Joining lead wires to thin platinum alloy films

A two step process of joining a lead wire to .000002 m thick platinum alloy film which rests upon an equally thin alumina insulating layer which is adhered to a metal substrate is described. Typically the platinum alloy film forms part of a thermocouple for measuring the surface temperature of a gas turbine airfoil. In the first step the lead wire is deformed 30 to 60% at room temperature while the characteristic one million ohm resistance of the alumina insulating layer is monitored for degradation. In the second step the cold pressed assembly is heated at 865 to 1025 C for 4 to 75 hr in air. During the heating step any degradation of insulating layer resistance may be reversed, provided the resistance was not decreased below 100 ohm in the cold pressing.