends on the application and the requirements of the applicable tool specification.

SAE AS81969 Is a Series, Not Just One Tool Specification

A common misunderstanding is that SAE AS81969 refers to one specific connector tool.

In reality, it represents a broader family of specifications.

Different slash-number specifications within the AS81969 series address different tool configurations and applications.

For example, individual specifications may define tools according to:

• Tool type
• Contact release direction
• Material composition
• Connector family
• Contact configuration
• Dimensional requirements
• Specific application requirements

This is why simply stating that a tool is “SAE AS81969 compliant” may not provide enough information for engineering or purchasing purposes.

The exact applicable specification should be identified.

How AS81969 Fits Into Aerospace Connector Maintenance

Aerospace and military connectors are often designed for demanding environments.

They may be exposed to:

• Vibration
• Temperature cycling
• Mechanical shock
• Humidity
• Frequent maintenance
• Long service periods

Connector reliability therefore depends not only on the design and materials of the connector but also on proper maintenance procedures.

When a contact needs to be replaced, technicians must remove the existing contact without damaging the connector cavity or retention system.

The replacement contact must then be installed correctly and securely.

Using the appropriate AS81969 tool helps make these operations more controlled and repeatable.

A Simple Example: Replacing a Connector Contact

Consider an aircraft wiring harness where one electrical contact needs to be replaced.

The technician should not simply select a tool based on its physical size.

Instead, the process should begin by identifying the connector and contact.

The technician can then determine:

Connector → Contact → Retention Method → Tool Type → Applicable AS81969 Specification

This approach reduces the risk of selecting an incompatible tool.

Once the correct tool has been identified, the contact can be removed and replaced using the appropriate procedure.

The same principle applies when assembling new wiring harnesses or performing maintenance on military and industrial electronic equipment.

What Should Buyers Check Before Ordering an AS81969 Tool?

For purchasing teams, “AS81969” should be treated as the starting point rather than the final specification.

Before placing an order, it is useful to confirm several details.

1. Exact Specification

Determine which AS81969 slash-number specification applies to the required tool.

2. Tool Function

Confirm whether the application requires an installation tool, removal tool, or combination tool.

3. Contact Release Configuration

Verify whether the connector uses a front-release, rear-release, or another retention configuration.

4. Tool Construction

Check whether the required tool should be metal, plastic, or a combination construction.

5. Connector Compatibility

Confirm that the tool is specifically compatible with the connector and contact being used.

6. Specification Revision

Always verify the applicable revision of the specification.

Standards can be revised over time, and project documentation may require compliance with a particular revision.

Common Mistakes When Selecting Connector Tools

Several mistakes appear repeatedly in connector maintenance and procurement.

Choosing by appearance

Two tools may look almost identical but have different dimensions or functions.

Choosing by connector size alone

The connector housing does not necessarily determine the correct contact tool. The contact and retention mechanism are equally important.

Assuming one tool fits an entire connector family

A connector family can contain multiple contact sizes and configurations.

Ignoring the specification revision

A tool that matches an older requirement may not necessarily satisfy the latest project specification.

Using excessive force

If a contact does not move as expected, forcing it can damage the connector. The problem may be an incorrect tool rather than a defective contact.

The Bigger Picture: Small Tools, High Reliability

Connector tools are sometimes treated as simple accessories, but their role is much more important in high-reliability applications.

A connector system can be manufactured to demanding engineering requirements, yet improper installation or removal can still compromise its performance.

SAE AS81969 provides a structured way to address this problem by defining requirements and classifications for connector contact installation and removal tools.

For aerospace, defense, military, and industrial electronics, selecting the correct tool is therefore part of maintaining the overall integrity of the connector system.

The key point is simple:

Do not select a connector contact tool based only on its appearance or general description.

Start with the connector and contact specifications, identify the retention and release configuration, determine the appropriate AS81969 classification, and then verify the exact applicable tool specification.

When the right connector meets the right contact and the right installation or removal tool, maintenance becomes more controlled, repeatable, and reliable.

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Technically equivalent writings published in all IAQG sectors
(R) Aerospace Series – First Article Inspection Requirements
RATIONALE
This standard was revised to emphasize and enhance the First Article Inspection (FAI) planning, evaluation, and re-accomplishment activities; aligning requirements to the 9100 standard. Additional changes to the standard requirements, definitions, and associated notes were incorporated in response to stakeholder needs.
FOREWORD
To assure customer satisfaction, the aviation, space, and defense industry organizations must produce and continually improve safe, reliable products that meet or exceed customer and regulatory requirements. The globalization of the industry and the resulting diversity of regional/national requirements and expectations have complicated this objective. End-product organizations face the challenge of assuring the quality and integration of products purchased from suppliers throughout the world and at all levels of the supply chain. Industry suppliers face the challenge of delivering products to multiple customers having varying quality requirements and expectations.
The aviation, space, and defense industry established the International Aerospace Quality Group (IAQG) for the purpose of achieving significant improvements in quality, delivery, safety, and reductions in cost throughout the value stream. This organization includes representation from companies in the Americas, Asia/Pacific, and Europe.
This document standardizes FAI process requirements to the greatest extent possible. While primarily developed for the aviation, space, and defense industry, this standard can also be used in other industry sectors where a standardized FAI process is needed.
SAE INTERNATIONAL AS9102™C Page 2 of 22
TABLE OF CONTENTS

• Provide confidence, through objective evidence, the product realization processes are capable of producing conforming product.
• Demonstrate the manufacturers and processors of the product have an understanding of the associated requirements.
• Provide assurance of product conformance at the start of production and after changes, as outlined in this standard.
  A FAI is intended to:
• Mitigate risks associated with production startup and process changes.
• Reduce future escapes.
• Help ensure product safety.
• Improve quality, delivery, and customer satisfaction.
• Reduce costs and production delays associated with product nonconformances.
• Identify product realization processes not capable of producing conforming characteristics, and initiate and/or validate associated corrective actions.
  1.3 Application
  This standard applies to organizations and their suppliers responsible for product realization processes that produce the design characteristics of the product. The organization shall flow down the requirements of this standard to suppliers who produce design characteristics.
  This standard also applies to suppliers performing special process(es). A Certificate of Conformance (CoC) provided by processors attests to satisfying the requirements. External suppliers providing special process(es) can satisfy this standard’s requirements by either:
• Documenting the design characteristics and associated results on a First Article Inspection Report (FAIR).
• Documenting the design characteristics and associated results on a detailed CoC.
  SAE INTERNATIONAL AS9102™C Page 4 of 22
  This standard applies to assemblies, sub-assemblies, and detail parts including castings, forgings, and modifications to standard catalogue or Commercial-Off-the-Shelf (COTS) items. Each of these items shall have a separate FAI.
  Unless contractually required, this standard does not apply to:
• Development and prototype parts that are not considered as part of the first production run.
• Procured standard catalogue item, COTS, or deliverable software. When these items are included in an assembly, they shall be documented in the index of part numbers in an assembly FAIR.
  1.4 Informative
  If there is a conflict between the requirements of this standard, and customer or applicable statutory/regulatory requirements, the latter shall take precedence.
  In this standard, the following verbal forms are used:
• “Shall” indicates a requirement.
• “Should” indicates a recommendation.
• “May” indicates a permission.
• “Can” indicates a possibility or a capability.
  Information marked as “NOTE” is for guidance in understanding or clarifying the associated requirement.

2. APPLICABLE DOCUMENTS
   The following referenced documents support the application/use of this standard. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. When a conflict in requirements between this standard and the referenced documents below exist, the requirements of this document shall take precedence.
   9100 Quality Management Systems – Requirements for Aviation, Space, and Defense Organizations
   9103 Aerospace Series – Quality Management Systems – Variation Management of Key Characteristics
   As developed under the auspices of the IAQG and published by various standards bodies [e.g., ASD-STAN, SAE International, European Committee for Standardization (CEN), Japanese Standards Association (JSA)/Society of Japanese Aerospace Companies (SJAC), Brazilian Association for Technical Norms (ABNT)].
   ASME Y14.41 Digital Product Definition Data Practices
   ISO 9000 Quality management systems – Fundamentals and vocabulary
   ISO 16792 Digital Product Definition Data Practices
   SAE INTERNATIONAL AS9102™C Page 5 of 22
3. TERMS AND DEFINITIONS
   Definitions for general terms can be found in ISO 9000 and the IAQG International Dictionary (located on the IAQG website). An acronym log for this standard is presented in Appendix A. For the purpose of this standard, the following definitions apply.
   3.1 ASSEMBLY
   A product that is produced by joining two or more detail parts, COTS, standard catalogue item, or sub-assemblies into one item.
   3.2 ATTRIBUTE DATA
   A result from a characteristic or property that is appraised only as to whether it does or does not conform to a given requirement (e.g., go/no-go, accept/reject, pass/fail).
   3.3 BALLOONED DESIGN CHARACTERISTIC
   Clear and uniquely identified design characteristic indicated on a ballooned document. The unique identifier may be circled or highlighted for easy visual identification.
   3.4 BALLOONED DOCUMENT
   An aid used in FAI to identify all the design characteristics, including all documents—e.g., drawings, purchase order, Digital Product Definition (DPD)—typically sequentially numbering the design characteristics and putting a circle around or highlighting the numbered design characteristics.
   3.5 BASELINE PART NUMBER
   This refers to a part number from the previous FAI or approved configuration, including revision level, to which a partial FAI is performed. An example of an approved configuration is a part produced and verified as conforming product prior to the requirements of this standard.
   3.6 COMMERCIAL-OFF-THE-SHELF (COTS) ITEM
   Commercially available item intended by design to be procured and utilized without modification (e.g., common electronic components). Any item or assembly meeting all of the following requirements:
   a. Defined by industry, manufacturer, military, or recognized specifications or standards.
   b. Without design modification, specifically for a customer.
   c. Customarily used by the public or industries.
   d. Offered for sale to the public, through catalogues, price list, brochures, stores, or websites.
   3.7 DELIVERABLE SOFTWARE
   Embedded or loadable airborne, spaceborne, or ground support software or firmware components which are part of an aircraft type design, weapon system, missile, or spacecraft.
   SAE INTERNATIONAL AS9102™C Page 6 of 22
   3.8 DESIGN CHARACTERISTIC
   Dimensional, visual, functional, mechanical, and material features or properties, which describe and constitute the design of the product. These characteristics can be measured, inspected, tested, or verified to determine conformance to the design requirements as specified on the parts list, purchasing document, drawing, or DPD, to which the product is to be produced.

• Dimensional design characteristics include in-process locating features (e.g., additive manufacturing, target-machined or forged/cast dimensions on forgings and castings, weld/braze joint preparation necessary for acceptance of finished joint).
• Material design characteristics include processing output variable (e.g., plating or coating thickness/runout, material hardness/conductivity). These provide assurance of intended characteristics that could not be otherwise defined.
  3.9 DESIGNED TOOLING
  Product specific tooling [e.g., check fixtures, Coordinate Measurement Machine (CMM) program] specifically made to validate the design characteristics of a product.
  3.10 DETAIL PART
  Article/part produced to engineering definition that does not include assembly processes (i.e., processes that join two or more parts together). Detail parts may include processing, finishes, and/or special process(es).
  3.11 DIGITAL PRODUCT DEFINITION (DPD)
  Digital data file(s) that disclose, directly or by reference, the physical or functional requirements, including data files that disclose the design or acceptance criteria of a product. Examples of DPD include the following:
• Digital data file(s) and fully dimensioned two-dimensional (2D) drawing sheets.
• Three-dimensional (3D) data model, and simplified or reduced content 2D drawing sheets.
• 3D data model with design characteristics displayed as text.
• Any other data files containing design characteristics that define a product in its entirety.
  3.12 FIRST ARTICLE INSPECTION (FAI)
  A planned, complete, independent, and documented inspection and verification process to ensure that prescribed production processes have produced an item conforming to engineering drawings, DPD, planning, purchase order, engineering specifications, and/or other applicable design documents.
  NOTE: The intent of independent as referenced above is to mitigate the effect of measurement error. This includes ensuring the person that verifies the characteristic for the first article not be the same person that generated the characteristic. Self-inspection (i.e., operator self-verification) is not considered independent. The equipment used to verify the characteristic should be different from the equipment used to produce the characteristic.
  3.13 FIRST ARTICLE INSPECTION REPORT (FAIR)
  Comprised of the forms identified in Appendix B, all ballooned design characteristics, and the supporting documentation determined by FAI planning for a part number (e.g., detail part, sub-assembly, or assembly).
  3.14 FIRST PRODUCTION RUN
  The initial group of one or more parts that are the result of a planned process designed to be used for production of these same parts.
  SAE INTERNATIONAL AS9102™C Page 7 of 22
  3.15 MODIFIED COMMERCIAL-OFF-THE-SHELF (COTS)/STANDARD CATALOGUE ITEM
  A COTS or Standard Catalogue item that has a change made to it from its original designed configuration.
  NOTE: Once modified, these items are categorized as detail parts for the purpose of assembly.
  3.16 MULTIPLE CHARACTERISTICS
  Identical characteristics that occur at more than one location (e.g., four places), but are identified by a single set of drawing or DPD requirements (e.g., rivet hole size, dovetail slots, corner radii, chemical milling pocket thickness).
  3.17 PRODUCT
  Any intended output resulting from the product realization process, which in the context of this standard includes finished detail parts, sub-assemblies, assemblies, forgings, and castings.
  3.18 QUALIFIED TOOLING
  Universal (not part specific) calibrated monitoring and measuring equipment (e.g., go/no go gauges, thread gauges, radius gauges) used to validate product design characteristics using attribute data.
  3.19 REFERENCE CHARACTERISTIC
  Characteristic (including reference and basic dimensions) that are used for “information only” or to show relationship; these are dimensions without tolerances and refer to other dimensions on the drawing or in the DPD.
  3.20 SPECIAL PROCESS
  Any process for production and service provision where the resulting output cannot be verified by subsequent monitoring or measurement and, as a consequence, deficiencies become apparent only after the product is in use or the service has been delivered.
  3.21 STANDARD CATALOGUE ITEM
  A part or material that conforms to an established industry or national authority published specification, having all characteristics identified by written description or an industry/national/military standard drawing.
  3.22 VARIABLE DATA
  Quantitative measurements taken on a continuous scale (e.g., the diameter of a cylinder, the gap between mating parts).
  SAE INTERNATIONAL AS9102™C Page 8 of 22

SAE INTERNATIONAL AS9100™D Page 17 of 54
The organization shall consider:
a. the capabilities of, and constraints on, existing internal resources;
b. what needs to be obtained from external providers.
7.1.2 People
The organization shall determine and provide the persons necessary for the effective implementation of its quality
management system and for the operation and control of its processes.
7.1.3 Infrastructure
The organization shall determine, provide, and maintain the infrastructure necessary for the operation of its processes and
to achieve conformity of products and services.
NOTE: Infrastructure can include:
a. buildings and associated utilities;
b. equipment, including hardware and software;
c. transportation resources;
d. information and communication technology.
7.1.4 Environment for the Operation of Processes
The organization shall determine, provide, and maintain the environment necessary for the operation of its processes and
to achieve conformity of products and services.
NOTE: A suitable environment can be a combination of human and physical factors, such as:
a. social (e.g., non-discriminatory, calm, non-confrontational);
b. psychological (e.g., stress-reducing, burnout prevention, emotionally protective);
c. physical (e.g., temperature, heat, humidity, light, airflow, hygiene, noise).
These factors can differ substantially depending on the products and services provided.
7.1.5 Monitoring and Measuring Resources
7.1.5.1 General
The organization shall determine and provide the resources needed to ensure valid and reliable results when monitoring or
measuring is used to verify the conformity of products and services to requirements.
The organization shall ensure that the resources provided:
a. are suitable for the specific type of monitoring and measurement activities being undertaken;
b. are maintained to ensure their continuing fitness for their purpose.
The organization shall retain appropriate documented information as evidence of fitness for purpose of the monitoring and
measurement resources.
SAE INTERNATIONAL AS9100™D Page 18 of 54 7.1.5.2 Measurement Traceability When measurement traceability is a requirement, or is considered by the organization to be an essential part of providing confidence in the validity of measurement results, measuring equipment shall be: a. calibrated or verified, or both, at specified intervals, or prior to use, against measurement standards traceable to international or national measurement standards; when no such standards exist, the basis used for calibration or verification shall be retained as documented information; b. identified in order to determine their status; c. safeguarded from adjustments, damage, or deterioration that would invalidate the calibration status and subsequent measurement results. The organization shall establish, implement, and maintain a process for the recall of monitoring and measuring equipment requiring calibration or verification. The organization shall maintain a register of the monitoring and measuring equipment. The register shall include the equipment type, unique identification, location, and the calibration or verification method, frequency, and acceptance criteria. NOTE: Monitoring and measuring equipment can include, but are not limited to: test hardware, test software, automated test equipment (ATE), and plotters used to produce verification data. It also includes personally owned and customer supplied equipment used to provide evidence of product and service conformity. Calibration or verification of monitoring and measuring equipment shall be carried out under suitable environmental conditions (see 7.1.4). The organization shall determine if the validity of previous measurement results has been adversely affected when measuring equipment is found to be unfit for its intended purpose, and shall take appropriate action as necessary. 7.1.6 Organizational Knowledge The organization shall determine the knowledge necessary for the operation of its processes and to achieve conformity of products and services. This knowledge shall be maintained and be made available to the extent necessary. When addressing changing needs and trends, the organization shall consider its current knowledge and determine how to acquire or access any necessary additional knowledge and required updates. NOTE 1: Organizational knowledge is knowledge specific to the organization; it is generally gained by experience. It is information that is used and shared to achieve the organization’s objectives. NOTE 2: Organizational knowledge can be based on: a. internal sources (e.g., intellectual property; knowledge gained from experience; lessons learned from failures and successful projects; capturing and sharing undocumented knowledge and experience; the results of improvements in processes, products and services); b. external sources (e.g., standards; academia; conferences; gathering knowledge from customers or external providers). Competence The organization shall: a. determine the necessary competence of person(s) doing work under its control that affects the performance and effectiveness of the quality management system; b. ensure that these persons are competent on the basis of appropriate education, training, or experience; c. where applicable, take actions to acquire the necessary competence, and evaluate the effectiveness of the actions taken; d. retain appropriate documented information as evidence of competence. NOTE: Consideration should be given for the periodic review of the necessary competence. NOTE: Applicable actions can include, for example, the provision of training to, the mentoring of, or the re-assignment of currently employed persons; or the hiring or contracting of competent persons. 7.3 Awareness The organization shall ensure that persons doing work under the organization’s control are aware of: a. the quality policy; b. relevant quality objectives; c. their contribution to the effectiveness of the quality management system, including the benefits of improved performance; d. the implications of not conforming with the quality management system requirements; e. relevant quality management system documented information and changes thereto; f. their contribution to product or service conformity; g. their contribution to product safety; h. the importance of ethical behavior. 7.4 Communication The organization shall determine the internal and external communications relevant to the quality management system, including: a. on what it will communicate; b. when to communicate; c. with whom to communicate; d. how to communicate; e. who communicates. NOTE: Communication should include internal and external feedback relevant to the quality management system. SAE INTERNATIONAL AS9100™D Page 20 of 54 7.5 Documented Information 7.5.1 General The organization’s quality management system shall include: a. documented information required by this International Standard; b. documented information determined by the organization as being necessary for the effectiveness of the quality management system. NOTE: The extent of documented information for a quality management system can differ from one organization to another due to: 􀃭 the size of organization and its type of activities, processes, products, and services; 􀃭 the complexity of processes and their interactions; 􀃭 the competence of persons. 7.5.2 Creating and Updating When creating and updating documented information, the organization shall ensure appropriate: a. identification and description (e.g., a title, date, author, or reference number); b. format (e.g., language, software version, graphics) and media (e.g., paper, electronic); c. review and approval for suitability and adequacy. NOTE: Approval implies authorized persons and approval methods are identified for the relevant types of documented information, as determined by the organization. 7.5.3 Control of Documented Information 7.5.3.1 Documented information required by the quality management system and by this International Standard shall be controlled to ensure: a. it is available and suitable for use, where and when it is needed; b. it is adequately protected (e.g., from loss of confidentiality, improper use, or loss of integrity). 7.5.3.2 For the control of documented information, the organization shall address the following activities, as applicable: a. distribution, access, retrieval, and use; b. storage and preservation, including preservation of legibility; c. control of changes (e.g., version control); d. retention and disposition; e. prevention of the unintended use of obsolete documented information by removal or by application of suitable identification or controls if kept for any purpose. -
SAE INTERNATIONAL AS9100™D Page 21 of 54
Documented information of external origin determined by the organization to be necessary for the planning and operation
of the quality management system shall be identified as appropriate, and be controlled.
Documented information retained as evidence of conformity shall be protected from unintended alterations.
When documented information is managed electronically, data protection processes shall be defined (e.g.,
protection from loss, unauthorized changes, unintended alteration, corruption, physical damage).
NOTE: Access can imply a decision regarding the permission to view the documented information only, or the permission
and authority to view and change the documented information.
8. OPERATION
8.1 Operational Planning and Control
The organization shall plan, implement, and control the processes (see 4.4) needed to meet the requirements for the
provision of products and services, and to implement the actions determined in clause 6, by:
a. determining the requirements for the products and services;
NOTE: Determination of requirements for the products and services should include consideration of:
􀃭 personal and product safety;
􀃭 producibility and inspectability;
􀃭 reliability, availability, and maintainability;
􀃭 suitability of parts and materials used in the product;
􀃭 selection and development of embedded software;
􀃭 product obsolescence;
􀃭 prevention, detection, and removal of foreign objects;
􀃭 handling, packaging, and preservation;
􀃭 recycling or final disposal of the product at the end of its life.
b. establishing criteria for:

SAE AMS2750H  RATIONALE
AMS2750H results from a Two-Year Review and update of this specification with changes to Definitions (see 2.4.21, 2.4.25, 2.4.36, 2.4.47, and 2.4.84); General Sensor Requirements (see Table 3); Sensor Calibration (see 3.1.4.6 and Table 5); SAT and TUS Sensor Reuse (see 3.1.7.4 and 3.1.7.5); Base Metal Load Sensors (see 3.1.10.3); General Instrumentation Requirements (see 3.2.1.4.1, 3.2.1.5, and Table 7); Control, Recording, and Over-Temperature Instruments (see 3.2.3.4, 3.2.3.5, 3.2.3.16, and 3.2.3.18); Instrumentation Calibration Results and Records (see 3.2.5.1); General Instrument Correction and Modification Offset Requirements (see 3.2.6.1.2 and 3.2.6.1.8); Thermal Processing Equipment (see 3.3.7); General SAT Requirements (see Table 11, Table 12, and 3.4.1.2.1); Performing an SAT (see 3.4.2.2); Alternate SAT Frequency (see 3.4.8.3); SAT Waiver (see 3.4.9.6.3); SAT Difference Pass/Fail Requirements (see 3.4.10.4); Comparison SAT (see 3.4.11.1.e); Parts furnace class, instrument type, and TUS internal (see Table 15); Raw material furnace class, instrument type, and TUS internal (see Table 16); Initial TUS Temperatures (see 3.5.2.4); TUS Requirements for Batch Furnaces, Salt Baths, Controlled Temperature Liquid Baths, and Fluidized Bed Furnaces (Excluding Controlled Temperature Quench Baths) (see Table 17); TUS Data Collection (see 3.5.10.1 and 3.5.10.2); Relocation of Hot or Cold Recording Sensors for Type A and C Instrumentation (see 3.5.15.2); Radiation Survey (see 3.5.17, 3.5.17.1, and 3.5.17.2); TUS Interval Deviations (see 3.5.18); Rounding (see 3.8); and Quality Assurance Provisions (see 4.2, 4.4, and Table 22). Deleted Zener Voltage Reference (was 3.5.87).

1. SCOPE
   1.1 This specification covers pyrometric requirements for equipment used for the thermal processing of metallic materials. Specifically, it covers temperature sensors, instrumentation, thermal processing equipment, correction factors and instrument offsets, system accuracy tests, and temperature uniformity surveys. These are necessary to ensure that parts or raw materials are heat treated in accordance with the applicable specification(s).
   1.2 This specification may be used in other non-heat-treating applications when specified.
   1.3 This specification is not applicable to heating or to intermediate thermal processing unless otherwise specified.
   1.4 This specification applies to laboratory furnaces to the extent specified in 3.6.
2. APPLICABLE DOCUMENTS
   The issue of the following documents in effect on the date of the purchase order forms a part of this specification to the extent specified herein. The supplier may work to a subsequent revision of a document unless a specific document issue is specified. When the referenced document has been cancelled and no superseding document has been specified, the last published issue of that document shall apply.
   SAE INTERNATIONAL AMS2750™H Page 2 of 57
   2.1 SAE Publications
   Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org.
   AS7766 Terms Used in Aerospace Metals Specifications
   2.2 ASTM Publications
   Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.
   ASTM E29 Using Significant Digits in Test Data to Determine Conformance with Specifications
   ASTM E207 Standard Test Method for Thermal EMF Test of Single Thermoelement Materials by Comparison with a Reference Thermoelement of Similar EMF-Temperature Properties
   ASTM E220 Calibration of Thermocouples by Comparison Techniques
   ASTM E230 Temperature-Electromotive Force (EMF) Tables for Standardized Thermocouples
   ASTM E608 Mineral-Insulated, Metal-Sheathed Base Metal Thermocouples
   ASTM E1137 Industrial Platinum Resistance Thermometers
   ASTM E1751 Standard Guide for Temperature Electromotive Force (emf) Tables for Non-Letter Designated Thermocouple Combinations
   ASTM MNL7 Presentation of Data and Control Chart Analysis
   ASTM MNL12 Use of Thermocouples in Temperature Measurement
   2.3 IEC Publications
   Available from IEC Central Office, 3, rue de Varembe, P.O. Box 131, CH-1211 Geneva 20, Switzerland, Tel: +41 22 919 02 11, www.iec.ch.
   IEC 60751 Industrial Platinum Resistance Thermometers and Platinum Temperature Sensors
   ISO/IEC 17025 General Requirements for the Competence of Testing and Calibration Laboratories
   2.4 Definitions
   Terms used in AMS2750 are defined in AS7766 and as follows:
   2.4.1 ACCURACY
   The maximum deviation of the instrument or sensor being tested from the values of a traceable standard.
   2.4.2 ADJUSTMENT
   Any change to an instrument’s parameters.
   2.4.3 AUTOCLAVE
   An oven capable of operating at pressures higher than atmospheric pressure (nominally 760 mm Hg), commonly used in the processing of materials. It may be pressurized with steam, compressed air, or inert gas.
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   2.4.4 BASE METAL SENSOR
   Sensor whose thermoelements are composed primarily of base metals and their alloys. Examples of base metal sensors include Types E, J, K, N, M, and T.
   2.4.5 BATCH FURNACE
   A furnace where parts or raw material are stationary during the soak.
   NOTE: Some batch furnaces may oscillate material within a stationary work zone.
   2.4.6 BIAS or INPUT SHIFT
   The act of making an adjustment to an instrument to add, remove, or alter an offset.
   2.4.7 BIMONTHLY
   See FREQUENCY.
   2.4.8 BIWEEKLY
   See FREQUENCY.
   2.4.9 CALIBRATION
   An assessment of the accuracy of a sensor or an instrument to a traceable standard sensor and/or field test or standard instrument, based on one or more measurements, and potentially adjusting an instrument and/or compiling a deviation chart for a sensor or instrument in order to ensure compliance with requirements.
   2.4.10 CONTINUOUS FURNACE
   A furnace where parts or raw material are conveyed continuously or semi-continuously from the charge area to the discharge area. Examples include: bump furnace, shaker furnace, belt furnace, roller furnace, and rotary hearth furnace.
   2.4.11 CONTROL INSTRUMENT
   An instrument connected to a control sensor used to control the temperature of thermal processing equipment. The instrument may or may not also record temperature data.
   2.4.12 CONTROL SENSOR
   A sensor connected to a control instrument on thermal processing equipment, the temperature of which may or may not be recorded.
   2.4.13 CONTROL ZONE
   A portion of the working zone in thermal processing equipment having a separate sensor, instrument, and heating or cooling system to control its temperature. This portion of the thermal processing equipment is independently controlled.
   2.4.14 CONTROLLED TEMPERATURE LIQUID BATH
   A furnace containing a liquid that is heated to the desired heat-treat temperature. Parts and raw material are normally immersed in the liquid.
   2.4.15 CONTROLLER
   A digital or mechanical device that controls the temperature of thermal processing equipment (e.g., furnace control instruments, quench mechanical thermostat, freezer pressure controls, etc.).
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   2.4.16 CORRECTION FACTOR
   The number of degrees, determined from the most recent calibration, that must be added to, or subtracted from, the temperature reading of a sensor, or an instrument, or a combination thereof (system) to obtain true temperature. The correction factors of sensors and instruments are usually kept separately and added together algebraically when a combination is used. Correction factor is the algebraic opposite of deviation (error).
   2.4.17 DATA ACQUISITION SYSTEM
   An instrument system used to automatically collect and store process data as an electronic record; for example, a Programmable Logic Controller (PLC).
   2.4.18 DEVIATION/ERROR
   In the context of this specification, the difference between the uncorrected indicated temperature and the true temperature (Indicated Temperature – True Temperature = Deviation/Error).