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Home » Quality 101: Understand Coating Thickness Measurement Test Methods

MeasurementQuality Exclusives

Quality 101: Understand Coating Thickness Measurement Test Methods

October 7, 2011
Paul Lomax
KEYWORDS coating thickness measurement
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8 Comments
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Develop a working knowledge of the test methods related to coating thickness measurement and the instruments available for both common and complex applications.

Dual purpose magnetic induction and eddy current gauges and probes would be beneficial in the case of an automobile where the doors might be steel and the hood might be aluminum. Source: Fischer Technology

Improving quality while reducing costs is a never-ending goal shared by small one-person companies, as well as by large organizations. Since virtually everything that we are surrounded by has a coating, it stands to reason
that tightening tolerances by using coating thickness measurement technology will help the bottom line. This is true for in-house plating and painting applications, companies that perform incoming inspection of goods from
suppliers, and third-party inspection firms and consultants. A reduction in costs also can take place by streamlining the time and effort it takes to evaluate the measurements and make adjustments to the process. Less
administrative time equates to more time fine tuning.

In order to improve quality and reduce costs, it is important to have a working knowledge of the test methods related to coating thickness measurement and the instruments available for both common and complex
applications. Most importantly, the operator should note that just because a test method is capable of measuring a coating, it might not necessarily be the best test method available.

We will discuss available test methods and point out some of the key factors an operator should consider before selecting the proper instrument. Recognizable applications, such as household fixtures, automobile parts and
fasteners will be used as examples. We also will discuss a means to streamline the measurement results and help guarantee the integrity of the data.

Multiple test methods could be used for the same task. One such example is the measurement of zinc plating over steel. Source: Fischer Technology

Test Methods
Common and complex plating and other coating thickness applications are typically measured using one of the following test methods: X-ray fluorescence, coulometric, beta backscatter, magnetic induction, amplitude eddy
current and phase-sensitive eddy current.

Energy dispersive X-ray fluorescence analysis (ED-XRFA) is a method for measuring the thickness of coatings and for analyzing materials. It can be used for the qualitative and quantitative determination of the elemental
composition of a material sample, as well as for measuring coatings and coating systems. It works nondestructively and without contact. Measurements can be completed quickly and usually without extensive sample
preparation.

With ED-XRFA, it is possible to measure both thickness and chemical composition of homogeneous materials and coatings. Even traces of harmful substances can be detected in the widest variety of samples. Moreover, X-
ray fluorescence analysis is a very clean method because no chemicals are used.

Many times hard copy documentation of inspection reports is required. Importing, copying and pasting measurement results into inspection forms are an administrative burden and can lead to mistakes. The direct population
of measurement results from the gage to virtually any report template will help reduce the likelihood of errors. Source: Fischer Technology

Chrome/Nickel/Copper Coatings Over Plastic

One of literally thousands of examples where X-ray fluorescence would be the test method of choice is the task of measuring chrome, nickel and copper coatings applied to a shower head. In most cases the substrate is
plastic, thus eliminating most other test methods from being able to perform the measurement. Furthermore, X-ray fluorescence is capable of measuring each individual layer of the decorative chrome in the range of 0-5
microns or less, the nickel coating of 5-10 microns, and the copper layer which might be 30 microns or greater.

As previously mentioned, X-ray fluorescence is nondestructive, providing a major advantage. Care should be taken with regard to the alignment of the part to the detector and correctly focusing the video on the measuring
point. The estimated or target thickness of the copper also should be considered in determining if X-ray fluorescence is the most appropriate test method. All things considered, X-ray fluorescence is ideally suited for this
application, but it is not the only test method capable of measuring the chrome/nickel/copper coatings over plastic.

The coulometric method measures nearly all metallic coatings including multiple coatings on any substrate material, such as plastic. It is, however, a destructive method because the coatings are successively removed at the
measuring area and determined by the time taken for removal.

X-ray fluorescence might still be the preferred choice because it is quick and nondestructive. However, the operator should consider the size of the part and if it will fit inside the chamber of the X-ray system-X-ray chambers
can be modified for large parts-and if there might be other alignment or focusing issues that might occur.

The thickness of the copper might also determine which method is best. If, for instance, the copper thickness is up to 50 microns, then the coulometric method could be an important complement to the XRF method.

The beta backscatter method allows for the thickness measurement of organic and metallic coatings on various substrate materials. Even soft coatings, such as well as oil and lubricating films, can be determined with the
appropriate probe configuration. Those that have thickness measurement applications that include organic and metallic coatings might choose beta backscatter over other methods because of the wide assortment of
coating/substrate combinations that this method is capable of measuring. In addition, beta backscatter is nondestructive.

Magnetic induction and eddy current test methods represent some of the most recognizable coating thickness instruments available. Magnetic induction instruments measure the thickness of nonferromagnetic metal coatings
such as chrome, copper, zinc, paint and powder coating over steel and iron. The amplitude eddy current method measures paint, powder coating, as well as anodize coatings over aluminum, stainless steel, copper and brass.

Depending on the capabilities of the particular instrument, there are dual-purpose magnetic induction and eddy current gages and probes. An example when these capabilities would be beneficial is in the case of an
automobile where the doors might be steel and the hood might be aluminum. The ability for the device to automatically detect the substrate material and apply the appropriate test method is crucial. It reduces time, reduces
the likelihood of erroneous measurements being taken and thus reduces time and costs.

Common and complex plating and other coating thickness applications are typically measured using one of the following test methods: X-ray fluorescence, coulometric, beta backscatter, magnetic induction, amplitude eddy
current and phase-sensitive eddy current. Source: Fischer Technology

Standards
ASTM D7091 Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nonconductive Coatings Applied to Non-Ferrous Metals is a
resource for those working with many of the aforementioned applications. Additional test methods have their own ASTM and ISO standards.

It is necessary for users to understand that not all gages and probes are ideally suited for all applications. Operators should review specifications such as trueness which is determined using calibration standards of known
thicknesses. Trueness can be stated as an absolute value or as a percentage. Another criterion of a particular system is the precision or repeatability standard deviation of X number of single readings.

Other factors include the performance of the gage or probe when measuring concave or convex diameters, the minimum measurement area required, the performance of the gage or probe in relation to the distance of the
probe tip to the edge of the part being measured, and the performance of the gage and probe as it relates to the substrate thickness.

Additional criteria to be considered in the selection process is the shape of the part that needs be measured, the type or types of substrates the coating is being applied to, and whether the user requires just a spot checker or an
instrument that provides memory and download capabilities.

Zinc Plating Over Steel

Another example where multiple test methods could be used for the same task is the measurement of zinc plating over steel.

Magnetic induction will measure zinc over steel; however, the spot size and measurement area might be too small for truly meaningful results. Likewise, X-ray fluorescence will measure these parts but cost and the
portability of a handheld instrument could be a factor in the decision. In this case, the phase-sensitive eddy current measurement test method should be utilized (ISO 21968).

The phase sensitive eddy current method allows for the measurement of metallic coatings on any substrate. This method also is advantageous for this example because it is capable of measuring small objects, such as nuts,
bolts and screws.

In other words, the shape of the part has very little influence on the results of the reading. Likewise, measurements of zinc or copper on steel over rough surfaces can be measured. Therefore, truer and more repeatable results
can be expected with this technique than with other traditional test methods for this example.

Inspection Plans and Report Templates

Streamlining the measurement and documentation process is often cumbersome. Making sure the correct number of readings is taken and in the right sequence is extremely important. If done correctly, a selective analysis of
different parts or areas on each part can be evaluated. For example, the spray patters on each automobile door, hood and trunk could be looked at individually. Adjustments can then be made to the spray patterns. Quick
meaningful evaluations and adjustments to a process have a direct effect on the bottom line.

Many times hard copy documentation of inspection reports is required. Importing, copying and pasting measurement results into inspection forms are an administrative burden and can lead to mistakes. A 5.30 mil value
could mistakenly be typed as 3.50 mil, resulting in unintentionally skewing of the statistical results of the data. The direct population of measurement results from the gage to virtually any report template will help reduce the
likelihood of errors.

There are multiple test methods available for coating thickness measurement requirements. Utilizing the appropriate test method for the specific application is necessary. Therefore, performance capabilities such as the
trueness of the gage and probe should be considered, particularly in regards to factors that influence the readings.

In addition to the capabilities of the gages and test methods, the operator is encouraged to take advantage of technological developments that have greatly enhanced efficiency through hardware and software capabilities.
These developments reduce the likelihood of errors. It also provides a selective analysis of parts or areas on each part to be evaluated.

Quicker and more meaningful data through paperless inspection and report templates allow for adjustments to the process. These adjustments will result in the improvement of quality and reduction of costs.

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BNP Media Owner & Co-CEO, Tagg Henderson

Paul Lomax works at Fischer Technology (Windsor, CT). For more in formation, call (860) 298-6069, e-mail plomax@fischer-technology.com or visit www.fischer-technology.com .

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You must login or register in order to post a comment.

Oina McAmbee
March 29, 2016
This is much easier to understand if you have a coating thickness gauge, also known as a paint meter, which is used to measure dry film thickness or custom wire mesh. Dry film thickness is probably the most critical
measurement in the coatings industry because of its impact on the coating process, quality and cost. These measurements can be used to evaluate a coating’s expected life, the product’s appearance and performance, and
ensure compliance with a host of International Standards.

Leo Asinovski
April 8, 2016
Nice Information ... :-) I would like to share something also helpful. If you are looking for most excellent thickness measurement services and instruments, I would like to Suggest you a website which is expert in building
affordable Measurement Instruments. Visit for More www.semiconsoft.com

Rick Morty
October 13, 2016
A coating thickness gauge, otherwise known as a paint meter is used to measure pvd coatings and dry film thickness. Dry film thickness is probably the most critical measurement in the coatings industry because of its
impact on the coating process, quality and cost. Dry film thickness measurements can be used to evaluate a coating’s expected life, the product’s appearance and performance, and ensure compliance with a host of
International Standards.

Bucuries Andrei
September 20, 2017
They cannot, because the current format for authorization does not include IP information. The processor can check based on IP/location but that is for the merchant's own fraud mitigation, they cannot pass this information
as part of the authorization at present. You can check things out at the access control systems Minneapolis MN. Users won't know their IPs anyway. Majority of Internet users in our side of the world are behind Network
Address Translation. This means that their IP addresses are assigned dynamically.

Bucuries Andrei
September 20, 2017
I would like to say a few things before I give you some advice. If you need repainting done, ll that you need is one layer of paint and some putty work to be done. However, if it is going to be a complete home painting
solution, make sure you hire a person with the right expertise according to your expectations. (in case you wanted some texture work on your walls etc.) Take a look at the exterior house painting hillsborough county fl if you
don't have ideas. Having said that, these guys here gave me amazing service when i needed painting at my home. The price was good and most importantly, it was completed in time for my next tenant to move in. You just
have to fill a form and they'll call you back in a few hours.

Nemo Dora
December 27, 2017
Various methods of NDT are used for the measurement of coating thickness – paint thickness, plating thickness, hvof coating, anodising etc. These methods may be X-ray, electron backscatter, magnetic, etc and the Table
gives a broad guide to the most appropriate methods for various coatings and substrates. Dry film thickness is probably the most critical measurement in the coatings industry because of its impact on the coating process,
quality and cost.

Dora Nemo
March 5, 2018
The scratch test has been used to assess the adhesion of thin hard coatings for some time now and is a useful tool for protective metal coatings development or quality assurance. However, the test is influenced by a number
of intrinsic and extrinsic factors which are not adhesion-related and the results of the test are usually regarded as only semi-quantitative. The stress state around a moving indenter scratching a coating/substrate system is very
complex and it is difficult to determine the stresses which lead to detachment. Furthermore the interfacial defect state responsible for failure is unknown. However, by a careful analysis of the observed failure modes in the
scratch test it is possible to identify adhesive failures and in some cases these occur in regions where the stress state is relatively simple and quantification can be attempted.

Collin Niesen
May 2, 2018
This is one of the best supplements for brain health my son has had. My son loves Dr. Poole, loves coming in for all visits. He has a certain way of talking to the children as a Brooklyn dentist to make them feel extremely
comfortable. He takes his time in explaining to me all about my son's treatment. I appreciate the care he holds for the children.
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