11/23/2022 The Water Break Test as a Surface Measurement Gauge

3 minute read

April 2021
The Water Break Test as a Surface Measurement
Gauge
Author: Brighton Science
Topics: Surface Science, Bonding & Sealing Processes

The water break test is a common way for manufacturers to test the surface
cleanliness of metals. Compared to other legacy cleanliness tests, it is relatively
simple to perform, however, the results rely almost entirely on the subjective eye of
the person performing the test.

Hydrophobic contaminants can be detrimental to adhesion — water break tests allow

users to test for the presence of these contaminants. Although this test is
nondestructive, because it only uses water, the test has significant limitations. The
test lacks the ability to detect surfactants or other hydrophilic substances on the
surface. As the test does not require purified water, and as purified water can contain
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contaminants, the water can introduce contaminants to the surface and can lead to
inaccurate test results.

Highly engineered materials are becoming the norm in complex manufacturing

environments. Manufacturers now rely on a wide array of raw materials including
custom designed metals, polymers and an extensive variety of advanced composites.
Advances in part molding technology have led to the development of parts with
increasingly complex geometries. Water break tests are not effective in this
increasingly sophisticated manufacturing environment. Although, historically, water
break tests were effective for large, flat surfaces, this test is becoming obsolete as
manufacturers embrace new technologies for highly sophisticated power production.

IoT and leveraging the power of data is transforming the way manufacturers collect
and analyze test results. Water break tests are not well suited for manufacturers who
are seeking to gain actionable, traceable and quantitative test results about surface
quality. Data-driven process control requires sophisticated testing methodologies that
can seamlessly capture all relevant surface analytics data.

How the Water Break Test is Performed

The ASTM-F22 Handbook sets the standard for water break tests. To perform a test, a
material is dipped into water and withdrawn vertically. In some instances, the water is
sprayed or poured onto the surface. The technician performing the test visually
evaluates the behavior of the water on the surface. The technician’s analysis is
subjective.

For strong, reliable adhesion, a material needs to have a high surface energy in order
to be chemically attractive to the adhesion, paint, ink or other coating that will be
applied to it. A clean surface generally has high energy and, in the case of the water
break test, should result in the water sliding off the surface in an unbroken sheet. If
the surface is clean the water will spread out due to its attraction to the surface. The
reaction of the water to the surface can strongly correlate to adhesion ability. Water is
an excellent indicator of surface energy but when applied in a subjective, difficult to
control manner, as it is in the water break test, the results aren’t suitable for process
control in the modern manufacturing process.

Uses of the Water Break Test

Water break tests are used primarily for metals to identify the presence of
contaminants on incoming raw materials or after surface processes, such as etching,

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anodizing, painting, priming, coating, grit-blasting, or sanding, have occurred. These

tests, however, can be messy and frequently result in unintended contaminating from
impure water.

Drying time is another constraint of the water break test. A significant amount of time
needs to be allocated for the part to dry after the test. This can include a manual wipe
of the part or a baking process — either process can transfer contaminants or alter
the surface chemistry of the part in an unintended way.

A Critical Control Point (CCP) represents any specific opportunity throughout the

manufacturing process when a material surface has the potential to inadvertently
change. A nondestructive methodology that can precisely capture surface quality at
any point in the production process is required to validate process control over CCPs.
The water break test does not hold up to these challenges because the testing
methods themselves can be a source of contamination.

Although technicians can be trained regarding how to conduct a water break test,
there are no definitive pass/fail standards for the water break test. This leaves test
results vulnerable to inconsistent standards both within a company and throughout
specific industries. This highly subjective test does not support the rigorous accuracy
needs required in tightly controlled manufacturing industries.

A lack of test sensitivity is another weakness of the water break test. Although a
surface may appear clean visually, it could actually be contaminated. Multiple tests on
the same surface can yield conflicting results. False positives, that indicate the
surface is clean when it is actually contaminated, are quite common with this test.

How Do You Obtain Surface Cleanliness Measurements That Are Reliable,

Repeatable, and Accurate?

Maintaining objectivity and capturing consistently accurate results can be achieved

with the appropriate processes and equipment. The Surface Analyst™ is a contact
angle measurement system that is sensitive to the top 2-3 molecular layers of a
surface where adhesion occurs. The Surface Analyst™ deposits a single drop of
highly purified water on a surface to accurately predict adhesion success. This
reliable and quantitative surface quality measurement is completely nondestructive
and poses no threat to the measurement surface.

The Surface Analyst has the ability to measure any surface or surface orientation,
regardless of shape, size, geometry or roughness. Unlike a water break test that

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requires a part to be removed from production in order to test surface adhesion

readiness, the Surface Analyst can perform measurements on actual parts during the
manufacturing process.

Results of the water contact angle measurement are available instantly so action can
be taken immediately if contamination is detected. The automatic calculation of
contact angle removes operator subjectivity. The Surface Analyst measures on a
cleanliness scale as opposed to a binary go/no go result. Measurements taken with
the Surface Analyst can more closely map out a surface's characteristics.
Manufacturers can know precise contamination levels and contamination locations.

Handpicked Related Surface Testing Content:

How to Bond PTFE to Anything
Single vs Multi-fluid Contact Angle Techniques Part 1: Surface energy and the
attractions between substances

Resources to Learn About Surface Science

To find out more about an alternative to the water break test, download the
"Manufacturer's Roadmap to Eliminating Adhesion Issues in Production" eBook. This
guide gives clear insight into eliminating guesswork around adhesion so
manufacturers can achieve consistent and successful results.

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Harnessing  the Power of Water to Achieve Precise

Results

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11/23/2022 The Water Break Test as a Surface Measurement Gauge

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