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Gauge-block thermal mismatch is the unequal change in length of a reference and an unknown gauge block caused by different temperatures or thermal expansion coefficients. Bringing both blocks to the same temperature does not cancel the effect when their expansion coefficients differ and that common temperature differs from the reference temperature.

Let the lengths at $T_0=20{}^{\circ }\mathrm{C}$ be $L_{X,0}$ and $L_{R,0}$, and let their linear expansion coefficients be ${\alpha }_X,{\alpha }_R$. To first order,Thus subtract the final two terms from the observed difference to estimate the difference at $T_0$. NIST's handbook explicitly treats both temperature and coefficient differences in gauge-block comparisons.^[ref]

For approximately equal nominal length $L$ at common temperature $T$, the differential thermal contribution becomesIn an original example with $L=100\mathrm{mm}$, ${\alpha }_X=11.5\times 10^{-6}{\mathrm{K}}^{-1}$, ${\alpha }_R=5.0\times 10^{-6}{\mathrm{K}}^{-1}$ and $T-T_0=2\mathrm{K}$, the contribution is $1.3\mu \mathrm{m}$. Identical temperatures have not made the comparator reading a reference-temperature difference. These are stipulated material coefficients, not certificates for particular blocks.

Even equal coefficients leave an effect if the temperatures differ: at $11.5\times 10^{-6}{\mathrm{K}}^{-1}$ and 100 mm, a temperature difference 0.2 K contributes $0.23\mu \mathrm{m}$. Handling and incomplete equilibration can therefore matter before the readout is considered.

Differential thermal-expansion uncertainty must include the temperature measurement, the coefficients and their dependence. A common uncertain temperature is one shared input, not two unrelated thermometer errors. In the common-temperature model its sensitivity is $L({\alpha }_X-{\alpha }_R)$; if the coefficients agree, that particular common-temperature term cancels. Independent block-temperature differences need separate terms. General propagation retains the appropriate covariance.^[ref]

A controlled comparison measures or bounds block temperatures, allows equilibration, and records the coefficient assumptions. Comparing unlike materials without that information can turn a thermal contribution into an apparent calibration error.

Second-order thermal mismatch uncertainty retains product terms that a linear uncertainty propagation can miss when calculating differential thermal-expansion uncertainty. For known nominal length $L$, expansion-coefficient difference $a$ and common temperature offset $\theta$, the correction is $d=La\theta$. Both first derivatives vanish at $a=\theta =0$, but the product of uncertain inputs need not vanish.

An original exact calculation assumes independent random variables with means $a_0,{\theta }_0$ and variances ${\sigma }_a^2,{\sigma }_{\theta }^2$. Independence givesTo derive the variance, use $\mathbb{E}[a^2{\theta }^2]=\mathbb{E}[a^2]\mathbb{E}[{\theta }^2]$ and subtract $a_0^2{\theta }_0^2$. No normal-distribution assumption is required for this independent-input result. The last term is absent from first-order propagation.

For stipulated $L=100\mathrm{mm}$, $a_0={\theta }_0=0$, ${\sigma }_a=10^{-6}{\mathrm{K}}^{-1}$ and ${\sigma }_{\theta }=0.1\mathrm{K}$, the exact standard deviation is 10 nm. A zero central correction therefore does not establish zero uncertainty. The GUM specifically warns that significant nonlinearity requires higher-order terms.^[ref]

Correlated inputs introduce a further distinction between the central product and the output mean. If $(a,\theta )$ has a multivariate normal distribution with covariance $c$, expansion about its means and the Gaussian fourth-moment identity giveThe covariance term in the mean must not be silently discarded. With the same zero means and standard deviations as above, but correlation coefficient $1/2$, the mean correction is 5 nm and its standard deviation about 11.18 nm. These are probability-model calculations, not measured block specifications.

The formulas assume known $L$ and a justified joint input model. A thermal-product input-distribution check must address shared temperature calibration and coefficient estimation before assigning a correlation. NIST's physical comparison procedure treats thermal corrections through measured temperatures and material expansion properties.^[ref] Keeping the nonlinear contribution is useful only when the inputs describe that actual measurement.