April 2005

Surface Engineering

Measurement

Standards for

Inorganic Materials

Stanley J. Dapkunas

Materials Science and 

Engineering Laboratory

April 2005

U.S. Department of Commerce

Carlos Gutierrez, Secretary

Technology Administration

Phillip J. Bond, Under Secretary for Technology

National Institute of Standards and Technology

Hratch G. Semerjian, Acting Director

Special Publication 960-9

NIST Recommended Practice Guide
ii

Certain commercial entities, equipment, or materials may be identified in this

document in order to describe an experimental procedure or concept adequately.

Such identification is not intended to imply recommendation or endorsement by

the National Institute of Standards and Technology, nor is it intended to imply

that the entities, materials, or equipment are necessarily the best available for the

purpose.

______________________________________

National Institute of Standards and Technology

Special Publication 960-9

Natl. Inst. Stand. Technol.

Spec. Publ. 960-9

252 pages (April 2005)

CODEN: NSPUE2

U.S. GOVERNMENT PRINTING OFFICE

WASHINGTON: 2005

For sale by the Superintendent of Documents

U.S. Government Printing Office

Internet: bookstore.gpo.gov Phone: (202) 512-1800 Fax: (202) 512-2250

Mail: Stop SSOP, Washington, DC 20402-0001
iii

Acknowledgements

This Recommended Practice Guide has benefited from the assistance of several

individuals at the National Institute of Standards and Technology (NIST) and ASM

International, and specifically members of the ASM International Surface Engineering

Committee. Staffs of the NIST Research Library and the National Center for Standards

and Certification at NIST, in particular, were critical in providing access to standards

described in this publication. Ed Mai of the NIST Administrative Services Division

gave valuable advice on formatting and information presentation that makes this

document accessible. His design of Figure 1 is greatly appreciated.

In addition to members of the Editorial Committee, Bill Scott and Fran Cverna of the

ASM International staff provided valuable perspectives.

Photomicrographs in Figure 1 were originally published by ASM International. These

illustrations of surface conditions clarify the organization of this Guide. Sources of the

photomicrographs are as follows:

Bare Material – ASM Micrograph Center On-Line Photo CS 1376

Heat Treated – ASM Micrograph Center On-Line, Photo 0027

Oxidized – ASM Micrograph Center On-Line CS 1079

Carburized – ASM Micrograph Center On-Line Photo 0001

Decarburized – ASM Micrograph Center On-Line Photo 0030

Aluminized – ASM Handbook Volume 5, Surface Engineering, 1994, page 614,

Figure 3D

Chromized – ASM Metals Handbook, 8th Edition, Atlas of Microstructures of

Industrial Alloys, 1972, page 13, Photo 83

Electroplated – ASM Metals Handbook, 8th Edition, Atlas of Microstructures of

Industrial Alloys, 1972, Photo 1877

Galvanized/clad – ASM Metals Handbook, 8th Edition, Atlas of Microstructures of

Industrial Alloys, 1972, Photo 72

Physical Vapor Deposition – ASM International, Journal of Thermal Spray Technology,

Vol. 6, No. 1, March 1988, page 37, Figure 5

Thermal Sprayed – ASM International, Journal of Thermal Spray Technology, Vol. 6,

No. 1, March 1988, page 37, Figure 4

Figure 2. Applicability of Coating Thickness Measuring Methods, is reprinted, with

permission, from ASTM B 659-90(2003) Standard Guide for Measuring Thickness of

Metallic and Inorganic Coatings, copyright ASTM International, 100 Barr Harbor Drive,

West Conshohocken, PA 19428.
iv
v

Preface

Surface engineering of materials is important in applications as diverse as medical

implants and gas turbines. Historically, a coating or cladding was added to a surface, or

a surface was treated, to enhance properties or performance. However, increasingly, heat

treated, implanted, coated and clad surfaces are viewed as part of a materials system

where the substrate and surface complement each other in achieving a performance goal

for a component. The integration of the surface and substrate as an engineered system

creates a situation where failure of the surface may, in effect, be failure of the system

and thus characterization of surfaces and measurement of surface properties are

important to the design, maintenance, and analysis of the whole system.

The advantages of engineered surfaces have stimulated development of surface treatment

and coating processes as well as materials and, consequently, commerce. Commerce in

engineered materials depends upon the ability to specify and measure composition,

microstructure, dimensions and properties as well as performance in applications

of interest.

The intent of this Guide is to give the materials community a resource for identifying

standard methods which are used to measure surface properties and to characterize

surface engineered materials.

This Guide has been prepared with the support of the Ceramics Division of the National

Institute of Standards and Technology and the cooperation of the Surface Engineering

Committee of ASM International. 

Specific thanks are due the Editorial Committee which oversaw this effort. Members of

that committee include:

Professor Christopher C. Berndt, James Cook University, School of Engineering,

Queensland, Australia; previously of Stony Brook University, Department of Materials

Science and Engineering, Stony Brook, NY

Dr. Debra Kaiser, Chief, Ceramics Division, NIST, Gaithersburg, MD

Mr. Steven Lampman, ASM International, Materials Park, OH

Dr. James Treglio, Molecular Metallurgy, Inc., El Cahon. CA

ASM International generously provided the illustrative photomicrographs in Figure 1,

Quick Guide to Surface Measurement Standards. Sources of specific photomicrographs

are provided in the Acknowledgements section of this document. 

ASTM International generously provided Figure 2, Applicability of Coating Thickness

Measuring Methods. The source of Figure 2 is ASTM B 659-90 (2003) Standard Guide

for Measuring Thickness of Metallic and Inorganic Coatings.

More information on the SP 960 series can be found on the Internet at

http://www.nist.gov/practice guides. This website includes a complete list of NIST

Practice Guides and ordering information.
vi
vii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. Organization of the Guide and Locating Standards . . . . . . . . . . . . . . . . . . . .4

2.1 Organization of the Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.2 Locating Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3. General Standards for Surface Engineering Measurement . . . . . . . . . . . . .10

3.1 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.2 Laboratory Accreditation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.3 Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4. Surface Inspection and Product Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4.1 General (bare and coated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4.2 Products (bare and coated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4.2.1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4.2.2 Sheet and Structural Steel . . . . . . . . . . . . . . . . . . . . . . . . . . .51

4.2.3 Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.2.4 Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

5. Surface Finish Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

5.1 General (bare and coated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

5.2 Methods for Specific Products and Processes . . . . . . . . . . . . . . . . . .66

6. General Product Quality Standards for Specific Coating Processes . . . . . .72

6.1 Anodic Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

6.2 Conversion Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

6.3 Galvanized Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

6.4 Electroplated Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

6.5 Diffusion Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

6.6 Physical Vapor Deposition (PVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

6.7 Thermal Spray Deposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

6.8 Glass and Enamel Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

7. Standards for Measurement of Surface Treatment Depth

Coating Thickness and Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

7.1 Surface Treatment Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

7.2 Coating Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

7.3 Coating Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

8. Standards for Analysis of Microstructure . . . . . . . . . . . . . . . . . . . . . . . . . .136

8.1 Metallography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

8.2 Porosity and Defect Measurement of Coatings . . . . . . . . . . . . . . . .141

9. Standards for Measurement of Composition and Crystal Structure . . . . . .148

9.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

9.2 Crystal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

10. Standards for Residual Stress and Hardness Measurement . . . . . . . . . . .153

10.1 Residual Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

10.2 Indentation Hardness Measurements . . . . . . . . . . . . . . . . . . . . . . . .155

10.3 Other Hardness Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
viii

11. Standards for Mechanical Properties and Adhesion of Coatings . . . . . . . .181

11.1 Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

11.2 Adhesion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

12. Standards for Measurement of Corrosion, Wear and Thermal

Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191

12.1 Bare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191

12.2 Coated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198

13. Surface Engineering Measurement Standards . . . . . . . . . . . . . . . . . . . . .210

13.1 ASME (American Society of Mechanical 

Engineers) Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210

13.2 ASTM International (American Society for

Testing and Materials) Standards . . . . . . . . . . . . . . . . . . . . . . . . . . .210

13.3 ISO (International Organization for

Standardization) Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217

13.4 Military and Industry Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . .222

13.5 SAE (Society of Automotive Engineers) Standards . . . . . . . . . . . . .223

14. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226

List of Figures

Figure 1. Quick Guide to Surface Measurement Standards . . . . . . . . . . . . . . . .6

Figure 2. Applicability of Coating Thickness Measuring Methods . . . . . . . . . . .97
1

1. Introduction 

This Guide is intended to aid the technical and scientific community in the evaluation

of engineered surfaces by identifying standard methods for measurement of pertinent

properties and characteristics. Methods included in this Guide are for use with inorganic

materials, i.e., metals and ceramics, used in structural, i.e., load bearing, applications. 

“Surface Engineering” has been defined as the treatment of the surface and near surface

regions of a material to allow the surface to perform functions that are distinct from

those functions demanded from the bulk of the material1. “Surface Engineering” has

also been expanded to include consideration of the design of the surface and substrate as

a system2. Engineered surfaces typically provide wear, corrosion or thermal protection

and may be created by techniques such as heat treatment to modify microstructure,

implantation to modify composition, or coating and cladding where a very different

material is applied to a surface. Generally, an engineered surface enhances the

performance of a load bearing substrate. This is in contrast to a functional surface,

like a printed circuit, which is supported by a substrate.

Surface engineering is critical to the technical and/or economic success of many

technologies. For example, gas turbines rely on coatings for corrosion and thermal

protection to achieve durability and high efficiency, reciprocating engines rely on treated

and coated surfaces for wear resistance, and medical implants are coated to improve

bone adherence and biocompatibility.

There are several reasons to evaluate engineered surfaces:

to ascertain conformance to specifications;

• to monitor process control by regular measurement of selected properties such as

hardness or finish;

• to assess relevant properties in the development of materials or processing methods

• to ascertain performance through exposure to, or operation in, the intended

application, followed by measurement or characterization of attributes such as

extent of corrosive penetration or wear; and,

• to predict performance through exposure in an environment which simulates the

intended application, again, followed by evaluation of appropriate attributes.

Addressing these three purposes requires property measurement or characterization by

methods that not only meet the needs of the party conducting the measurement but also

are satisfactory to the user or purchaser of the material or component of interest.

Therefore, it is often necessary for organizations that develop, or provide, and purchase,

or use, materials and components to agree on a commonly accepted method of

measurement. Obviously, the availability of commonly accepted measurement methods

facilitates commerce by removing ambiguities that may arise when the same nominal

property is determined by unique or unusual techniques.

Furthermore, some properties are so broadly useful, because they provide a common

denominator for comparing materials, that considerable effort has been invested in their

consistent measurement. Hardness, for example, is a useful property for comparing
2

materials or for determining the effect of different heat treatments on a single material.

The value of consistent and valid measurement of such properties has led to the

development of standard test methods, i.e., “standards”. Standards specify measurement

details such as specimen design, test apparatus and calibration, test procedures, data

reporting, limits of applicability, and uncertainty. 

Standard measurement methods are an important component in engineering design and

construction. For example, standard test methods may be codified, that is, made part of

a system of principles or rules. ASTM (formerly the American Society for Testing and

Materials) standards for property measurement are included in the ASME (American

Society of Mechanical Engineers) Boiler and Pressure Vessel Code, which is a basis

for design and fabrication.

The widespread use of standards and the value they bring to commerce in materials and

components has necessitated the formation of organizations whose function is to foster

development of standard measurement methods. These standards organizations can

be civilian and voluntary, as is ASTM, or governmental, as is the JIS (Japan Institute

of Standards). 

The organizations which have accepted responsibility for standards development also

make the standards available for interested parties and update the standards, as

appropriate. The standards are usually up-dated with significant contribution and

review by the technical community concerned. 

In the United States, standards organizations with an interest in surface engineering

measurements include ASTM, SAE (Society of Automotive Engineers), ASME

International (American Society of Mechanical Engineers) and ANSI (American

National Standards Institute). These organizations develop consensus standards through

the efforts of volunteers, often with scientific support from NIST (the National Institute

of Standards and Technology).

The DOD (Department of Defense), NASA ( National Aeronautics and Space

Administration) and other government agencies conduct research on engineered surfaces

and can establish test methods which amount to standards. These test methods address

those agencies’ specific needs but may eventually be adopted by ASTM or other

standards organizations. 

International standards are generally developed through the cooperative efforts of

national or regional standards organizations and reflect the methods developed for those

bodies’ standards. The ISO (International Organization for Standardization) is the most

notable international organization active in the development of methods for measurement

of material properties.

This Guide includes few standards for measurement of corrosion, friction, wear and

abrasion. Standards in these fields that are included focus on evaluation of specific

surface conditions. The large number of corrosion and wear standards based on

corrodent or wear mechanism warrant separate compilation, as has been done in the
3

“Friction and Wear Testing Source Book of Selected References from ASTM Standards

and ASM Handbooks”. That Source Book was issued jointly by ASTM International

and ASM International in 1997 and is available from those organizations.

Lastly, it is important to note that “standards”, i.e., standard test methods, are well

considered approaches to property measurement or material characterization and are the

consensus opinion of experienced practitioners and researchers. As such, they are a

means for those inexperienced in a specific field to quickly gain knowledge of what is

regarded as a reputable measurement technique. Standard test methods do not always

include state-of-the-art techniques or address applications which are still in the research

stage and subject to rapid change.

This Guide does not provide details included in the standards identified and should not

be viewed as a substitute for those standards. Standards should be purchased from the

issuing organization at the following addresses:

ASTM

100 Barr Harbor Drive

West Conshocken, PA 19428-2959

ASME

Three Park Avenue

New York, NY 10016-5990

ISO

Case postale 56

CH-1211

Geneva 20

Switzerland

SAE International

400 Commonwealth Drive

Warrendale, PA 15096-0001

1 ASM Handbook, Volume 5, Surface Engineering, Copyright 1994 by ASM

International, Materials Park, Ohio 44073-0002

2 http://www.twi.co.uk/j32/unprotected/band_1/surfaceengineering.htm
4

2. Organization of the Guide and Locating Standards

2.1 Organization of the Guide

This Guide is organized to enable rapid identification of standard measurement methods

(“standards”) appropriate to the user’s interests. 

The Guide includes standards appropriate for the following surface conditions:

• bare surfaces which have the same composition, phase and structure from surface

to interior;

• treated surfaces wherein the base material has been subjected to conditions which

change surface composition, structure, phase, or properties; and,

• coated surfaces wherein the base material has had specific additional material

deposited on its surface, often significantly increasing the base material’s 

dimensions.

Treated surfaces are those that have been subjected to processes such as carburization,

decarburization, nitridation, surface implantation, surface heat treatments and abrasive

blast hardening or cleaning.

Coated surfaces are those that have been covered with material having composition and

properties significantly different from the base material. Coating processes include

electroplating, physical vapor deposition, thermal spray and galvanizing, for example.

The greatest part of this document consists of summaries of over 200 standards. 

A summary of each standard is provided in a template that includes the following

information, as appropriate:

• Standards Identification including issuing organization, standard identification

number and standard title;

• General Description including an overview of the method and the contents of the

standard;

• Intended Application including the stated purpose for which the standard was

developed;

• Specimen Requirements including the size, condition or other characteristics

necessary or valid use of the method;

• Data Produced including the nature of the data produced (visual or instrument

generated numeric, for example) and further refinements or calculations

necessary, and,

• Limits of the method including inappropriate application, accuracy, precision or

safety concerns.

The templates are within Sections 3 through 12 of this Guide.

Within each Section or Sub-section, standards are in the following order:

• ASME Standards,

• ASTM Standards,

• ISO Standards,
5

• Military and Industry Standards, and

• SAE Standards.

Sections 3 through 12 are organized as follows:

• general aspects of surface inspection and product evaluation (Sections 3,4 and 5),

• standards specific to selected coating processes (Section 6), and

• standards for measurement of specific characteristics or properties (Sections 7

through 12).

This Guide also has the following features which support Sections 3 through 12:

• Figure 1. Quick Guide to Surface Measurement Standards which progresses in

increasing detail from “Surface Condition” to “Property of Interest” to

“Measurement method” to the "Appropriate Section” which includes relevant

standards;

• Section 13. Surface Engineering Measurement Standards, a compilation of titles of

all standards in Sections 3 through 12, organized by issuing organizations and those

organizations’ alpha-numeric identification; 

• Section 14. Index, a comprehensive compilation of key words associated with each

standard;

• Figure 2. Applicability of Coating Thickness Measuring Methods, which is

included in Section 7 and provides an ASTM summary of methods for measuring

thickness by several methods.

2.2 Locating Standards

There are four routes for locating a standard of interest:

• Surface Condition Based

Figure 1, Quick Guide to Surface Measurement Standards, gives a rapid, although

not comprehensive, route to a relevant standard by starting with the surface condition

illustrated and proceeding through the property of interest to measurement method to

the section in which the standard(s) are located;

• Property or Characteristic Based

Proceeding directly to Sections 3 through 12 will enable browsing through standards

which address general issues such as terminology or accreditation, properties or

characteristics, material, or measurement method;

• Standard Based

Section 13, the compilation of standards in Sections 3 through 12, enables the user

to proceed directly to the summary of the standard of interest when the standard is

known; and,

• Key Words

Standards can also be accessed by use of the alphabetized Index in Section 14. The

Index is based on key words descriptive of the content of each standard.

Also, Figure 2, Applicability of Coating Thickness Measuring Methods, can be used

within Section 7 to focus on useful methods and the Index can be used to quickly

identify standards with similar purposes or methods issued by different organizations.

Sections 3 through 12 also enable comparison of standards issued by different

organizations.
6

Figure 1. Quick Guide to Surface Measurement Standards

Surface Condition Property Method Section Page

Bare Specifications

Geometrical Product Specifications (GPS)

Acceptance standards, Visual

Surface defects, fasteners

4.1

4.1

4.2

25

25

42

Surface chemistry 9.1 148

− Terminology

− Depth profiling (AES)

− Glow discharge optical

− Emission spectroscopy

Surface

profile &

texture

− Visual

− Profilometry

− Scanning Tunnel Micros.

− Focussing microscope

− Replica

4.1,

4.2

25,

42

Surface defects 4.1 25

− Classification

− Liquid penetrant

− Infrared

− Eddy current

− Acoustic emission

− Etch

− Replica

− Magnetic particle

Cleanliness 4.1 25

− Visual

− Tape

− Bresle

− Conductometric

− Refractometric

− Titimetric

Gloss 4.2 42

− Goniophotometry

Oxide finger penetration 8.1 136

− Microscopy

Microstructure 8.1 136

− Microscopy

Hardness 10.2, 3 155ff

− Comparison testers

− Scratch testers

− Indentation testers

(7 types)

− Scleroscope

− Files

Residual stress 10.1 153

− Hole-drilling strain gages

− X-ray diffraction
7

Figure 1. Quick Guide to Surface Measurement Standards (cont’d)

Surface Condition Property Method Section Page

Heat Treated Contractor accreditation 3.2 12

Case depth 7.1 88

− Hardness

Surface temper 4.2 42

− Etch inspection

Oxidized Oxide thickness 7.2 97

− Microscopy

Carburized Carburization depth 7.1 88

− Hardness

− Microscopy

Decarburized Decarburization depth 7.1 88

− Hardness

− Microscopy

− Chemical

Anodized Sampling 3.3 21

Thickness 7.2 97

− Gravimetric

− Split beam microscopy

Aluminized Specification 6.5 80

Coating thickness 7.2 97

− Microscopy

Chromized Contractor accreditation 3.2 12

Coating thickness 7.2 97

− Microscopy
8

Figure 1. Quick Guide to Surface Measurement Standards (cont’d)

Surface Condition Property Method Section Page

Electroplated Sampling 3.2 12

Contractor accreditation 3.3 21

Coating thickness 7.2 97

− Coulometric

− Magnetic

− Acid dissolution

− Beta backscatter

− X-ray spectrometry

− Interference microscopy

− Microscopical

− Eddy current

− Profilometric

− Radial sectioning

Coating mass, X-ray fluorescence 7.3 125

Grinding damage 4.1 25

Interfacial width, sputter depth profiling 9.1 148

Porosity, Gold 8.2 141

− Acid vapor

− Paper electrography

− Gel-bulk electrography

− Sulfurous acid/sulfur dioxide

− Flowers of sulfur

Gross defects & mechanical damage 8.2 141

− Polysulfide immersion

Hardness 10.2 155

− Knoop

− Vickers

Ductility 11.1 181

− Bend test 11.2 187

Adhesion

Corrosion site characterization

− Interference microscopy 12.2 198

Hydrogen embrittlement

− Electronic 12.2 198
9

Figure 1. Quick Guide to Surface Measurement Standards (cont’d)

Surface Condition Property Method Section Page

Galvanized/

Clad

Case study practices 6.3 75

Coating mass measurement 7.3 125

− Gravimetric

− X-ray fluorescence

− Triple spot

Composition 7.3 125

− Triple spot

Physical

Vapor

Deposited

TiN Specification 6.6 82

Contractor accreditation 3.2 12

Coating thickness 7.2 97

− Microscopical

− Radial sectioning

Thermal

Sprayed

Contractor accreditation 3.2 12

Specifications 6.7 83

Thickness 7.2 97

− Radial sectioning

Phase content, hydroxyapatite 9.2 152

− X-ray diffraction

Shear strength 11.1 181

− Mechanical

Tensile strength 11.1 181

− Mechanical

Fatigue strength 11.1 181

− Mechanical

Adhesion/cohesion strength 11.2 187

− Mechanical

Abrasion resistance 11.2 187

− Taber Abraser
10

3. General Standards for Surface Engineering Measurement

3.1 Terminology

ASTM A 902

Standard Terminology Relating to Metallic Coated Steel Products

General Description Data Produced

This Standard is a compilation of 47

definitions of terms related to metallic

coatings used in the steel industry.

The Standard also includes

recommended key words for ASTM

Committee A-5 Standards.

Not applicable/specified.

Intended Application Specimen Requirement Limits

Clarity of terminology

used in coated steel

product descriptions.

Not specified. Not specified.

ISO 2079

Surface Treatment and Metallic Coatings – General Classification of Terms

General Description Data Produced

This document provides general terms

and definitions for several surface

treatments and identifies relevant

ISO standards for those treatments.

Terms and definitions are provided in

English, French, Russian and

German. 

Not specified.

Intended Application Specimen Requirement Limits

Intended to clarify

relevant standards.

Not specified. Not specified.
11

ISO 2080

Electroplating and Related Processes – Vocabulary

General Description Data Produced

This Standard provides definitions of

804 terms used in electroplating and

related processes such as metal

finishing. Definitions are in English,

French, Russian and German.

Not specified.

Intended Application Specimen Requirement Limits

Intended to clarify

relevant standards.

Not specified. Not specified.

SAE AS 4194

Sheet and Strip Surface Finish Nomenclature

(Aerospace Standard)

General Description Data Produced

Defines nomenclature for two surfaces

(2D and 2B) of sheet and two

surfaces (No. 1 and No. 2) of strip

material and bright annealed finish.

Not specified/applicable.

Intended Application Specimen Requirement Limits

Provides explanations of

terms used to describe

surface finish of iron,

nickel, cobalt and

titanium base alloys

used in aerospace

applications.

Not specified/applicable. Not specified/applicable.
12

3.2 Laboratory Accreditation

SAE AS 7101

National Aerospace and Defense Contractors Accreditation Program (NADCAP)

General Requirements for Materials Test Laboratory Accreditation Program 

(Aerospace Standard)

General Description Data Produced

Establishes the minimum

requirements for materials testing

laboratories accredited by NADCAP.

Test methods for metallic materials

are specified by reference to SAE,

ASTM, military, ISO and ANSI

documents. Methods referenced

include those for: chemical,

mechanical, metallography and

microhardness, hardness, corrosion,

mechanical test specimen preparation,

differential thermal analysis, heat

treating, X-ray diffraction and fastener

testing. Document includes definitions,

and survey requirements.

Not specified/applicable.

Intended Application Specimen Requirement Limits

Intended to give

guidance for many

aspects of a testing

laboratory required

for accreditation.

Not specified/applicable. Not specified/applicable.
13

SAE AS 7109

National Aerospace and Defense Contractors Accreditation 

Program Requirements for Coatings

(Aerospace Standard)

General Description Data Produced

This Standard establishes

requirements for suppliers of coating

services to be accredited by the

National Aerospace and Defense

Contractors Accreditation Program

(NADCAP). It does not include

measurement methods but serves as

the basic document for accompanying

Aerospace Standards for specific

types of coatings which include

measurement or testing requirements.

Not specified.

Intended Application Specimen Requirement Limits

Coating supplier

accreditation.

Not specified. Not specified.
14

SAE AS 7109-1

National Aerospace and Defense Contractors Accreditation 

Program Requirements for Thermal Spray

(Aerospace Standard)

General Description Data Produced

This Standard is a supplement to SAE

AS 7109 addressing: OXY/Fuel

Powder and Wire Spray, Plasma

Thermal Spray, HVOF/D-Gun Spray,

Low Pressure Plasma Spray (LPPS)

and Electric Arc Wire Spray.

Accreditation requirements for the

following applications are included:

High/low Temperature Hard Coatings,

Anti-fretting Coatings, Thermal Barrier

Coatings, Abrasive Seal Coatings,

Abradable Coatings, Dimensional

Build-up Coatings and High

Temperature LPPS Coatings. Aspects

addressed include: Technical

Experience, Process Planning,

Manufacturing, Material Powder/Wire

Control, Cleaning, Masking, Grit

Blasting, Spray Booths, Oxy/Fuel,

Plasma Thermal Spray, HVOF/D-Gun,

LPPS, Electric Arc Wire, Process

Gases, De-mask/Clean, Supplemental

Heat Treating, Sealing Sprayed

Coatings, Inspection and Compliance.

Characterization and measurement

are covered in the “Inspection”

section.

Not specified.

Intended Application Specimen Requirement Limits

Coating supplier

accreditation.

Not specified. Not specified.
15

SAE AS 7109-2

National Aerospace and Defense Contractors Accreditation 

Program Requirements for Vapor Deposit

(Aerospace Standard)

General Description Data Produced

This Standard supplements SAE

AS 7109, specifically addressing

physical vapor deposition (PVD, Class

A) which includes sputter and electron

beam deposition and chemical vapor

deposition (CVD, Class B). The

following aspects of accreditation are

described: Technical Experience,

Manufacturing, Material Control,

Vapor Process Operation Sheet,

Part Treatment, Cleaning, Masking,

Surface Preparation, Chambers/Pump

Systems, Process Gases,

Supplementary Chemical Treatment,

Inspection and Compliance.

Characterization and measurement

are included in the “Inspection”

section.

Not specified.

Intended Application Specimen Requirement Limits

Coating supplier

accreditation.

Not specified. Standard methods for

characterization or

inspection are

not specified.
16

SAE AS 7109-3

National Aerospace and Defense Contractors Accreditation

Program Requirements for Cementation

(Aerospace Standard)

General Description Data Produced

This Standard supplements SAE

AS 7109, specifically addressing pack

processes (Class A) which includes

above pack and in-pack deposition,

and slurry processes (Class B).

The following aspects of accreditation

are included: Technical Experience,

Process Planning, Manufacturing,

Material Control, Cleaning, Masking,

Grit Blasting, Packing/Furnace

Loading, Coating/ Thermal Treatment,

De-mask/Clean, Supplementary

Chemical Processing, Inspection and

Compliance. Characterization and

measurement are included in the

“Inspection” section.

Not specified.

Intended Application Specimen Requirement Limits

Coating supplier

accreditation.

Not specified. Standard methods for

characterization or

inspection are

not specified.
17

SAE AS 7109-4

National Aerospace and Defense Contractors Accreditation 

Program Requirements for Stripping

(Aerospace Standard)

General Description Data Produced

This Standard supplements SAE

AS 7109, specifically addressing

stripping of coated material.

Stripping methods addressed include:

electrolytic, mechanical (grit blast,

grinding, machining) water jet, molten

salt and chemical. The following

aspects of accreditation are included:

Equipment and Facilities, Process

Planning, Manufacturing, Material

Control, Stripping, Water Jet, Molten

Salt, Chemical, Process Control

Laboratory Procedures (Solution

Analysis), Post Strip Cleaning, Bake

Embrittlement Relief and Compliance.

Not applicable/specified.

Intended Application Specimen Requirement Limits

Coating supplier

accreditation.

Not specified. Not specified.
18

SAE AS 7109-5

National Aerospace and Defense Contractors Accreditation 

Program Requirements for Coating Evaluation Laboratory Practices

(Aerospace Standard)

General Description Data Produced

This Standard supplements SAE

AS 7109, specifically addressing

coating evaluation. Specific details of

evaluation methods are not described

but appropriate references to other

documentation (e.g. ASTM) are

included. The Standard covers those

aspects of evaluation which must be

addresses to warrant accreditation,

including: Personnel, Procedures,

Equipment and Facilities, Quality

Assurance-Lab Specific, Round Robin

Programs, Hardness Testing,

Metallography and Thickness,

Mechanical Testing, Heat treating of

Specimens, Specimens (such as per

ASTM C 633), Replacement Testing

and Retesting, Test Reports/

Certificates, Tensile Testing, Bend

Testing and Nonstandard Compliance.

Not specified.

Intended Application Specimen Requirement Limits

Coating supplier

accreditation.

Not specified. Not specified.
19

SAE AS 7109-6

National Aerospace and Defense Contractors Accreditation

Program Requirements for Plating of Coated Parts Laboratory Practices

(Aerospace Standard)

General Description Data Produced

This standard is a supplement to SAE

AS 7109, specifically addressing

plating of coated parts. The document

calls out aspects of plating which must

be addressed to meet accreditation

requirements. These aspects are

included: Equipment and Facilities,

Part Processing Control, Cleaning

Procedures, Masking, Lot Integrity,

Housekeeping, Test and Inspection,

Process Control Laboratory

Procedures (Solution Analysis) and

Compliance. Test and Inspection

specifies the use of procedures in the

following ASTM Standards:

B 244, B 487, B 499, B 504,

B 530, B 567 and B 568.

Not specified.

Intended Application Specimen Requirement Limits

Coating supplier

accreditation.

Not specified. Not specified.
20

SAE AS 7109-7

National Aerospace and Defense Contractors Accreditation

Program Requirements for Heat Treating for Suppliers of Coatings

(Aerospace Standard)

General Description Data Produced

This Standard is a complement to

SAE AS 7109, specifically addressing

heat treating during the coating

process. This standard does not

include surface related measurement

or testing and is included only for

completeness in the AS 7109 series.

Not specified.

Intended Application Specimen Requirement Limits

Coating supplier

accreditation.

Not specified. Not specified.
21

3.3 Sampling

ASTM B 602

Standard Test Method for Attribute Sampling of Metallic and Inorganic Coatings

General Description Data Produced

This Method gives sampling plans

intended for use in the inspection of

coatings for conformance to ASTM

specifications. The plans are based on

inspection by attributes. That is, the

article is inspected and classified as

either conforming to a requirement

placed on it or not conforming. The

Method includes a general description

of the approach, ordering information,

formation of inspection lot,sampling,

inspection and lot disposal,

and drawing of samples.

Varies with specification.

Intended Application Specimen Requirement Limits

Sampling inspection

permits the estimation of

the overall quality of a

group of product articles

through the inspection of

a relatively small number

of product items drawn

from the group. The

selection of a sampling

plan provides purchasers

and sellers a means of

identifying the minimum

quality levels that are

considered satisfactory.

Varies with specification. Sampling plans yield

estimates of the quality

of product, thus the

results of the inspection

are subject to error.

Through the use of

sampling plans, the risk

of error is known

and controlled.
22

ASTM B 697

Standard Guide for Selection of Sampling Plans for Inspection of

Electrodeposited Metallic and Inorganic Coatings

General Description Data Produced

This Guide provides guidance in the

selection of sampling plans to

determine whether submitted lots of

coated products comply with the

specifications applicable to the

coatings. A sampling plan guides the

examination of a relatively small part

of the articles in a lot. That

examination allows a decision as to

whether the lot does or does not

conform to specifications. The

sampling plans are attribute plans.

Each examined article is classified as

conforming or not conforming to each

coating requirement and the number

of nonconforming articles compared to

a maximum allowable number.

Supplements ASTM B 602.

Number of articles with acceptable

properties.

Intended Application Specimen Requirement Limits

Acceptance sampling is

used when a decision

must be made about

what to do with a

quantity of articles.

Used where cost of

inspection is high and

consequences of

accepting a

nonconforming article

are not serious; or,

where 100% inspection

is boring or fatiguing

and likely to result in

errors; or, when

inspection requires a

destructive test.

Varies with property or

characteristic of interest.

It is important that the

inspection lot be

homogeneous; i.e., that

the articles in the lot be

from the same supplier,

single finishing line,

finished at the

same time, etc.
23

ASTM B 762

Standard Test Method of Variables Sampling of Metallic and Inorganic Coatings

General Description Data Produced

This Method gives sampling plans for

inspection of coatings on products for

the purpose of deciding whether lots

of the coated articles conform to

specifications for the coatings. A

characteristic of the coating on drawn

articles is measured and the values

obtained are used to estimate the

number of articles in the lot that do not

conform to a numerical limit.

Number of articles in a lot that do not

conform to a numerical limit.

Intended Application Specimen Requirement Limits

Acceptance testing of

lots of coated articles.

Varies with property or

characteristic of interest.

A variables plan requires

that: the characteristic of

interest is measurable;

the test method gives a

numerical measure of

the characteristic; the

specification places a

numerical limit on the

measured value;

variation of the

characteristic from article

to article be normally

distributed; and, each

article is tested in the

same way. If one or

more of the above

conditions are not met,

an attributes plan must

be used; e.g., ASTM

B 602 or ASTM B 697.
24

ISO 4519

Electrodeposited Metallic Coatings and Related Finishes – Sampling

Procedures for Inspection by Attributes

General Description Data Produced

This Standard establishes sampling

plans and procedures for inspection of

electrodeposited metallic coatings

using attributes of those materials.

The procedures described may be

applied to finished products or

materials processing. The sampling

plans are based on acceptable quality

levels (AQLs) of 1.5 and 4.0%. The

standard includes definitions, defect

classifications, acceptance and

rejection responsibilities, sample

selection methods and plans, detailed

guidance on determination of

acceptability and procedures for

drawing random samples. This

standard is based on ISO 2858.

Varies with property of interest.

Intended Application Specimen Requirement Limits

Provides a basis for

purchase specifications

and may be applied to

related finishes. This

standard supports

determination of lot

acceptability by the use

of a sampling plan.

Not specified. The plans are intended

primarily for examination

of continuing series of

lots but may be used for

examination of isolated

lots. This standard is not

applicable to sampling

and testing of

electroplated mechanical

fasteners

(See ISO 3269).
25

4. Surface Inspection and Product Quality

4.1 General (bare and coated)

ASTM B 866 

Standard Test Method for Gross Defects and Mechanical Damage in Metallic

Coatings by Polysulfide Immersion

General Description Data Produced

This Method describes a technique for

determining gross defects and/or

mechanical damage to metallic

coatings on copper or copper alloy

substrates. The Method is useful for

techniques where the coating does

not tarnish in an alkaline polysulfide

solution. Suitable coatings include

gold, nickel, tin, tin-lead, palladium or

their alloys. The Method consists of

immersing the test area in a solution

of alkaline sodium sulfite for 60 s at

74 °C and examining the test area for

signs of copper reaction products

using a 10x microscope. The Method

gives polysulfide solution preparation,

test procedure and examination

and evaluation guidelines.

Visible indications of defects.

Intended Application Specimen Requirement Limits

Intended to ascertain the

presence of defects from

processing and

mechanical damage

from use as manifested

by exposure of copper

under plate or copper

basis metal.

Clean surfaces. Method is relatively

insensitive to the

presence of small pores.

ASTM B 809 should be

used instead. Method is

not recommended for

prediction of product

performance or

simulation of field failure

mechanisms. Generally,

corrosion products less

than 0.05 mm (0.002 in.)

in diameter are not

counted in the evaluation.

Work should be performed

in a fume hood.
26

ASTM B 877

Standard Test Method for Gross Defects and Mechanical Damage in Metallic

Coatings by the Phosphomolybdic Acid (PMA) Method

General Description Data Produced

This test standard gives equipment

and methods for using phosomolybdic

acid (PMA, a solid complex of

molybdenum trioxide and phosphoric

acid) to detect gross defects and

mechanical damage in gold, silver or

palladium coatings over substrates of

nickel, copper or copper alloys. The

test consists of removing oxides in the

defect area by exposure to

hydrochloric acid fumes and applying

a drop of PMA with an applicator to

the area in question. PMA contact with

exposed under plate or substrate

causes the molybdenum trioxide

to turn blue.

Visible indications of defects.

Intended Application Specimen Requirement Limits

To determine the

presence of mechanical

damage, wear-through

and other gross defects

in the coating. Intended

for the evaluation of

individual samples, one

at a time, with a

microscope at 10x

to 30x.

Thoroughly cleaned,

particle free surfaces.

A test area of less than

2 mm allows

examination by

microscope. Test areas

may require masking to

prevent PMA reaction

with exposed base

metal edges.

This is essentially a

pass/fail test. It may not

be suitable for some

precious metal alloy

coatings that contain

significant concentrations

of non-precious metals

(e.g., nickel or copper).

PMA reacts with tin, lead

and tin-lead solder. Test

is relatively insensitive to

small pores. Test not

recommended for

prediction of product

performance. Test is

destructive and tested

pieces should not be

put into service.
27

ISO 3274

Geometrical product Specifications (GPS) – Surface Texture: Profile Method –

Nominal Characteristics of Contact (stylus) Instruments

General Description Data Produced

This Standard defines profiles and the

general structure of contact (stylus)

instruments for measuring surface

roughness and waviness. Instrument

properties and basic specifications for

profile meters and profile recorders

are included. It influences chain link 5

for roughness, waviness and primary

profiles in the GPS matrix model.

Not specified/applicable.

Intended Application Specimen Requirement Limits

The primary purpose is

to enable comparison of

similar surfaces or the

comparison of results

from different measuring

instruments.

Not specified/applicable. Not specified/applicable.
28

ISO 4288

Geometrical Product Specification (GPS) – Surface Texture: Profile Method –

Rules and Procedures for the Assessment of Surface Texture

General Description Data Produced

This Standard specifies the rules for

comparison of the measured values

with the tolerance limits for surface

texture parameters defined inISO

4287, ISO 12085, ISO 13565-2 and

ISO 13565-3. It includes: parameter

estimation, rules for comparison

(areas to be inspected, 16% rule,

max.-rule, uncertainty), parameter

estimation, rules and procedures for

inspection, and a “Simplified

procedure for roughness inspection”.

Numeric values of roughness.

Intended Application Specimen Requirement Limits

Influences chain links 3

and 4 of ISO standards

for roughness and

primary profiles in the

GPS matrix model.

Not specified/applicable. Not useful for

descriptions of surface

defects.
29

ISO 8502

Preparation of Steel Substrates Before Application of Paints and Related

Products – Tests for the Assessment of Surface Cleanliness

Part 1: Field test for soluble iron corrosion products

Part 2: Laboratory determination of chloride on cleaned surfaces

Part 3: Assessment of dust on steel surfaces prepared for painting (pressuresensitive tape method)

Part 4: Guidance on the estimation of the probability of condensation prior to paint

application

Part 5: Measurement of chloride on steel surfaces prepared for painting (ion 

detection tube method)

General Description Data Produced

This comprehensive standard describes

eight methods for the quantitative

determination of surface contaminants

on blast cleaned steel, prior to paint or

other coating application. Both field

and laboratory measurement methods

are included.

Part 1 describes a semi-quantitative

method for analysis of ferrous ions by

swabbing the test surface with water

soaked cotton and analyzing the wash

liquid with an indicator strip.

Part 2 describes a technique for

determination of chloride by water

washing and subsequent titration with

mercury nitrate.

Part 3 describes a method for analysis

of dust contamination by controlled

application of transparent pressure

sensitive tape to the test surface

followed by analysis of the removed

tape for adherent particle size and

quantity, using a hand lens and

comparator charts included in

the standard.

Part 4: Guidance on the estimation of

the probability of condensation prior to

paint application based on relative

humidity and steel surface temperature.

Part 5 describes a field test in which

water-soluble chlorides are washed

from the surface and the wash liquid

analyzed to determine the chloride ion

concentration using a detection tube

containing silver chromate in a sand

carrier. The color change of the tube

contents with immersion in different

known chloride ion concentrations

serves as the calibration for the

field test.

Data collected varies with method but

generally consists of concentration of

contaminant per unit volume which is

converted to contaminant per unit

surface area.
30

ISO 8502, Continued

Preparation of Steel Substrates Before Application of Paints and Related

Products – Tests for the Assessment of Surface Cleanliness

Part 6: Extraction of soluble contaminants for analysis – The Bresle method

Part 8: Field method for the refractometric determination of moisture

Part 9: Field method for the conductometric determination of water-soluble salts

Part 10: Field method for the titimetric determination of water-soluble chloride

Part 12: Field method for the titimetric determination of water-soluble ferrous ions

General Description Data Produced

Part 6 describes the fabrication and use

of an adhesive patch applied to the test

surface into which a suitable solvent for

analysis of the contaminant in question

is injected. The solvent is repeatedly

injected and removed with a syringe and

the solvent subsequently analyzed to

ascertain the contaminant level. The

method is suitable for field use.

Part 8 describes the measurement of

moisture, generally from condensation,

on a surface to which an adhesive patch

described in Part 6 is used to contain a

mixture of monoethylene glycol and

water. The mixture is repeatedly injected

and removed followed by measurement

of the glycol mass fraction in a

refractometer.

Part 9 describes a field test for water

soluble salts using the technique of

Part 6. The change in conductivity of the

test water due to solution of salts from

the surface is measured and used to

calculate the surface density of the

salts.

Part 10 describes a field method in

which the procedure of Part 6 is used to

inject water containing sodium fluoride

and hydrogen fluoride. The water acts

as a solvent for chloride on the surface.

The chloride concentration is

determined by titration with mercuric

nitrate. 

Part 12 describes the use of the

technique in Part 6, or another

appropriate method, to remove

contaminants from the surface and

acidifying the solution with phosphoric

acid. The ferrous ion concentration is

determined by titration with a dichromate

solution.

Data collected varies with method but

generally consists of concentration of

contaminant per unit volume which is

converted to contaminant per unit

surface area.
31

ISO 8502, Continued

Intended Application Specimen Requirement Limits

Intended to determine

whether a mechanically

blast cleaned surface, or

a surface between

coating applications,

meets cleanliness

specifications required to

achieve coating

performance goals.

Not specified. Not specified.

ISO 8785

Geometrical Product Specification (GPS) – Surface Imperfections – Terms,

Definitions and Parameters

General Description Data Produced

This Standard defines terms used to

describe different types of surface

imperfections and includes illustrative

drawings. The document provides a

common vocabulary for use in many

types of technical publications and

drawings. Fifty-five imperfections are

described. Dents, warts and blisters

are typical imperfections described

in English and French.

Not applicable.

Intended Application Specimen Requirement Limits

Technical documents

and specifications.

Not applicable. Defined imperfections

are not related to surface

roughness.
32

ISO 11562

Geometrical Product Specifications (GPS) – Surface tTexture: Profile Method –

Metrological Characteristics of Phase Correct Filters

General Description Data Produced

This Standard specifies the

metrological characteristics of phase

correct filters for measurement of

surface profiles, particularly how to

separate the long and short wave

content of a surface profile. The

document includes definitions of

relevant terms, characteristics of

phase correct profile filters (including

transmission characteristics of long

and short wave profile components),

limits of error of phase correct filters,

and criteria for selection of phase

correct filters. The relation of this

standard to the GPS matrix model

is provided.

Roughness profile.

Intended Application Specimen Requirement Limits

Influences links 2 and 3

in the chains of

standards for primary

profile in the GPS

matrix model.

Not specified/applicable. Not specified.
33

ISO 12085

Geometrical Product Specification (GPS) – Surface Texture: Profile Method –

Motif Parameters

General Description Data Produced

This Standard defines terms used in

the determination of surface texture by

the motif method and the motif

method, including a calculation

method for combination of motifs.

Annexes provide information on the

relation between motif parameters

(roughness profile, waviness profile

and primary profile) and function of

surfaces as well as the relation of the

standard to the GPS matrix model.

Quantifiable roughness profile

representation.

Intended Application Specimen Requirement Limits

Influences links 2, 3 and

4 of the surface texture

chain of standards on

roughness and waviness

profile in the GPS

matrix model.

Not specified/applicable. Not specified.
34

ISO 13565-1 

Geometrical Product Specifications (GPS) – Surface Texture: Profile Method –

Surfaces Having Stratified Functional Properties

Part 1: Filtering and general measurement conditions

General Description Data Produced

This Standard describes a filtering

method for description of surfaces that

have deep valleys underlying a finely

finished plateau with a small amount

of waviness. ISO 11562, by

comparison, describes a reference

line undesirably influenced by the

presence of valleys. ISO 13565-1

provides a filtering approach that

suppresses the valley influence on the

reference line. This Standard

addresses surfaces common in

internal combustion cylinder liners.

The filtering process to determine the

roughness profile, selection of cut-off

wavelength and the evaluation length

and relation to the GPS matrix

model are included.

Quantifiable roughness profile

representation.

Intended Application Specimen Requirement Limits

This Standard influences

links 2 and 3 in the chain

of standards for

roughness profile in the

GPS matrix model. 

Not specified. Not specified.
35

ISO 13565-2

Geometrical Product Specifications (GPS) – Surface Texture: Profile Method –

Surfaces Having Stratified functional Properties

Part 2: Height characterization using the linear material ratio curve

General Description Data Produced

This document defines parameters

based on the linear material ratio

curve for the evaluation of the valley

suppressed roughness profile defined

in ISO 13565-1. The Standard

includes determination of parameters,

covering roughness profile, calculating

equivalent straight line, and

calculation of parameters for

the material ratio curve.

Quantifiable roughness profile

representation.

Intended Application Specimen Requirement Limits

This Standard addresses

chain link 2 for

roughness profile in the

General GPS matrix.

Not specified. Not specified.
36

ISO 13565-3

Geometrical Product Specifications(GPS) – Surface Texture: Profile Method –

Surfaces Having Stratified Functional Properties

Part 3: Height characterization using the material probability curve

General Description Data Produced

This Standard gives a method for

calculation of parameters used to

numerically characterize two

components, a coarse valley texture

and a fine plateau texture, through the

generation of a material probability

curve, determination of its linear

regions and linear regressions

through these regions.

Quantifiable roughness profile

representation.

Intended Application Specimen Requirement Limits

The parameters are

intended to aid in

assessing tribological

behavior of, for example,

lubricated sliding

surfaces and to control

manufacturing

processes.

Not specified. Not specified.
37

SAE J358 

Nondestructive Tests (SAE Information Report)

General Description Data Produced

This Information Report identifies

several techniques and associated

SAE documents applicable for the

detection and in some cases

measurement of, defects which may

be surface related. A table is included

which provides physical principles of

the techniques, appropriate materials

to be inspected, applications,

advantages and limitations. Infrared,

magnetic particle, eddy current,

penetrating radiation, ultrasonic,

acoustic, and leakage techniques

are briefly described.

Not specified.

Intended Application Specimen Requirement Limits

Information purposes. Not specified. Not specified.

SAE J359 

Infrared Testing (SAE Information Report)

General Description Data Produced

This is a very brief description of the

infrared technique for nondestructive

testing. This does not contain

significant detail regarding technique

or capabilities.

Not specified.

Intended Application Specimen Requirement Limits

Information purposes. Not specified. Not specified.
38

SAE J420

Magnetic Particle Inspection (SAE Information Report)

General Description Data Produced

This is a very brief description of the

use of magnetic particle inspection to

nondestructively identify surface and

near surface defects and

discontinuities in ferromagnetic

materials such as iron and steel.This

technique aids in visual inspection and

may be enhanced through the use

of long wavelength ultraviolet light. 

Not specified.

Intended Application Specimen Requirement Limits

Not specified. Not specified. Not specified.

SAE J425

Electromagnetic Testing by Eddy-Current Methods (SAE Information Report)

General Description Data Produced

This Report gives very general

descriptions on the uses of eddy

current testing, a nondestructive

technique, for inspection of surface

defects, principles of operation and

procedures. The Report is not

intended to give detailed guidance.

ASTM Standards and other

documents are identified as sources

of additional information.

Data varies with instrument design

and manufacturer.

Intended Application Specimen Requirement Limits

General information. Surface free of loose

scale and other material.

Hot rolled material with

thin, tight scale – seams

as shallow as 0.25 mm

(0.010 in.) are detected.

Polished (ground)

surfaces- seams and

cracks as shallow as

0.025 mm (0.001 in.)

are detected.
39

SAE J426 

Liquid Penetrant Test Methods (SAE Information Report)

General Description Data Produced

This Report provides a brief

description of the principle of the use

of liquid penetrant inspection. In this

technique, a liquid is applied to a

surface and excess fluid removed and

remaining penetrant trapped in

surface imperfections such as cracks

or pores is detected when a “developer”

is applied. The developer shows the

presence of remaining liquid. Short

descriptions of types of penetrants,

developers and methods of penetrant

removal are provided. Related SAE

and ASTM documents are listed.

Visible indications of surface

discontinuities.

Intended Application Specimen Requirement Limits

General information. Clean parts without paint

or other surface coatings

which can mask

imperfections of interest

on metal or other nonporous materials.

Not specified.
40

SAE J428 

Ultrasonic Inspection (SAE Information Report)

General Description Data Produced

This document provides brief

descriptions of the uses (including

surface discontinuities) of ultrasonic

techniques, principles of operation,

types of tests with limited discussion

of advantages and disadvantages.

Not specified.

Intended Application Specimen Requirement Limits

Not specified. Not specified. Not specified.

SAE J1242 

Acoustic Emission Test Methods (SAE Information Report)

General Description Data Produced

This Report gives brief descriptions of

the operating principle and procedure

for acoustic emission detection and

monitoring of changes such as

crack growth in a material.

Varies with instrument.

Intended Application Specimen Requirement Limits

Provides information on

this nondestructive

technique to determine

whether further

consideration

is warranted.

Not specified. Not specified.
41

SAE AMS 2440A

Inspection of Ground, Chromium Plated Steel Parts 

(Aerospace Material Specification)

General Description Data Produced

This Specification covers the

requirements, procedures, and

acceptance/rejection criteria for

inspecting ground chromium plated

surfaces for grinder induced damage

to the chromium plate substructure.

Examples of damage revealed by

fluorescent dye inspection

are provided.

Visual appearance of cracks when

viewed with black light.

Intended Application Specimen Requirement Limits

Not specified. Specimens should be

temper etch inspected

and magnetic particle

inspected prior to plating.

Ground plated parts are

cleaned and dried to

remove any material that

would interfere with the

inspection.

Inspection shall be

conducted by certified

inspectors (STN-TC-1A,

Level II). Questionable

inspections shall be

resolved by a Level III

penetrant inspector.

Procedure is as specified

in ASTM E-1417. Temper

etch is per AMS 2649

and magnetic particle

inspection is per

ASTM E 1444.
42

4.2 Products (bare and coated)

4.2.1 Fasteners

ASTM F 788/F 788M 

Standard Specification for Surface Discontinuities of Bolts, Screws, and Studs,

Inch and Metric Series

General Description Data Produced

This Specification establishes

allowable limits for various types of

surface discontinuities that result from

manufacture of bolts, nuts screws and

studs. The specification covers metric

series with nominal diameters of 4mm

and greater and minimum tensile

strengths of 800 MPa and inch series

with nominal diameters of No. 5

(0.1250 in.) and larger and with

specified minimum tensile strengths of

90,000 psi and greater. The

Specification describes types of

discontinuities, limits of size and

location permitted, inspection and

evaluation. Inspection is visual with

magnification to 10x allowed.

Visible evidence of surface defects.

Intended Application Specimen Requirement Limits

Intended for

establishment of

purchase specifications.

Not specified. Not specified.
43

ASTM F 812/F 812M

Standard Specification for Surface Discontinuities of Nuts, Inch and Metric

Series

General Description Data Produced

This Specification establishes

allowable limits for various types of

surface discontinuities that result from

manufacture of metric series nuts with

nominal diameters 5 mm and larger

and inch series nuts with nominal

diameters 0.250 inch and larger.

Types of discontinuities are described,

limits on discontinuity size and

location provided, test method

(ASTM F 606) for strength of nuts

specified, visual inspection and

evaluation procedures described.

Visible evidence of surface defects.

Intended Application Specimen Requirement Limits

Intended for

establishment of

purchase specifications.

Not specified. The limits established for

metric nuts with nominal

diameters of 5 mm to

24 mm are essentially

identical to those in

ISO/DIS 6157/II. There

are no ISO standards for

nuts greater than 24 mm.
44

ISO 4042 

Fasteners – Electroplated coatings

General Description Data Produced

This is a broad Standard which

addresses the dimensional requirements

for coating thickness for steel and

copper alloy fasteners and gives

recommendations for hydrogen

embrittlement relief for high tensile

strength or hardness and for surface

hardened fasteners. The following

issues are addressed: dimensional

requirements before and after

electroplating, situations which call for

hydrogen embrittlement relief, corrosion

protection, coating thickness

requirements and measurement.

Ordering requirements and surface

coating designation systems are

identified. Annexes address: hydrogen

embrittlement relief; salt spray corrosion

protection performance; guidance for

procedures to accommodate thick

coatings; determination of batch

average thickness; designation code for

coatings; and, surface areas of bolts,

screws and nuts.

Measured characteristics or

performance required by

specifications.

Intended Application Specimen Requirement Limits

Provides a basis for

description of and

specification of threaded

fasteners coated by

electroplating. It may

also be applied to nonthreaded parts such as

washers and pins.

Varies with property

measured.

Recommended coatings

may be applied to screws

that cut their own threads

(wood screws, self

tapping screws, etc.) with

maximum batch average

thickness given in the

standard ignored unless

otherwise specified.

Hydrogen embrittlement is

a major issue highlighted.

Note is made that

complete elimination of

hydrogen embrittlement

cannot be assured and

alternative procedures to

those in the standard

should be evaluated,

as appropriate.
45

ISO 6157-1

Fasteners – Surface Discontinuities

Part 1: Bolts, screws and studs for general requirements

General Description Data Produced

This Standard details the causes,

appearance and limits for the following

surface discontinuities: quench cracks,

forging cracks, forging bursts, shear

bursts, raw material seams and laps,

voids, folds and tool marks. It applies

to bolts, screws and studs with

nominal thread diameters 5 mm and

larger, product grades A and B and

property classes up to and including

10.9 unless otherwise specified in

product standards or purchasing

agreements.

Varies with technique.

Intended Application Specimen Requirement Limits

Establishes limits for

surface discontinuities.

Product of interest must

be sufficiently clean to

be examined visually or

non-destructively (e.g.,

eddy current or magnetic

method). Secondary

samples examined by

cross-sectioning if first

examination indicates

surface discontinuities.

Limits (size of

discontinuity) vary with

type and size of item.
46

ISO 6157-2

Fasteners – Surface Discontinuities

Part 2: Nuts

General Description Data Produced

This Standard details the causes,

appearance and limits of the following

surface discontinuities: quench cracks,

forging and inclusion cracks, cracks in

the locking element of all – metal

prevailing torque type nuts, cracks in

the washer ring of nuts with captive

washers, shear bursts, bursts, seams,

folds, voids and tool marks. It applies

to nuts with nominal thread diameters

from 5 mm through 39 mm, product

grades A and B and all property

classes according to ISO 898-2 and

ISO 898-6 unless otherwise agreed to

in product standards or

purchasing agreements.

Varies with technique.

Intended Application Specimen Requirement Limits

Establishes limits for

surface discontinuities.

Product of interest shall

be sufficiently clean to

be examined visually at

10x magnification and

with appropriate

nondestructive methods.

ISO 10484, Widening

test on nuts, and ISO

10485, Cone proof load

on nuts are identified as

destructive or referee

tests when necessary.

Limits (size of

discontinuity) vary with

type and size of item.
47

ISO 6157-3

Fasteners – Surface Discontinuities

Part 2: Bolts, screws and studs for special requirements

General Description Data Produced

This Standard details the causes,

appearance and limits of the following

surface discontinuities: quench cracks,

forging cracks, forging bursts for

hexagonal head and circular head

screws, shear bursts for hexagonal

and circular head screws, forging

cracks in socket head screws, raw

material seams and laps, voids, folds,

tool marks, laps on the thread, and

damages. It applies to bolts, screws

and studs with nominal thread

diameters of 5 mm and larger; product

grads A and B, nominal lengths l < 10d;

property class 12.9 or property

classes 8.8, 9.8, 10.9 when so

specified or agreed to in

purchasing agreements.

Varies with technique.

Intended Application Specimen Requirement Limits

Establishes limits for

surface discontinuities.

Surface coating shall be

removed before

inspection by visual or

nondestructive test.

Destructive testing by

sectioning at 90°

through the discontinuity

shall be conducted when

nondestructive or visual

examination indicates

defective products.

Limits (size of

discontinuity) vary with

type and size of item.
48

SAE J121 

Decarburization in Hardened and Tempered Unified Thread Fasteners

(SAE Recommended Practice)

General Description Data Produced

This Recommended Practice

describes measurement classification

and specification of decarburization of

hardened and tempered steel bolts,

screws, studs etc. Microscopic

examination of polished and etched

cross-sections and microhardness

(Knoop 500g, Vickers DPH 300g)

measurements are interpreted with

respect to cross-section

decarburization to establish Class C

and Class D inch series threaded

products. Definitions of degrees

of decarburization are provided.

Microstructure or microhardness

indicative of carbon content changes.

Intended Application Specimen Requirement Limits

Microscopic examination

is intended for inspection

purposes, hardness is

intended or reference

purposes.

Metallographically

prepared cross-sections

of fasteners.

Not intended to cover

steel products which are

carburized to achieve

special properties.
49

SAE J122 

Surface Discontinuities on Nuts (SAE Recommended Practice)

General Description Data Produced

This Practice defines, illustrates and

specifies allowable limits for eight

types of discontinuities on metric

series nuts 6.3 mm to 25 mm and inch

– series nuts 0.250 in. to 1 in. which

are primarily intended for automotive

assemblies. Inspection procedures

and a sampling plan are included.

Varies with inspection technique,

generally visual.

Intended Application Specimen Requirement Limits

General information

and inspection.

Representative

lot samples.

Does not include

sampling requirements.

SAE J123 

Surface Discontinuities on Bolts, Screws, and Studs in Fatigue Applications 

(SAE Recommended Practice)

General Description Data Produced

This document defines, illustrates and

specifies allowable limits for surface

discontinuities (cracks, seams, bursts,

voids, laps, folds, tool marks, nicks

and gouges) in bolts, screws and

studs primarily intended for

automotive applications subjected to

severe dynamic stresses (fatigue)

where high strength fasteners with

fatigue resistance is required.

Sampling plans for visual and

microscopic inspection are appended.

Observable discontinuities which

determine acceptance or rejection of

batch.

Intended Application Specimen Requirement Limits

Intended for visual

inspection of batches of

fasteners, and

metallographic

examination for laps

and seams.

As-manufactured items. Defect limitations are

provided primarily as

location and orientation

specific features.
50

SAE J1061

Surface Discontinuities on General Application Bolts, Screws, and Studs

(SAE Recommended Practice)

General Description Data Produced

This Practice defines, illustrates and

specifies allowable limits for surface

discontinuities on bolts, screws and

threads in sizes through 24 mm or

1 in. in diameter, lengths to 150 mm or

6 in. with minimum specified tensile

strengths of 900 MPa or 120,000 psi

and greater intended for use in

automotive assemblies. Brief

descriptions of inspection and

sampling are included.

Varies with inspection method.

Intended Application Specimen Requirement Limits

General information

and guidance.

Samples representative

of the lot(s) of interest.

Does not include

sampling requirements.
51

4.2.2 Sheet and Structural Steel

ASTM D 4417

Standard Test Methods for Field Measurement of Surface Profile of

Blast-Cleaned Steel

General Description Data Produced

This method describes measurement

of the surface profile of abrasive

cleaned steel using:

a. visual comparison with materials of

known profile depths;

b. measurement of the surface with a

fine pointed probe; 

c. micrometer measurement of a

replica of the surface.

Method (a) is a visual examination

with 5x or 10x optical magnification

and comparison to prepared surfaces.

Method (b) provides a dial gage

reading.

Method (c) provides a micrometer

reading.

Intended Application Specimen Requirement Limits

Specification

acceptance.

Flat, clean surfaces. For 37 μm to 135 μm

peak to height

correlation coefficients

of: 0.75 visual,

0.99 – probe,

0.93 – tape have been

determined. More

extensive descriptions

of repeatability,

reproducibility and

precision are provided.
52

ASTM E 430 

Standard Test Methods for Measurement of Gloss of High-Gloss Surfaces by

Goniophotometry

General Description Data Produced

Two test methods for measuring the

reflection characteristics responsible

for the glossy appearance of high

gloss surfaces are covered. These

methods evaluate surface

characteristics at specular angles of

30° and 20° using commercial

instruments. Details of the apparatus

and sources, other ASTM methods

and guides relevant to the

measurement, calibration standards,

preparation and standardization of the

apparatus, procedure, calculation of

gloss and other parameters, reporting,

precision and bias are included.

Instrument readings of parameters at

various angles and use of these

readings to calculate relevant

characteristics.

Intended Application Specimen Requirement Limits

Measurement of

properties for

automotive, architectural

or other applications to

facilitate different

components to be

specified with matching

glossy appearance.

Originally applied to

bright metals, now

applied to automotive

and other finishes.

Flat and at least 70 mm

(2.75 in.) in the smallest

dimension.

Not suitable for diffuse

finish surfaces or

measurement of color.
53

ASTM E 1418 

Standard Test Methods for Visible Penetrant Examination Using the

Water-Washable Process

General Description Data Produced

This Method describes the use of a

water washable visible penetrant for

detection of surface discontinuities

that are open such as cracks, laps

and isolated pores. The Method can

be used for non-porous metallic and

nonmetallic materials. A liquid

penetrant is applied to a surface,

allowed to enter discontinuities,

washed off with water and a developer

applied to draw remaining penetrant

out. The Method includes descriptions

of reagents and penetrants, procedure,

a flow sheet for the general

procedure, personnel qualification

and requalification requirements.

Visible discontinuities.

Intended Application Specimen Requirement Limits

Used for the production

examination of large

volumes of parts or

structures where the

emphasis is on

productivity.

Surface should be

cleaned of grease, dirt

and loose debris.

Users and suppliers may

require the certification

of examination staff per

identified ASNT, MIL

STD or ANSI

recommended practices.

In some cases test

pieces with real or

simulated discontinuities

of the smallest expected

features may be

required.
54

SAE J810

Classification of Common Surface Imperfections in Sheet Steel 

(SAE Information Report)

General Description Data Produced

This Report provides illustrations of

26 common surface imperfections in

sheet steel which can be seen with

the naked eye. The imperfections are

defined, photographically and

schematically illustrated, and

causes identified.

Not specified.

Intended Application Specimen Requirement Limits

Defect/imperfection

description for purposes

of classification.

Not specified. Not specified.
55

SAE J911

Surface Roughness and Peak Count Measurement of Cold Rolled Steel Sheet 

(SAE Recommended Practice)

General Description Data Produced

This Practice provides guidance on

the measurement of the Roughness

Average (Ra) and Peak Count (PC)

on the surface of cold-rolled steel. The

document relies on ASME B 46.1 for

instrumentation specifics. Definitions,

equipment, test conditions, materials,

procedures and calibration are

included. Technique is stylus based.

Data produced varies with instrument.

Intended Application Specimen Requirement Limits

General information

and guidance.

Specimens

representative of the

material as produced

and removed from an

area at least 50 mm

(2 in.) from the coil edge.

Rolling direction should

be identified and the

sample be flat and

roughly 150 mm (6 in.)

long parallel to the rolling

direction and 100 mm

(4 in.) wide.

The instrument should

be calibrated for average

surface roughness with a

nominal Ra value in the

range, typically, of

0.25 μm to 2.5 μm

(10 μm to 100 μin.).

The standard value for

the peak count level

should be 1.25 μm

(50 μin.) and the

standard filter cutoff

length for average

roughness and peak

count measurements on

cold-rolled steel should

be 0.8 mm (nominally

0.03 in.).
56

SAE AMS 2649B 

Etch Inspection of High Strength Steel Parts

(Aerospace Material Specification)

General Description Data Produced

This Specification establishes the

requirements for detection of

overheating by grinding or machining

of high strength low alloy steel (tensile

strength of 1241 MPa (180 ksi) and

higher) and of carburized material in

the heat treated condition. The

procedure consists of cleaning,

etching and visually inspecting for

color changes/ variations.

Acceptance criteria are included.

Visual indications of overheating.

Intended Application Specimen Requirement Limits

Intended for the

inspection of bare

material and carburized

parts.

Guidance for cleaning,

including Government

documents specifying

chemicals, is provided.

SAE ARP 1923

Qualification and

Certification of Etch

Inspectors are included

by reference.
57

4.2.3 Castings

ASTM A 802/A 802M

Standard Practice for Steel Castings, Surface Acceptance Standards, Visual

Examination

General Description Data Produced

This Practice covers the acceptance

criteria for steel castings using visual

examination and comparing surface

texture, roughness and discontinuities

to Steel Castings Research and Trade

Association graded reference

comparators.

Surface texture, nonmetallic

inclusions, gas porosity, solidification

discontinuities, sand expansion

discontinuities, metal inserts, thermally

cut surfaces, mechanically prepared

surfaces, welded surfaces.

Intended Application Specimen Requirement Limits

Quality control (QC),

specification acceptance.

Not specified. This technique

is qualitative.

ISO 11971

Visual Examination of Surface Quality of Steel Castings

General Description Data Produced

This Standard provides comparisons

of standards prepared by the Bureau

de Normalisation des Industries de la

Founderie (BNIF) and Steel Castings

Research and Trade Association

(SCRATA) for the visual inspection of

surface roughness and surface

discontinuities on steel castings.

Not applicable.

Intended Application Specimen Requirement Limits

Purchase specifications. Not applicable. Qualitative descriptions

of surface roughness are

determined.
58

4.2.4 Other

ISO 14104

Gears – Surface Temper Etch Inspection After Grinding

General Description Data Produced

This Standard describes the cleaners,

etchants and procedures used to

determine and evaluate localized

overheating on ground steel surfaces.

The method is applicable to gears,

shafts, splines and bearings. A surface

temper classification system is

provided which is based on the visual

appearance of the etched surface.

ISO 14104 was prepared by The

American Gear Manufacturers

Association (AGMA) as

ANSI/AGMA 2007-B92.

Visual indication of tempering.

Intended Application Specimen Requirement Limits

Qualitative indication of 

tempering due to surface

grinding suitable for

process control and

purchase specifications.

Debris free degreased

surface.

Not applicable to nitrided

or stainless steels.

Approximately 0.003 mm

of stock is removed

by nitric acid etching

each time the process is

performed and may

require masking of close

tolerance areas. Users

are advised to set their

own reference

standards.
59

ISO 13665

Seamless and Welded Steel Tubes for Pressure Purposes – Magnetic Particle

Inspection of the Tube Body for the Detection of Surface Imperfections

General Description Data Produced

This document specifies requirements

for magnetic particle particle

inspection of seamless and welded

steel tubes according to four different

acceptance levels. The Standard

includes: Method of test, Evaluation of

indications, Acceptance criteria

and Reporting requirements.

Visual indication.

Intended Application Specimen Requirement Limits

Intended to be used to

detect surface

imperfections on outer

surfaces of tubes as

required by product

standards.

Surface should be clean

and free of matter which

would interfere with

indicating particles.

Type and dimension of

imperfections detected

are dependent on tube

manufacturing process

and surface finish.

SAE J349

Detection of Surface Imperfections in Ferrous Rods, Bars, Tubes and Wires 

(SAE Information Report)

General Description Data Produced

This information Report provides a

brief description of techniques for

detecting surface imperfections and

associated SAE documents which

provide more detail. Destructive and

non-destructive methods of measuring

(quantifying) imperfections

are also identified.

Inspection of features which are open

to the surface of ferrous bars, tubes,

wires; including, seams, laps, pits,

scratches, nicks, gouges.

Intended Application Specimen Requirement Limits

Information only. Not specified. Applicable only to

features open to the

surface of the article

inspected.
60

SAE AMS 2633B

Ultrasonic Inspection (Aerospace Material Specification)

General Description Data Produced

This document covers ultrasonic

inspection of tubular, centrifugallycast, corrosion resistant steel

cylinders. Applicable ASTM, MIL-STD,

ANSI, ASNT and ATA documents as

are equipment couplants, reference

standards, procedures, and

QA provisions.

Varies with instrument.

Intended Application Specimen Requirement Limits

Typically used to locate

defects such as cracks,

voids, spongy areas.

OD and ID surfaces

machined to be not

rougher than 3.2 μm

(125 μin.) (per ANSI

B46.1). Surface

discontinuities remaining

after surface preparation

shall not be removed

before ultrasonic

inspection. Surfaces

shall be free of loose

scale, particles, oil,

grease or other foreign

materials.

Not applicable to

austenitic alloys where

grain boundaries may

mask results. Personnel

shall be certified per

MIL-STD-410.
61

SAE AMS 2647B

Fluorescent Penetrant Inspection Aircraft and Engine Component Maintenance

(Aerospace Material Specification)

General Description Data Produced

This specification is an extensive

guide to the inspection of aircraft and

engine components for defects

present at an exposed surface using

fluorescent penetrant(s). The

Specification describes, in detail,

procedures for surface preparation,

cleaning, defect calibration standards,

inspection process, equipment

requirements, quality assurance

provisions, definition of terms, safety,

applicable SAE, ASTM, MIL-STD,

ATA, AIA specifications including

personnel requirements.

Visual signs of defects.

Intended Application Specimen Requirement Limits

Intended for the

detection of defects by

maintenance and

overhaul facilities in the

inspection of aircraft and

engine components and

associated accessories

when fluorescent

penetrant inspection is

specified, but not limited

to such applications.

Comprehensive

guidance is provided for,

primarily, cleaning to

remove contaminants

which can impede

inspection.

Considerations for

coatings and platings

are included.

Defect calibration

standards cover cracks

in the range of 0.38 mm

to 6.35 mm (0.015 in.

to 0.250 in.) in five

size groups.
62

5. Surface Finish Evaluation

5.1 General (bare and coated)

ASTM E 1813

Standard Practice for Measuring and Reporting Probe Tip Shape in Scanning

Probe Microscopy

General Description Data Produced

This Practice provides a method for

measuring the size and shape of a

stylus used in scanning probe

microscopy (see ASTM F 1438, for

example). Sample shapes and probe

characterizers are used for gaining

data required for stylus measurement.

The Practice includes descriptions of

probe and characterizer shapes,

procedure and information on

analytical probe approximations.

Data can be numeric or graphic.

Intended Application Specimen Requirement Limits

Probe shape and

orientation data are

necessary for

determination of which

data can reliably be

extracted from a scan.

Not specified. Precision can be

affected by characterizer

roughness and

instrument factors.
63

ASME B46.1-2002

Surface Texture (Surface Roughness, Waviness, and Lay)

(American National Standard)

General Description Data Produced

ASME B46.1 is a comprehensive

primer on surface texture and has

been updated since its introduction in

1940. The current Standard includes

the following sections: Terms Related

to Surface Texture; Classification of

Instruments for Surface Texture

Measurement; Terminology and

Measurement Procedures for Profiling,

Contact, Skidless Instruments;

Measurement Procedures for Contact,

Skidded Instruments; Measurement

Techniques for Area Averaging;

Nanometer Surface Texture and Step

Height Measurements by Stylus

Profiling Instruments; Nanometer

Surface Roughness as Measured with

Phase Measuring Interferometric

Microscopy; Filtering of Surface

Profiles; Terminology and Procedures

for Evaluation of Surface Textures

Using Fractal Geometry;

Specifications and Procedures for

Precision Reference Specimens; and

Specifications and Procedures for

Roughness Comparison Specimens.

Non-mandatory Appendices A

through I provide valuable

supporting information.

Data produced varies with instrument.

Intended Application Specimen Requirement Limits

Intended to provide a

comprehensive, current

standard for surface

texture measurement.

Surface must be clean of

any material which would

interfere with a

measurement.

Sources of uncertainty

are identified for the

techniques.
64

ISO 4287

Geometrical Product Specifications (GPS) – Surface Texture: Profile Method –

Terms, Definitions and Surface Texture Parameters

General Description Data Produced

This Standard specifies terms,

definitions and parameters for the

determination of surface roughness,

waviness and primary profile by

profiling methods.

Not specified/applicable.

Intended Application Specimen Requirement Limits

This document underlies

other standards which

describe GPS in detail.

Not specified/applicable. Not specified/applicable.

ISO 8501-1

Preparation of Steel Substrates Before Application of Paints and Related

Products – Visual Assessment of Surface Cleanliness

General Description Data Produced

This is an Informative Supplement

which provides photographic

examples of the change of

appearance imparted to steel when

blast-cleaned with different abrasives

to remove rust (Grade C) to

preparation grade Sa3, prior to

painting. Procedure for use of the

comparison photographs is provided.

Visual comparison.

Intended Application Specimen Requirement Limits

Pre-painting inspection. Steel panels. Qualitative analysis.
65

SAE J448a

Surface Texture (SAE Standard)

General Description Data Produced

This document defines terms used in

describing surface texture, establishes

classifications for degrees of

roughness and waviness for lays and

gives symbols indicating surface

characteristics in drawings. 

The document does not specify

surfaces for specific application,

means of processing or any other

surface characteristics such as

luster, appearance, properties

or performance.

Not specified.

Intended Application Specimen Requirement Limits

General information. Not specified. Not specified.

SAE J449a

Surface Texture Control (SAE Recommended Practice)

General Description Data Produced

This Practice describes the use of

control specimens that are used to

facilitate inspection of surfaces

prepared at different geographic

locations. The document is succinct,

giving an outline of steps for control

of surface texture.

Comparison of test pieces with control

samples varies with inspection

method.

Intended Application Specimen Requirement Limits

General information. Roughness and

waviness heights are

identified for specific

control specimens.

Not specified.
66

5.2 Methods for Specific Products and Processes

ASTM F 1438

Standard Practice for Determination of Surface Roughness by Scanning

Tunneling Microscopy for Gas Distribution System Components

General Description Data Produced

This Method defines the analysis of

surface texture using scanning

tunneling microscopy (STM) in air or

inert liquids; includes interferences,

apparatus, sampling, calibration,

conditioning, procedure, calculations,

and interpretation of data. STM is a

non-contact method that can

measure surface features in

the nanometer range.

Primary data from the test method is

graphical.

Intended Application Specimen Requirement Limits

Used where surface

texture is a selection

criteria.

Intended for use on

stainless steel with

surfaces smoother than

Ra = 0.25 μm. Does not

cover steels with an

oxide layer too thick to

permit tunneling.

Repeatability standard

deviation (RSD) for

successive results

obtained by the same

operator in the same

apparatus with the same

sample:

Zmax 39 % RSD

Ra 31 % RSD
67

ISO 8503

Preparation of Steel Substrates Before Application of Paints and Related

Products – Surface Roughness Characteristics of Blast-Cleaned Steel

Substrates

Part 1: Specifications and definitions for ISO surface profile comparators for

the assessment of abrasive blast-cleaned surfaces

General Description Data Produced

ISO 8503 addresses the

characterization of steel surfaces

which have been blast cleaned with

either shot abrasives or grit abrasives

prior to painting or application of other

coatings. Part 1 specifies the

requirements for ISO surface profile

comparators which are intended for

visual or tactile comparison with

blasted steel surfaces. The

comparators are made by forming

positive replicas (of electroformed

nickel, for example) from mild steel

master coupons. Separate

comparators, with four roughnesses

each, are required for shot or grit

blasted surfaces. Nominal

roughnesses for shot blasted

comparators are 25 μm, 40 μm, 70

μm and 100 μm. Nominal

roughnesses for grit blasted

comparators are 25 μm, 60 μm, 100

μm and 150 μm. Test pieces are rated

fine, medium or coarse when matched

to the appropriate comparator.

Not specified.

Intended Application Specimen Requirement Limits

Process control and

specification compliance

on-site before application

of paints or other

coatings.

Comparators should be

treated as an instrument

and maintained in a

clean, grease free

condition.

Supports accompanying

standards and, where

appropriate, may be

used to assess surfaces

cleaned by other types

of blast-cleaning. May

be used on surfaces

not to be painted.
68

ISO 8503

Preparation of Steel Substrates Before Application of Paints and Related

Products – Surface Roughness Characteristics of Blast-Cleaned Steel

Substrates

Part 2: Method for the grading of surface profile of abrasive blast-cleaned

steel – Comparator procedure

General Description Data Produced

Part 2 gives the procedure for

comparing the surface of the test

piece with each of the four blasted

areas on the comparator using visual

technique (hand lens up to 7x)

or tactile technique.

Visual or tactile comparison.

Intended Application Specimen Requirement Limits

Process control and

specification compliance

on site before application

of paints or other

coatings.

Dust and debris

free surface.

Qualitative evaluation of

fine, medium or coarse

roughness.
69

ISO 8503

Preparation of Steel Substrates Before Application of Paints and Related

Products – Surface Roughness Characteristics of Blast-Cleaned Steel

Substrates

Part 3: Method for the calibration of ISO surface profile comparators and for

the determination of surface profile – Focusing microscope procedure

General Description Data Produced

Part 3 addresses the measurement of

surface roughness using a microscope

either directly on the test piece or

replica, or comparator described in

Part 1. The method consists of making

a series of maximum peak-to-valley

measurements by measuring the

distance of microscope stage or

objective lens travel from focus on a

peak to focus on a valley. The

technique requires a microscope with

a graduated vernier scale with a scale

value of not more than 1 μm.

Numerical peak-to-valley values.

Intended Application Specimen Requirement Limits

Calibration of

comparators and test

piece measurement.

Dust and debris free

surface.

The technique is

applicable for

determination of surface

profile within the range

for maximum peak-tovalley of 20 μm to

200 μm. The

microscope’s acceptable

depth of field is 2 μm.
70

ISO 8503

Preparation of Steel Substrates Before Application of Paints and Related

Products – Surface Roughness Characteristics of Blast-Cleaned Steel

Substrates

Part 4: Method for the calibration of ISO surface profile comparators and for

the determination of surface profile – Stylus instrument procedure

General Description Data Produced

Part 4 addresses the measurement of

surface roughness using a stylus with

a diamond tip of radius 5 ± 1μm.

The method is applicable to the

measurement of comparators

(Part 1) or to test pieces or replicas.

Procedures and calculation

are included.

Numerical peak-to-valley values.

Intended Application Specimen Requirement Limits

Calibration of

comparators and test

piece measurement.

Dust and debris free

surface.

Qualitative evaluation of

fine, medium or coarse.
71

ISO 8503

Preparation of Steel Substrates Before Application of Paints and Related

Products – Surface Roughness Characteristics of Blast-Cleaned Steel

Substrates

Part 5: Replica tape method for the determination of the surface profile

General Description Data Produced

Part 5 addresses the use of a replica

tape in measuring surface roughness.

Procedures for use of the tape, and

a micrometer gage, for the

measurement are given.

Numerical peak-to-valley values.

Intended Application Specimen Requirement Limits

For on-site measurement

of surface profiles before

application of paint

or other coatings.

Dust and debris free

surface.

Applicable within the

range of profiles cited

for a given grade or

thickness of replica tape,

typically peak-to-valley

profiles of 20 μm

to 115 μm.
72

6. General Product Quality Standards for Specific Coating Processes

6.1 Anodic Coatings

ISO 7599

Anodizing of Aluminum and its Alloys – General Specifications for Anodic

Coatings on Aluminum

General Description Data Produced

This Standard gives general

specifications for anodic coatings on

aluminum. It defines characteristic

properties, lists test methods (ISO

Standards) for thickness and mass

per unit area, quality of sealing,

appearance and color, corrosion

resistance, resistance to crazing by

deformation, fastness to light and

ultraviolet radiation, light reflection

properties, electrical breakdown

potential, and continuity of the

coating. A classification system for

anodic coatings is provided based

on minimum average thickness

in micrometers.

Varies with property of interest.

Intended Application Specimen Requirement Limits

Intended to provide a

broad inventory of test

methods useful in

specifying a product or

material. The Standard

is applicable mainly to

coatings of aluminum

oxide which are formed

on aluminum by an

electrolytic oxidation

process in which the

aluminum acts as

the anode.

Varies with property

measured.

Not applicable to: 

(a) non-porous coatings

of the barrier type

(b) oxide coatings

intended to prepare the

substrate for subsequent

application of organic

coatings or electrode

position of metals;

(c) “Hard anodized”

coatings where wear

and abrasion resistance

are the primary

characteristics.
73

6.2 Conversion Coatings

ISO 3613

Chromate Conversion Coatings on Zinc, Cadmium, Aluminum-Zinc Alloys and

Zinc-Aluminum Alloys – Test Methods

General Description Data Produced

This Standard gives methods for

determination of: the presence of

colorless chromate conversion

coatings; presence and quantity of

hexavalent chromium and colored

coatings; total chromium content per

unit area; mass per unit area of

colorless and colored coatings,

satisfactory adhesion of chromate

conversion coatings and quality of

chromate coating. The test methods

are generally spot tests or absorption

cell measurement with procedures

and test solution preparation provided.

Adhesion testing is conducted by

rubbing the coating with paper and

examining for evidence of coating

rubbed off. Corrosion resistance is

by ISO 9227-salt spray tests.

Color changes indicate presence of

species of interest or absorption cell

changes for quantitative measures.

Intended Application Specimen Requirement Limits

Provides a basis for

purchase specifications.

Clean grease free

surfaces.

Methods are applicable

to (1) colorless and

colored chromate

conversion coatings

containing tri- and

hexavalent chromium

produced by chemical or

electrochemical

processes and (2) only

to chromate coatings

that are free from any

supplementary coatings

such as oil, water or

solvent-based polymers

or wax. Substances or

procedures are specified

that can be injurious to

health. Adequate safety

precautions are required.
74

ISO 4520

Chromate Conversion Coatings on Electroplated Zinc and Cadmium Coatings

General Description Data Produced

This Standard specifies the

requirements for chromate conversion

coatings on zinc and cadmium

intended to give protection against

corrosion. A method of application

is described in general terms, a

classification/designation system

is provided and requirements for

corrosion resistance based on

classification/ designation.

Adhesion properties are to be

determined by ISO 3613.

Varies with property of interest.

Intended Application Specimen Requirement Limits

Provides a basis for

purchase specifications.

Varies with property

measured.

Finishes for giving

particular colors only or

specifically to improve

paint adhesion are not

covered in this standard.
75

6.3 Galvanized Coatings

ASTM A 896

Standard Practice for Conducting Case Studies on Galvanized Structures

General Description Data Produced

This Practice gives procedures for

conducting case-studies on

permanent galvanized structures.

The document gives

recommendations for visual

inspection, general procedure, data to

be collected and appropriate forms to

be completed. General surveys and

accurate monitoring of thickness are

covered. For accurate measurement,

method B 499 using an electronic

magnetic-flux gage is recommended.

For general surveys, a hand held

magnetic gage using the magnetic

attraction principle in accordance

with ASTM E 376 is identified. 

Coating thickness.

Intended Application Specimen Requirement Limits

Determination of the

condition of galvanized

coatings on buildings,

bridges, industrial and

other structures.

Surfaces clean of debris. Method B 499 can

achieve accuracies of 

± 3 to ± 5% using

commercial instruments.
76

6.4 Electroplated Coatings

ISO 1456

Metallic Coatings – Electrodeposited Coatings of Nickel Plus Chromium and of

Copper Plus Nickel Plus Chromium

General Description Data Produced

This Standard specifies the

requirements for decorative,

electroplated nickel plus chromium,

and copper plus nickel plus chromium

coatings on iron, steel, zinc alloys,

copper and copper alloys and

aluminum and aluminum alloys to

provide an attractive appearance

and enhanced corrosion resistance.

Coating designations which are

appropriate to various service

conditions are given in terms of

thickness and type. Methods of

measurement of cracks and pores

in chromium coatings, ductility of

electrodeposited nickel, and sulfur

content of electrodeposited nickel

are detailed. Other property

measurements are identified by

reference to ISO or ASTM Standards.

Varies with property of interest.

Intended Application Specimen Requirement Limits

Provides a basis for

purchase specifications.

Varies with property

measured.

Does not apply to

surface condition of

substrate metal prior to

coating. Does not apply

to coatings on sheet,

strip or wire in the nonfabricated form or to

threaded fasteners

or coil springs.
77

ISO 1458

Metallic Coatings – Electrodeposited Coatings of Nickel

General Description Data Produced

This Standard gives requirements for

nickel electrodeposited coatings that

are applied to iron, steel, zinc alloys,

copper and copper alloys, aluminum

and aluminum alloys for decorative

and corrosion resistance purposes.

Copper plus nickel coatings applied to

iron, steel and zinc alloys are also

included. Service condition numbers

and coating designations are defined.

Requirements for appearance, local

thickness, adhesion, ductility,

corrosion resistance, stress relief

treatments, hydrogen embrittlement

relief treatments and sampling are

included. ISO thickness measurement

methods are referenced. Ductility is

determined by bending the coated test

piece over a mandrel. Sulfur content

of nickel coatings is determined by

combustion and iodate titrimetry or by

sulfide formation and iodate titrimetry.

Varies with property of interest.

Intended Application Specimen Requirement Limits

Provides a basis for

purchase specifications.

Clean, grease free

surfaces.

The standard does not

specify the surface

condition required by the

substrate prior to

coating, and is not

applicable to coatings on

sheet strip or wire in the

non-fabricated form nor

to threaded fasteners

or coil springs.
78

ISO 2081

Metallic Coatings – Electroplated Coatings of Zinc on Iron or Steel

General Description Data Produced

This Standard specifies requirements

for a range of electroplated coatings

of zinc for the protection of iron and

steel against corrosion in various

service environments. Information

which must be supplied to an

electroplater, a classification code,

heat treatment including hydrogen

embrittlement relief, and simple test

methods for thickness and adhesion

measurement (by hand burnishing)

are provided. Relevant ISO Standards

for specification or measurement

of some properties are cited.

Quantitative measures of coating

thickness are specified. Qualitative

measures of adhesion.

Intended Application Specimen Requirement Limits

Provides a basis for

purchase specifications

including heat treating

requirements before

and after plating.

Base metal surface

requirements are

qualitative. Plated

surfaces should be

free of visible defects.

This Standard does not

apply to: sheet, strip or

wire in the unfabricated

form; close-coiled

springs; other than

protective or decorative

purposes. Surface

condition of base metal

is not specified. The

importance of conversion

coatings is recognized

but those coatings are

described in ISO 4520.
79

ISO 2082

Metallic Coatings – Electroplated Coatings of Cadmium on Iron or Steel

General Description Data Produced

This Standard specifies requirements

for a range of electroplated coatings

of cadmium for the protection of iron

and steel against corrosion in various

service environments. Information

which must be supplied to an

electroplater, a classification code,

heat treatment including hydrogen

embrittlement relief, and simple test

methods for thickness and adhesion

measurement (by hand burnishing)

are provided. Relevant ISO Standards

for specification or measurement of

some properties are cited. This

standard is very similar to ISO 2081.

Quantitative measures of coating

thickness are specified. Qualitative

measures of adhesion.

Intended Application Specimen Requirement Limits

Provides a basis for

purchase specifications

including heat treating

requirements before

and after plating.

Base metal surface

requirements are

qualitative. Plated

surfaces should be

free of visible defects.

This Standard does not

apply to: sheet, strip or

wire in the unfabricated

form; close-coiled

springs; other than

protective or decorative

purposes. Surface

condition of base metal

is not specified.The

importance of conversion

coatings is recognized

but those coatings are

described in ISO 4520.

Purchasers must specify

the classification code

required, not only

ISO 2082.
80

6.5 Diffusion Coatings

ASTM B 874

Standard Specification for Chromium Diffusion Coating Applied by Pack

Cementation Process

General Description Data Produced

This Specification gives requirements

for chromium diffusion of metals by

the pack cementation process. A brief

description of the process, definition

of terms used in the process,

classification by base metal category,

ordering and processing requirements,

test methods and sampling

requirements. Test methods are

referenced for coating thickness

(ASTM C 664, B 487) decarburization

(E 1077), chromium content (E 766).

Varies with property of interest.

Intended Application Specimen Requirement Limits

This Specification can

be used in establishing

specifications for

purchase of coated

materials and

components.

Not specified. Diffusion thickness

requirements are as

follows:

Class I (carbon base)

0.0762 mm*

(0.003 in.) min.

Class II (low alloys)

0.0762 mm

(0.003 in.) min.

Class III (stainless

steels) 0.0508 mm

(0.002 in.) min.

Class IV (nickel base

alloys) 0.0254 mm

(0.001 in.) min.

The outer 15% of the

coating shall contain

20% chromium

by weight.

* SI (metric) units are calculated because the original standard included only customary

units
81

ASTM B 875

Standard Specification for Aluminum Diffusion Coating Applied by Pack

Cementation Process

General Description Data Produced

This Specification gives requirements

for aluminum diffusion of metals by

the pack cementation process. A brief

description of the process, definition

of terms used in the process,

classification by base metal category,

ordering and processing requirements,

test methods and sampling

requirements. Test methods are

referenced for coating thickness

(ASTM C 664, B487), aluminum

content to be measured by beta

backscatter or X-ray fluorescence.

Varies with property of interest.

Intended Application Specimen Requirement Limits

This Specification can

be used in establishing

specifications for

purchase of coated

materials and

components.

Not specified. Diffusion thickness

requirements are as

follows:

Class I (carbon and low

alloy) 0.127 mm*

(0.005 in.) min.

Class II (stainless steels)

0.0762 mm

(0.003 in.) min.

Class III (nickel base

alloys) 0.0254 mm

(0.001 in.) min.

The outer 15% of the

coating shall contain

28% aluminum by

weight, minimum.

* SI (metric) units are calculated because the original standard included only customary

units
82

6.6 Physical Vapor Deposition (PVD)

AMS 2444A

Coating, Titanium Nitride Physical Vapor Deposition

(Aerospace Material Specification)

General Description Data Produced

This document provides requirements

for the application and properties of

titanium nitride coating on metallic

parts applied by physical vapor

deposition. Coatings covered are

divided into three classes:

Class 1 – 1.27 μm to 3.81 μm

(0.00005 in. to 0.00015 in.) thick;

Class 2 – 2.54 μm to 6.10 μm

(0.00010 in. to 0.00024 in.) thick; and,

Class 3 – 6.35 μm to 12.70 μm

(0.00025 in. to 0.00050 in.) thick.

Processing requirements, properties,

quality, quality assurance, preparation

for delivery and surface roughness

suggestions are included. Property

measurement methods are identified

by reference to ASTM Standards,

including: for thickness ASTM B 487,

B 499, B568, E 376, E 1182; for

hardness E 92 and E 384. A

qualitative adhesion test using a tape

pull-off method is described.

Varies with property or characteristic

of interest.

Intended Application Specimen Requirement Limits

Provides information

useful in purchase

specification.

Varies with property or

characteristic of interest.

Useful for identifying

those properties and

characteristics important

to PVD materials and

methods of

measurement.
83

6.7 Thermal Spray

ISO 2063

Metallic and Other Inorganic Coatings – Thermal Spraying – Zinc Aluminum and

Their Alloys

General Description Data Produced

This Standard gives general information

useful to thermal spray materials users.

The standard applies to thermal sprayed

coatings of zinc or aluminum deposited

on iron and steel for corrosion

protection. A classification scheme

for zinc, aluminum or Zn-Al alloy

coatings based on thickness is included.

The standard addresses surface

preparation, extent of thickness

measurement required based on

surface area, measurement method by

reference to ISO 2178 and ISO 1463.

Adhesion testing by a “Grid test”

wherein a hand scribed grid allows

delamination of the coating with tape

pull off, and a “Tensile” method similar

to ASTM C 633, is included.

Measure of coating thickness

and adhesion.

Intended Application Specimen Requirement Limits

Provides some basis for

material specification.

Varies with property

measured.

The standard does not

apply to coatings other

than zinc or aluminum.

Application of aspects of

the standard to other

metals may be adopted by

agreement of interested

parties. The standard

does not apply to repairs

of damaged metal areas.

The method of thermal

spray (plasma, flame, cold

spray, etc) is not specified.

The tensile adhesion test

is not claimed to be

reproducible, requiring the

same operation in the

same facility to

have consistency.
84

MILITARY STANDARD

MIL-STD 1687A(SH) 

Thermal Spray Processes for Naval Ship Machinery Applications

General Description Data Produced

This Standard addresses many

aspects of the deposition of materials

for the repair and corrosion protection

of Naval shipboard machinery.

Evaluation of deposits and

deposit/substrate systems by

metallographic analysis for oxide

and porosity content, bond strength

by ASTM C 633, and bend tests

are identified.

Data varies with test.

Intended Application Specimen Requirement Limits

Intended to provide

guidance for shipboard

machinery repair.

Bend tests are

conducted on nominally

2 in. x 3 in. x 0.50 in.

thick (5.18 cm x 7.62 cm

x 1.17 cm)* panels.

Coating thicknesses are

to be 0.008 ± 0.002 in.

(0.0203 cm ±

0.00508 cm)* unless

otherwise specified by

the manufacturer.

Not specified.

* SI (metric) units are calculated because the original standard included only customary

units
85

6.8 Glass and Enamel Coatings

ASTM C 536 

Standard Test Method for Continuity of Coatings in Glassed Steel Equipment

by Electrical Testing

General Description Data Produced

This method covers the detection of

discontinuities in the glass coating

applied to steel equipment where the

discontinuities would result in early

failure due to chemical attack of the

metal substrate. The test consists of

sweeping the surface of the glass

with a point or brush type probe and

observing discharges between the

probe and the metal substrate. The

metal substrate is connected to the

ground side of a voltage generator,

the probe to the other side.

The voltage used is 5000 V at

2.5 mA and may be from stationary

AC or portable DC. Equipment

suppliers are identified.

A visible and audible spark forms at

discontinuities in the glass coating.

Intended Application Specimen Requirement Limits

The test is applicable to

manufacturing and

inspection testing as

well as field testing.

Clean dry surfaces. The method

is qualitative.
86

ASTM C 537 

Standard Test Method for Reliability of Glass Coatings on Glassed Steel

Reaction Equipment by High Voltage

General Description Data Produced

This Method covers the detection of

discontinuities in the glass coating as

areas of the coating where the glass

may be thin enough to result in

premature failure in service where

highly corrosive conditions can cause

severe damage to the exposed metal

substrate. The test consists of

sweeping the surface of the glass

with a point or brush type probe and

observing discharges between the

probe and the metal substrate.The

metal substrate is connected to the

ground side of a voltage generator,

the probe to the other side. The DC

voltage used is up to 20,000 V

at 2.5 mA. Equipment supplier

is identified.

A visible and audible spark forms at

discontinuities in the glass coating.

Intended Application Specimen Requirement Limits

The test is intended to

provide information

which allows repair

of the coating before

leaving the

manufacturing facility.

Clean dry surfaces. The method is

qualitative. Voltage

levels can be preset

based on desired

minimum thickness of

glass. Testing can create

punctures in the glass

coating when the glass

thickness is insufficient

to withstand the applied

voltage. Those punctures

can be repaired by

additional glass

application before the

equipment leaves the

manufacturing facility.
87

ASTM C 743 

Standard Test Method for Continuity of Porcelain Enamel Coatings

General Description Data Produced

This Method permits the detection of

discontinuities and areas of light

coverage (thin coatings) in porcelain

enamel coatings on metal substrates.

The technique is similar to ASTM

C 536 and ASTM 537 which are

intended for thicker glass coatings.

An AC or DC high voltage discharge

instrument with a continuously

variable output voltage over the range

of at least 0 kV to 4 kV which can be

set to 0.1 kV is required. A calibration

curve of enamel thickness vs.

discharge arcing voltage is

established per Annex A1. A test

probe of 100 mesh wire gauze is

passed over the surface at selected

voltages. An arc between probe and

base metal will occur at

discontinuities, indicating failure.

The test can be used to indicate

presence of defects open to the base

metal and enamel surface, areas of

light coverage, or compliance with

a specification. Procedures are

given and equipment suppliers

are identified.

A visible and audible spark.

Intended Application Specimen Requirement Limits

Material evaluation or

specification compliance.

Clean dry surfaces. Arc formation can be

calibrated to coating

thickness for specific

material and equipment.
88

7. Standards for Measurement of Surface Treatment Depth, Coating

Thickness and Mass

7.1 Surface Treatment Depth

ASTM B 721

Standard Test Method for Microhardness and Case Depth of Powder

Metallurgy (P/M) Parts

General Description Data Produced

This method describes the

measurement of Knoop or Vickers

microhardness on the polished crosssection of a powder metallurgy part,

including the hardened surface, to

develop a hardness vs depth curve

used to define the transition from case

hardened to core material. Case

depth and effective case depth

determinations are described. Method

includes summary of microhardness

and case depth measurements,

surface preparation, procedure

reporting, precision and bias. This is

intended to be a companion to ASTM

Test Method E 384, Test Method

for Microhardness of Materials.

Microhardness as a function of

distance from surface.

Intended Application Specimen Requirement Limits

Measurement of proper

hardness and thickness

of the case to meet

engineering function.

Metallographic specimen

with edge retention and

for densities below

6.6 g/cm3, vacuum

impregnation with resin

or epoxy to support

the structure.

Interlaboratory

measurements of an

unknown sample after

measurement of test

blocks with known

hardnesses were

conducted. For a

laboratory to duplicate

any of the other

laboratories, 95% of the

readings should be

within 5.3 HRC; for six

reading averages,

within 2.2 HRC.
89

ASTM E 1077

Standard Test Methods for Estimating the Depth of Decarburization of Steel

Specimens

General Description Data Produced

This document describes screening

methods, microscopical methods,

microindentation hardness methods

and chemical analysis methods to

determine the depth of decarburization

of steels. Sampling, procedures for

the methods, reporting, precision

and bias are included.

Carbon content as a function of depth

from the surface determined by

chemical analysis, microstructural

change or microhardness change with

depth, both reflecting decarburization.

Intended Application Specimen Requirement Limits

The methods may be

used to qualify material

for shipment, machining

guidance, or to assess

the effect of processing.

Varies with method. For 20 or more

measurements

decarburization depths

can be estimated to

within 0.025 mm

(0.001 in.) with a relative

accuracy of 10% to 20%

with microscopical

methods. Estimates of

total or effective

decarburization by

microindentation at

a given location are

generally accurate within

0.025 mm (0.001 in.).
90

ISO 2639

Steels – Determination and Verification of the Depth of Carburized and

Hardened Cases

General Description Data Produced

This Standard defines case-hardened

depth and gives methods for its

determination. The depth is

determined by measurement of a

hardness gradient on a cross-section

perpendicular to the surface.

Hardness may be measured by

Vickers or Knoop methods, upon

agreement of the parties concerned.

The procedure for determination of

case-hardened depth, verification of

the measurement and reporting

are included.

Microhardness as a function of

distance from the surface.

Intended Application Specimen Requirement Limits

Applicable for

measurement of

carburized and

carbonitrided cases and

parts heat treated to a

final hardness of less

than 450 HV 1 at a

distance of three times

the case hardened depth

from the surface or by

special agreement

between parties.

Polished cross-sections. Case hardened depth is

defined as the

perpendicular depth

between the surface

and the layer having a

Vickers hardness of

550 HV 1 in accordance

with ISO 6507-1 or

equivalent Knoop

hardness in accordance

with ISO 4545.
91

ISO 3754

Steel – Determination of Effective Depth of Hardening After Flame or

Induction Hardening

General Description Data Produced

This Standard defines the effective

depth of flame or induction hardening

by measurement of Vickers hardness

on a polished cross-section

perpendicular to the hardened

surface. Effective depth is defined as

the distance from the surface where

the Vickers hardness under a load of

9.8 N is equal to the “hardness limit”.

The hardness limit is defined as

0.80x minimum surface hardness,

expressed in mm.

Microhardness as a function of

distance from the surface.

Intended Application Specimen Requirement Limits

Suitable for

measurement of

hardness where a crosssection can be removed.

Polished cross-sections. Applies to hardened

layers with a depth

greater than 0.3 mm and

parts which in the

surface hardened

condition, have a

hardness less than the

hardness limit-100 at a

distance 3x the effective

depth of hardening.
92

ISO 4970

Steel – Determination of Total or Effective Thickness of Thin

Surface-Hardened layers

General Description Data Produced

This Standard specifies a

micrographic method and a

microhardness method for measuring

the total effective thickness of

surface-hardened layers less than

0.3 mm in thickness. These layers

may be obtained by mechanical

or thermochemical methods.

Procedures for the micrographic

and microhardness are given in

general terms.

Microhardness as a function of

distance from surface or

microstructural variation resulting

from hardening treatment.

Intended Application Specimen Requirement Limits

Not specified. Metallographic

specimens suitable for

visual microstructural

analysis or

microhardness

measurements.

Not applicable to thin

layers not continuous

with the base metal.

Thicknesses greater

than 0.3 mm are covered

by ISO 2639, SteelDetermination and

verification of the

effective depth of

carburized and hardened

cases, and ISO 3754,

Steel-Determination of

effective depth of

hardening after flame or

induction hardening.
93

SAE J419

Methods of Measuring Decarburization 

(SAE Recommended Practice)

General Description Data Produced

This document describes typical

methods for measurement of the

extent of decarburization (loss of

carbon from the surface) of ferrous

materials. The methods described

are: microscopic examination of the

microstructure of a metallographic

specimen; measurement of hardness,

including cross-section microhardness

traverse, longitudinal traverse and

measurement of file hardness; and

chemical analysis including analysis

of machining chips and electron

microprobe.

Definitions and illustrative micrographs

are included.

Images of microstructure which

illustrate changes due to carbon loss,

hardness measurements which reflect

change in carbon content and

qualatative differences in hardness

manifested by changes in

resistance to filing. 

Intended Application Specimen Requirement Limits

To determine suitablity of

material for intended

purpose, process

evaluation, acceptance

testing.

Metallographic sections

typically normal to the

surface with edge

protection and retention.

Hardness measurements

are made on specimens

hardened by quenching

with minimum

carbon loss.

Accuracy of method

used is dependent on

degree of

decarburization, base

carbon content and

microstructure.

Metallographic and

hardness methods are

inaccurate for small

amounts of

decarburization in high

carbon (above 0.06%),

high hardness steels.
94

SAE J423

Methods of Measuring Case Depth (SAE Standard)

General Description Data Produced

This Standard addresses techniques

of measuring the case depth of

ferrous material. The case is much

harder than the core material as a

result of carburizing, nitriding,

carbonitriding, cyaniding, induction

or flame heating or another process

in which chemical composition or

mechanical properties or both are

affected by the process. Chemical

methods, including analysis of

machining chips or microprobe

analysis of prepared cross-sections,

are described. Mechanical (hardness)

measurements and visual techniques

(observation of cut or fractured and

etched cross-sections) and

microscopic methods are

described in detail.

Information or data relating

composition or hardness to distance

from surface.

Intended Application Specimen Requirement Limits

Specification

acceptance, process

evaluation.

Varies with technique. Case depths measured

by different methods can

vary significantly.
95

SAE ARP 1341

Determining Decarburization and Carburization in Finished Parts of Carbon

and Low-Alloy Steels

(Aerospace Recommended Practice)

General Description Data Produced

This Practice addresses determination

of decarburization and carburization

for heat treated carbon and low-alloy

steel parts other than those case

hardened. The Practice includes

visual inspection of metallographic

specimens and microhardness survey.

ASTM E 3 and E 407 are the

metallographic references. ASTM

E 384 is the microhardness guide.

Criteria for determination of

(1) complete decarburization by

visual examination and (2) total

decarburization (complete plus

partial) by microhardness of

(a) hardened and (b) hardened

and tempered are provided.

Microhardness values determined

from indent traverses perpendicular to

the surface and visual interpretation of

microstructure at 100x.

Intended Application Specimen Requirement Limits

Inspection for

acceptance.

Metallographic

specimens may be

prepared from a part

after complete heat

treatment or from

separate samples

processed with the part,

having identical surface

treatment and from the

same heat, preferably.

Not applicable to raw

material or case

hardened parts.
96

SAE ARP 1820

Chord Method of Evaluating Surface Microstructural Characteristics

(Aerospace Recommended Practice)

General Description Data Produced

This Practice describes a

metallographic preparation technique

in which a simple disc specimen which

has been subjected to the same

treatment as a batch of identical

material is polished on a chord of

its circular cross-section to provide

a magnified cross-section for

microstructural and microhardness

assessment of thin layers of

decarburization and intergranular

oxidation. The Practice is intended for

hardened steel and gives procedures

for hardness assessments for depth

of partial decarburization, severity of

partial decarburization, carburization

and nitriding, and recommended

rejection criteria for the preceeding

conditions as well as depth

of intergranular oxidation.

Microhardness as a function of

distance from surface.

Intended Application Specimen Requirement Limits

It is useful for process

control in heat treatment

of steel parts and may

be useful for evaluation

of plated coatings.

Disc or disc-sector

specimens 3 mm to

6 mm (0.125 in. to

0.250 in.) thick, 6 mm

to 12 mm (0.250 in. to

0.50 in.) radius of same

alloy as parts at issue

with texture of

circumferential surface

approximately 0.8 μm

(32 μin.). Surfaces must

be free of carburization,

nitriding, decarburization

and intergranular

oxidation before use.

Limits (rejection criteria)

are based on achieving,

for high strength steels

(maximum tensile

strength of greater than

1520 MPa (220,000 psi))

optimum fatigue

performance of surfaces

which are shot peened

and for low strength

steels (maximum tensile

strength less than

1520 MPa (220,000 psi))

what is commonly

achievable in modern

protective atmosphere

furnaces.
97

7.2 Coating Thickness

Figure 2. Applicability of Coating Thickness Measuring Methods

Substrates

Coatings

Copper Nickel

Chromium

Autocatalytic

Nickel Zinc

Cadmium GoldPalladium

Magnetic

steel

(including

corrosionresisting

steel)

CM CMA CM CBMA CM BCM BM BM

Nonmagnetic

stainless

steels

CED CMA C CB C BC B B

Copper and

alloys

C only

on

brass

and

Cu-Be

CMA C CB C BC B B

Zinc and

alloys

C MA − − − B B B

Aluminum

and alloys

BC BCMA BC BCB

EA,B

BC BC B B

Magnesium 

and alloys

B BMA B B B B B B

Nickel C − C − C BC B B

Silver B BMA B B B − B −

Glass

sealing

nickelcobalt-iron

alloys UNS

No. K94610

M CMA M CBMA M BM BM BM

Nonmetals BCED BCMA BC BCB BC BC B B

Titanium B BMA BCB BEA,B B B B B

AMethod is sensitive to permeability variations of the coating.

BMethod is sensitive to variations in the phosphorus content of the coating.

CMethod is sensitive to alloy composition.

DMethod is sensitive to conductivity variations of the coating.
98

Figure 2. Applicability of Coating Thickness Measuring Methods (cont’d)

Substrates

Coatings

Rhodium Silver Tin Lead

Tin-Lead

Alloys

NonMetals

Vitreous

and Porcelain

Enamels

Magnetic

steel

(including

corrosionresisting

steel)

BM BCM BCM BCM BC CC M BM M

Nonmagnetic

stainless

steels

B BCED BC BC BC CC BE E

Copper and

alloys

B BC BC BC BC CC BE E

Zinc and

alloys

B B B B BC BE −

Aluminum

and alloys

B BC BC BC BC CC E E

Magnesium 

and alloys

B B B B BC E −

Nickel B BC BC BC BC CC BE −

Silver − − − BC BC BE E

Glass

sealing

nickelcobalt-iron

alloys UNS

No. K94610

BM BM BM BCM BA CC M BM −

Nonmetals B BC BC BC BC CC − −

Titanium B B B B BC BE −

Note: Figure 2, Applicability of Coating Thickness Measuring Methods, is reprinted, with

permission, from ASTM B 659-90(2003) Standard Guide for Measuring Thickness of

Metallic and Inorganic Coatings, copyright ASTM International, 100 Barr Harbor Drive,

West Conshohocken, PA 19428.

Note: B = Beta backsetter; C = Coulometric; E = Eddy current; and M = Magnetic
99

ASTM B 244

Standard Test Method for Measurement of Thickness of Anodic Coatings on

Aluminum and of Other Nonconductive Coatings on Nonmagnetic Basis Metals

with Eddy-Current Instruments

General Description Data Produced

Coating thickness is determined with

an electromagnetic instrument that

measures changes in apparent

impedance of the coil inducing the

eddy currents in the basis metal.

The method is useful for measuring

the thickness of anodic coatings

on aluminum alloys but chemical

conversion coatings are too thin to

be measured with this method.

Includes apparatus, list of instrument

suppliers, factors affecting accuracy,

calibration, procedure, reporting.

Coating thickness.

Intended Application Specimen Requirement Limits

Nondestructive

measurement of

thickness of a

nonconductive coating

on a nonmagnetic

basis metal.

Calibration standard

required.

Uncertainty for a single

measurement of a thin

coating is constant and

independent of coating

thickness and is not less

than 0.5 μm.

For thicknesses greater

than 25 μm, uncertainty

is proportional to coating

thickness.

Coating thickness can be

determined within 10%

or 1 μm, whichever is

greater, of the

true thickness.
100

ASTM B 487

Standard Test Method for Measurement of Metal and Oxide Coating Thickness

by Microscopical Examination of a Cross-Section

General Description Data Produced

Local thickness measurement of

metal and oxide coatings using an

optical microscope on a mounted,

ground and polished cross-section.

Provides factors influencing the

measurement, guidance on

preparation and measurement of

cross-sections, procedure, reporting,

precision and bias.

Numerical value of coating thickness.

Intended Application Specimen Requirement Limits

Suitable for acceptance

testing.

Polished cross-section

through oxide/coating

and substrate. Crosssection perpendicular to

coating, surface flat,

entire width of coating in

focus at magnification

used for measurement,

coating cross-section.

Thickness can be

determined to within

1 μm or 10% whichever

is greater of the actual

coating thickness. The

method is capable of

giving an absolute

measuring accuracy of

0.8 μm and for

thicknesses greater than

25 μm a reasonable

error is of the order

of 5% or better.
101

ASTM B 499

Standard Test Method for Measurement of Coating Thickness by the Magnetic

Method: Nonmagnetic Coatings on Magnetic Basis Metals

General Description Data Produced

The thickness of nonmagnetic

coatings on magnetic substrates is

measured with instruments which

measure the magnetic attraction

between a magnet and the substrate

as influenced by the thickness of

nonmagnetic coatings on magnetic

substrates; or the reluctance of a

magnetic flux path passing through

the coating and the substrate.

Standard includes factors influencing

accuracy, instrument calibration,

procedure, reporting, precision and

bias. Method is nondestructive.

Coating thickness.

Intended Application Specimen Requirement Limits

Suitable for specification

acceptance testing and

SPC/SQC. Method

requires same magnetic

properties in calibration

specimen substrate as

in the test specimen.

Substrate (basis metal)

thickness affects

measurement and is

dependent on specific

instrument. Roughness,

curvature, edge effects

are important.

Measurement

uncertainty may be less

than 10% at 95%

confidence level

consistently. Uncertainty

may be greater for

coating thicknesses

less than 25 μm.
102

ASTM B 504

Standard Test Method for Measurement of Thickness of Metallic Coatings by

the Coulometric Method

General Description Data Produced

The thickness of metallic coatings is

determined by electrochemically

stripping an approximately 0.1 cm2

test area and either calculating the

amount of material removed based on

the amount of electricity used or by

calibration against standards with

known coating thicknesses. Standard

includes factors affecting accuracy,

calibration of instrument, procedure,

precision and bias, electrolytes, and

measurable coating/substrate

combinations suitable for this method.

Coating mass interpreted as coating

thickness.

Intended Application Specimen Requirement Limits

Useful where a small

spot of coating can

be destroyed.

This localized test may

not measure variations in

coating or alloying

between coating

and substrate.

Uncertainty of less than

10% may be achieved.

The uncertainty may be

greater for thicknesses

less than 1 μm or

greater than 50 μm.
103

ASTM B 530

Standard Test Method for Measurement of Coating Thickness by the Magnetic

Method: Electrodeposited Nickel Coatings on Magnetic and Nonmagnetic

Substrates

General Description Data Produced

This is a nondestructive technique

for measuring the thickness of

electrodeposited nickel using the

principle of magnetic attraction for up

to 50 μm for magnetic substrates and

25 μm for nonmagnetic substrates.

Reluctance gage measurements for

coating thicknesses of up to 1 mm

or more can be made on both types

of coating/substrates. Calibration,

procedure, reporting, precision

and bias are included.

Coating thickness as provided on

specific instruments.

Intended Application Specimen Requirement Limits

Specification

acceptance.

The magnetic properties

of the coating and

substrate should be the

same as the instrument

calibration standard.

Uncertainty of less than

10% may be achieved.

The uncertainty may be

greater for thicknesses

less than 25 μm.
104

ASTM B 555

Standard Guide for Measurement of Electrodeposited Metallic Coating

Thickness by the Dropping Test

General Description Data Produced

This is a destructive test which

consists of measuring the time it takes

to dissolve an electroplated surface

with drops of corrosive solution

applied at a constant rate until the

substrate is exposed, assuming the

time is proportional to the coating

thickness. This method is suitable

for an approximate determination.

Includes factors affecting accuracy,

apparatus, reagents and materials,

test solutions for cadmium, zinc, tin

and copper, procedure, computation

of thickness, reproducibility and

accuracy. End point is determined

visually and is operator dependent. 

Time to penetrate through the coating

converted to coating thickness.

Intended Application Specimen Requirement Limits

Approximate

determination of coating

thickness.

A clean surface is

required and calibration

against a specimen of

the same composition to

reduce uncertainty.

Reproducibility for a

single operator is

estimated to be

± 2 drops (equivalent

to 1.2 s) or ± 5%,

whichever is greater.
105

ASTM B 556 

Standard Guide for Measurement of Thin Chromium Coatings by Spot Test

General Description Data Produced

This is a destructive test wherein a

drop of hydrochloric acid is placed

on a thin electrodeposited chromium

coating on nickel or stainless steel

and the time to penetrate the

chromium is measured. The time

to penetrate is proportional to the

thickness of the coating. The method

is not as accurate as ASTM B 504.

The guide includes: test solutions,

preparation of test area, procedure,

calculation of thickness as a

function of temperature.

Time to penetrate the coating

converted to thickness.

Intended Application Specimen Requirement Limits

Approximate

determination of

thickness of decorative

coatings up to 1.2 μm

in thickness.

A clean surface is

required on which a

6 mm diameter ring of

paraffin or wax is formed

to retain the acid.

Accuracy is about ± 20%

for thicknesses up

to 1.2 μm.
106

ASTM B 567 

Standard Test Method for Measurement of Coating Thickness by the Beta

Backscatter Method

General Description Data Produced

This is a nondestructive method

wherein beta particles from a

radioisotope impinge the test piece

through a mask which controls the

area exposed and the back scattered

beta particles are counted and

interpreted as coating thickness. The

area exposed and the back scattered

beta particles are used to measure

the mass of the coating per unit area

which is used to calculate thickness

when the coating density is known.

Metallic and nonmetallic coatings on

metallic and nonmetallic substrates

can be measured when the atomic

numbers of the coating and substrate

differ by at least 5 for most

applications. The test method

includes terminology, summary of the

test method, instrumentation, factors

affecting measurement accuracy,

instrument calibration, referee test,

procedure reporting and

precision and bias.

Coating thickness determined by

calculation from density and measured

backscattered radiation.

Intended Application Specimen Requirement Limits

Suitable for specification

acceptance if mass per

unit area is specified.

Not suitable if thickness

is specified and density

of the coating material

varies or is unknown.

The method is sensitive

to thickness of thin

substrates. Sensitivity is

reflective of saturation

thickness which depends

on energy of the isotope

and density of material.

Coating thickness can

be determined with an

uncertainty of less than

10% at 95% confidence

level.
107

ASTM B 568 

Standard Test Method for Measurement of Coating Thickness by X-ray

Spectrometry

General Description Data Produced

This is a nondestructive technique for

measuring the thickness of metallic

and nonmetallic coatings. Incident

radiation from X-ray tubes or

radioisotopes causes emission of

secondary radions characteristic ofthe

elements comprising the coating and

the substrate. Secondary radiation is

analyzed by wavelength dispersion or

energy dispersion. Measurement of

the intensity of the coating material’s

emission or substrate’s emission and

subsequent absorption by the coating

are compared to standards of the

same material combination. The

method includes: summary of the

method, factors affecting accuracy,

instrument calibration, standardless

techniques, referee test, procedure,

precision and bias.

Coating thickness determined by

X-ray emission or absorption

compared to emission or absorption

of a standard.

Intended Application Specimen Requirement Limits

Measures coating

substrate combinations

not readily measured by

other techniques.

Addresses electroplated

coatings.

Reference materials of

the same density,

composition, voids and

porosity needed.

Coating thicknesses of

0.01 μm to 75 μm can

be measured.

Uncertainty of less than

10% at 95% confidence

level can be determined.

Uncertainty may be

greater than 10% with

coating thicknesses

less than 1 μm.
108

ASTM B 588 

Standard Test Method for Measurement of Thickness of Transparent or Opaque

Coatings by Double-Beam Interference Microscope Technique

General Description Data Produced

This is a nondestructive method for

measuring the thickness of transparent

coatings (e.g., anodic coatings on

aluminum) by use of a double beam

interference microscope. The top

surface of the coating and the substrate

surface are located with white light

interference fringe group(s) and the

elevation difference determined by

counting the number of monochromatic

fringes by which the white light fringes

are displaced. The number of fringes

multiplied by half the light wavelength is

the coating thickness. Opaque coatings

are destructively measured by stripping

the coating and similarly measuring the

number of fringes between surfaces.

The method includes apparatus, sample

preparation for destructive technique,

thickness measurement, accuracy

requirement, precision and bias.

Fringes which are counted and

interpreted as film or coating thickness.

Intended Application Specimen Requirement Limits

Suitable for specification

acceptance.

Surface(s) must be

sufficiently mirrorlike to

form recognizable

fringes.

Transparent coatings 1 μm

to 10 μm can be

measured. Opaque

coatings 0.1 μm to 10 μm

can be stripped and

measured. Transparent

coatings 0.2 μm to 10 μm

can be stripped and

measured. Transparent

coating thickness on a

metal substrate can be

determined either within 

± 0.2 μm or within 5% of

the thickness, whichever is

greater. A metal coating on

a metal substrate can be

determined to either within

0.1 μm or within 5% of the

coating thickness,

whichever is greater.
109

ASTM B 659

Standard Guide for Measuring Thickness of Metallic and Inorganic Coatings

General Description Data Produced

This guide provides a brief overview of

methods for measuring the thickness

of metallic and inorganic coatings

applied by electrodeposition,

mechanical methods, vacuum

deposition, anodic oxide and chemical

conversion which are addressed by

ASTM standards. ASTM standards

and corresponding ISO standards

are referenced. A table showing the

applicability of various coating

thickness measuring methods for

combinations of coating materials

and substrates is included.

Not included.

Intended Application Specimen Requirement Limits

Acceptance testing. Not included. Generally,

measurements with an

uncertainty of less than

10% of the coating

thickness are included.
110

ASTM B 681 

Standard Test Method for Measurement of Anodic Coatings on Aluminum and

Other Transparent Coatings on Opaque Surfaces Using the Light-Section

Microscope

General Description Data Produced

This Method covers a procedure for

the nondestructive measurement of

transparent coatings on reflective,

opaque substrates. A beam of light

(preferably filtered or monochromatic)

approximately 1 μm in width by 1 mm

in length, is reflected off the specimen

surface at an incident angle of 45°.

The displacement between the rays

reflected off the coating surface and

the coating-substrate interface is

related mathematically to the coating

thickness. The method provides

apparatus requirements,

measurement procedure, calibration,

calculations and precision and bias

information. The microscope should

have a magnification range from

100x to 500x, and a filar micrometer

eyepiece capable of measuring object

distances in the range of 1 μm to

40 m with an accuracy of ± 0.2 μm.

Distance between coating surface and

coating-substrate interface used to

calculate coating thickness.

Intended Application Specimen Requirement Limits

Suitable for quality

control and acceptance

testing.

The coating must be

between 2 μm to 40 μm

in thickness and its index

of refraction must be

known. Coating and

substrate must be

sufficiently smooth

and clear.

Single operator

repeatability is ± 0.2 μm.

Reproducibility is

± 0.5 μm by different

operators using different

instruments. Accuracies

of ± 1 μm can be

achieved using the

calibration procedures

specified.
111

ASTM C 664

Standard Test Methods for Thickness of Diffusion Coating

General Description Data Produced

Two test methods are provided.

Method A, determination of

dimensional change thickness,

defined as the difference in thickness

before and after coating utilizes a

machinist’s type micrometer reading

to 0.0025 mm (0.0001 in).

Method B, determination of total

coating thickness, defined as the

distance between the observably

unaffected substrate and the exterior

of the coating, utilizes an optical

microscope to measure features

on a polished cross-section.

Thickness is measured.

Intended Application Specimen Requirement Limits

Quality control and

acceptance testing.

Method A requires a

surface free of debris.

Method B requires a

polished cross-section.

Method A has a

precision of ± 0.005 mm

(0.0002 in.).

Method B has a

precision of ± 0.0025 mm

(0.0001 in.).
112

ASTM E 376

Standard Practice for Measuring Coating Thickness by Magnetic-Field or

Eddy-Current (Electromagnetic) Examination Methods

General Description Data Produced

This Practice is a general description

of the issues pertinent to the use of

magnetic-field or eddy-current

measurement of coating thickness.

Both techniques are non-destructive.

Factors which can interfere with the

measurements are enumerated.

Magnetic gages are designed to

measure thickness of a non-magnetic

coating on a magnetic substrate as

well as nickel on magnetic or nonmagnetic substrates. Eddy current

gages can only be used if the

electrical conductivity of the coating

and substrate differ significantly.

The Practice includes descriptions

of the phenomena on which the

measurements are based, factors

interfering with the measurements,

items which should be agreed upon

by contractual parties using the

methods, calibration and

standardization, procedure, reporting,

precision and bias.

Can vary with instrument but generally

parameter measured is compared to a

standard material.

Intended Application Specimen Requirement Limits

Used in specification

compliance assessment.

Specimens should be

clean and preferably flat.

Detailed specimen

requirements vary with

material combination,

and instrument.

Generally, measurement

should be conducted

such that the coating

thickness can be

determined within ± 10%

of its true thickness or

within ± 2.5 μm or

± 0.0001 in, whichever is

the greater. Qualification/

certification of nondestructive testing (NDT)

personnel may be

required in contractual

agreement.
113

ASTM E 1182

Standard Test Method for Measurement of Surface Layer Thickness by Radial

Sectioning

General Description Data Produced

This Method describes a technique

wherein a cylindrical or spherial tool is

used to grind through the coating into

the substrate. A microscope is used to

measure the dimensions of the crater

at the surface and at the coating/

substrate interface. The measured

properties are used to calculate the

coating thickness.

Measurement of dimensions of

exposed surface edge and

substrate/surface layer interface,

together with dimensions of the

cylinder or sphere used to wear

through the surface layer, are used to

calculate thickness of surface layer.

Intended Application Specimen Requirement Limits

Quality control

measurement, research,

development and

materials acceptance of

surface layers applied for

corrosion, wear

resistance or other

purposes. This method is

used for evaluation of

PVD (physical vapor

deposited) coatings.

Specimen surfaces to be

worn should be

representative of

product. Surfaces should

be cleaned before

testing. Cleaning

solvents should not alter

the coated surface.

Suitable for

measurement of surface

layers 0.05 μm to

200 μm in thickness.

Thicker layers should be

measured by other

methods, e.g., ASTM

B 487. This method shall

not be used for layers

thinner than 0.5 μm if

other suitable methods

are available. Relative

precision decreases with

decreasing layer

thickness. For platings

greater than 12 μm thick,

95% repeatability and

reproducibility become

relatively constant at

± 4 to 5% of the

coating thickness.
114

ISO 1463

Metallic and Oxide Coatings – Measurement of Coating Thickness –

Microscopical Method

General Description Data Produced

This Standard is an excellent guide

to measurement of local thickness

of metallic coatings, oxide layers

and porcelain or vitreous enamel

coatings by use of optical microscopy

and polished cross-sections.

The Standard includes factors

affecting measurement uncertainty,

specimen preparation, measurement

method, reporting, uncertainty, use

of tapered cross-sections and

measurement of tooth-constructed

coatings. Typical etchants and their

application are listed.

Numeric measure of dimensions.

Intended Application Specimen Requirement Limits

Routine analysis. Polished metallographic

specimens.

Appropriate methods will

allow coating thickness

to be measured to within

1 μm or 10%, whichever

is greater, of the actual

coating thickness. 

Absolute measurement

uncertainty of 0.8 μm

possible. Careful

preparation and suitable

instruments give a

capability of

measurement uncertainty

of 0.4 μm under

reproducible conditions.
115

ISO 2128

Anodizing of Aluminum and its Alloys – Determination of Thickness of Anodic

Oxide Coatings – Non-destructive Measurement by Split Beam Microscope

General Description Data Produced

This method consists of using a split

beam microscope which directs

parallel beams of light onto the

transparent coating on a reflective

substrate. Luminous lines from the

coating surface reflection and from the

coating- substrate interface reflection

are observed at the ocular. The

measured distance between the lines

is used to calculate coating thickness.

Distance measured with microscope,

with magnification and refractive index

data used to calculate oxide coating

thickness.

Intended Application Specimen Requirement Limits

Measurement of oxide

coating thickness.

Oxide coating should not

be opaque and the

surface should not be

severely pitted.

Useful for industrial

aluminum oxide coatings

greater than 10 μm thick

or for smooth coatings

greater than 5 μm thick.
116

ISO 2177

Metallic Coatings – Measurement of Coating Thickness – Coulometric Method

by Anodic Dissolution

General Description Data Produced

This Standard describes

measurement of coating thickness by

anodic dissolution of the metallic

coating on

a substrate based on knowledge of

the area being dissolved, current

density, time of dissolution and

integrated quantity of electricity used.

Measurements and calculations are

based on comparison with control

specimens of known thickness in the

same test conditions. The Standard

includes information on suitable

electrolytes, factors affecting

measurement accuracy, procedure,

expression (calculation) of results,

reporting, types of instruments

Electrochemical data used in

calculation of thickness.

Intended Application Specimen Requirement Limits

Routine analysis. Specimens must be

clean of any material

which can interfere with

material dissolution,

including corrosion

products, conversion

coatings and passive

layers.

The method can provide

coating thickness

measurements within

10% of true thickness.

Special equipment is

required for coatings

greater than 50 μm or

less than 0.2 μm. The

method is only

applicable to conductive

coatings.
117

ISO 2178

Nonmagnetic Coatings on Magnetic Substrates – Measurement of Coating

Thickness – Magnetic Method

General Description Data Produced

This Standard specifies the method

for use of commercially available

(generally) instruments which

determine the thickness of nonmagnetic coatings, including enamel,

on magnetic substrates. Instruments

measure either the magnetic attraction

between a permanent magnet (probe)

and the magnetic substrate, as

influenced by the coating thickness,

or the reluctance of a magnetic flux

path passing through the coating and

the substrate. The Standard includes

descriptions of factors affecting

accuracy, instrument calibration

and procedure.

Instrument specific read-out.

Intended Application Specimen Requirement Limits

Nondestructive thickness

measurement, generally.

Specimens should be

generally flat with

measurements not made

near edges or abrupt

changes in surface

contour.

Calibration standards as

similar to the test piece

as practical are desired.

The coating thickness

should be determinable

to within 10% of its true

thickness or to within

1.5 μm, whichever

is greater.
118

ISO 2361

Electrodeposited Nickel Coatings on Magnetic and Nonmagnetic Substrates –

Measurement of Coating Thickness – Magnetic Method

General Description Data Produced

This Standard specifies the method

of use of instruments which measure

the thickness of nickel coatings on

magnetic (Type A) and non-magnetic

(Type B) substrates. Instruments use

either the magnetic attraction between

a permanent magnet and the coating/

substrate combination, or the

reluctance of a flux path passing

through the coating and the substrate.

Factors affecting measurement

accuracy and procedure are included.

Instrument specific.

Intended Application Specimen Requirement Limits

Routine measurement. Test specimens should

be similar to calibration

standards.

Instruments using

magnetic attraction

principle can measure

Type A coatings up to

50 μm thick and Type B

coatings up to 25 μm

thick. Instruments using

the reluctance principle

can measure thicknesses

of Types A and B up to

1 mm. Measurement of

thickness should be

determined to within

10% of true thickness or

within 1.5 μm, whichever

is greater.
119

ISO 3497

Metallic coatings – Measurement of Coating Thickness – X-ray

Spectrometric Methods

General Description Data Produced

This Standard specifies methods for

measuring the thickness of metallic

coatings by the use of spectrographic

techniques which provide mass per

unit area data that is converted to

linear thickness when coating density

is known. Incident radiation from

either radioisotopes or X-ray tubes

impinges the test piece. Secondary

radiation from coating and substrate

is measured and compared to

radiation from calibration standards.

The Standard includes descriptions

of the principles of operation and

apparatus, factors affecting

measurement results, instrument

calibration, measurement procedure,

reporting and ranges of thickness

that can be measured for common

coating materials and substrates.

Instrument specific read-out.

Intended Application Specimen Requirement Limits

Non-destructive

thickness measurements

including the evaluation

of PVD (physical vapor

deposited) coatings.

Standards as similar to

test pieces as practical.

The uncertainty should

be better than 10%.

Measuring ranges for

substrate/coating

systems vary with

measurable thicknesses

generally between 7 μm

(palladium on titanium)

to 60 μm (tin on

copper or nickel).
120

ISO 3543

Metallic and Nonmetallic Coatings – Measurement of Thickness – 

Beta Backscatter Method

General Description Data Produced

This Standard describes the use of

backscattered beta radiation to

measure the thickness of metallic and

nonmetallic coatings on metallic and

nonmetallic substrates. The technique

is appropriate where coating and

substrate have appropriately different

atomic numbers or equivalent atomic

numbers. In that case the intensity of

the backscatter will be between that

of the substrate and the coating and

can be used to determine coating

thickness. Principle of operation,

apparatus description, factors affecting

measurement uncertainty, calibration

and procedure are included.

Varies with instrument.

Intended Application Specimen Requirement Limits

Non-destructive

thickness

measurements,

generally.

Test specimens should

be clean and have

oxides or conversion

coatings removed.

Calibration specimens

should be of same

curvature and

composition and density.

Coating thickness should

be measurable to

within 10% of the

true thickness.
121

ISO 3868

Metallic and Oher Non-Organic Coatings – Measurement of Coating

Thickness – Fizeau Multiple-Beam Interferometry Method

General Description Data Produced

This Standard provides a method for

measurement of the thickness of

highly reflective coatings up to 2 μm in

thickness using Fizeau multiple-beam

interferometry. In this method, a

monochromatic light beam of known

wavelength is reflected back and forth

between the specimen surface, which

includes a step between the substrate

surface and the exposed (top) coating

surface, and a superimposed

transparent mirror (Fizeau plate). An

interference fringe pattern is formed

in the air wedge between the slightly

inclined plate and the specimen

surface. The fringe spacing and shape

are viewed and measured through a

microscope with a filar micrometer

eyepiece to calculate the step height

between the exposed surfaces.

The Standard includes factors

affecting the measurement accuracy

and measurement procedure.

Instrument calibration is not required.

Micrometer eyepiece measurements

of a visual image of interference

fringes.

Intended Application Specimen Requirement Limits

Accurate measurement

where a portion of the

coating can be removed

or a portion of the

substrate not coated.

Clean, relatively flat

and smooth specimens. 

A highly reflective

coating of aluminum or

silver on the test piece

may be required.

The technique provides

an absolute measure of

the vertical surface

variation ranging from

0.002 μm to 2 μm.

Precision is normally

± 0.001 μm in the range

0.002 μm to 0.01 μm

using the fringe-line

width method, and

normally ± 0.003 μm

in the 0.01 μm to

2 μm range.
122

ISO 4518

Metallic coatings – Measurement of Coating Thickness – Profilometric Method

General Description Data Produced

This Standard specifies a method for

the measurement of metal coating

thickness by the measurement of the

step height from the exterior surface

of the coating to the surface of the

substrate which has been revealed by

removal of the coating or masking

during coating deposition. Step height

is measured by use of an electronic

stylus instrument, a type generally

used to measure surface roughness,

or by use of an electronic inductive

comparator equipped with styli.

The Standard provides: operational

instrument, factors affecting accuracy,

calibration requirements, and

measurement procedure.

Instrument generated coating

thickness and edge build-up

readings.

Intended Application Specimen Requirement Limits

Accurate measurement

where a portion of the

coating can be removed

or masked. This method

is used for the evaluation

of PVD (physical vapor

deposited) coatings.

Clean relatively flat well

prepared step.

Preferably, four well

defined circles are

prepared by coating

removal within a 1 cm

by 1 cm square. If a

portion of the substrate

is masked prior to

coating, the area for

measurement shall be

sufficiently small (1 mm

to 2 mm diameter) to

preclude edge build-up.

The measurement

should be determinable

to within 10% or

± 0.005 μm, whichever is

greater. Electronic stylus

instruments cover a

thickness range of

0.005 μm to 250 μm.

Electronic inductive

comparators cover

the range of 1 μm

to 1000 μm.
123

ISO 4522-1

Metallic Coatings – Test Methods for Electrodeposited Silver and Silver

Alloy Coatings

Part 1: Determination of coating thickness

General Description Data Produced

This brief Standard lists techniques

for gravimetric and chemical analysis

methods of determination of thickness

of silver coatings. Microscopical

method (ISO 1463), Coulometric

method (ISO 2177), magnetic method

(ISO 2178), X-ray spectrometric

method (ISO 3497), Beta backscatter

method (ISO 4543), Interferometric

method (ISO 3868) and Profilometric

method (ISO 4518) are identified

for reference.

Calculation from mass measurements

for gravimetric and chemical methods.

Intended Application Specimen Requirement Limits

Measurement of

thickness of coatings for

engineering, decorative

or protective purposes.

Varies with technique. Not specified.
124

ISO 2064

Metallic and Other Inorganic Coatings – Definitions and Conventions

Concerning the Measurement of Thickness

General Description Data Produced

This Standard defines what is meant

by the term “minimum thickness”

when used in specifications for

metallic and related coatings;

specifically, it is defined as a local

thickness over a small area. It also

specifies some general rules to be

followed in the measurement of

minimum thickness of coatings.

Not specified.

Intended Application Specimen Requirement Limits

Clarification of terms

used in specifications.

Not specified. Articles with less than

1 cm2 of significant

surfaces shall have the

number of single

measurements made

agreed upon by the

parties concerned.

Articles with more than

1 cm2 of significant

surfaces shall have up

to five distributed

measurements made

in this reference area,

and the number of

measurements shall

be agreed upon by

the parties concerned.
125

7.3 Coating Mass

ASTM A 90/A 90M

Standard Test Method for Weight (Mass) of Coating on Steel Articles with Zinc

or Zinc-Alloy Coatings

General Description Data Produced

This Method details procedures for

acidic dissolution of zinc and its alloys

from steel products with mass/area

determined by mass difference.

The Method includes reagents,

hazards, sampling, procedure,

calculation and reporting.

Coating mass per unit area.

Intended Application Specimen Requirement Limits

Comparison with

specification

requirements.

Sheet- 3330 mm2

(5.08 in.2)

wire- 305 mm to 609 mm

(12 in. to 24 in.) in

length;

other articles- 2000 mm2

(3 in.2) minimum;

threaded articles- portion

without thread.

Repeatability=

15.24 g/m2 (0.049 oz/ft2)*

Reproducibility=

18.66 g/m2 (0.06 oz/ft2)*

precision not

determined.

* SI (metric) units are calculated because the original standard included only customary

units
126

ASTM A 309

Standard Test Method for Weight and Composition of Coating on Terne Sheet

by the Triple Spot Test

General Description Data Produced

This Method describes methods for

determining the mass and tin content

of terne (80% Pb, 20% Sn) on steel

sheet using three acids for stripping

the coating. The method includes

procedures, reagents, and chemical

analysis for stripping with sulfuric acid,

electrolytic stripping with hydrochloric

acid and sodium hydroxide, silver

nitrate, hydrochloric acid and

antimony trichloride, hydrobromic

acid-bromine solution.

Coating mass per unit area, percent

tin in coating.

Intended Application Specimen Requirement Limits

Comparison with

specification

requirements.

Specimens not less than

2000 mm2 (3 in.2)

in area.

The sulfuric acid

technique is not

recommended for tin

determination but yields

coating weights which

agree to within

3.11 g/m2 (0.01 oz./ft.2)*

between replicate

samples and between

laboratories. The HCl

and antimony trichloride

method yields a coating

weight which agrees to

within 3.11 g/m2 

(0.01 oz./ft.2)* between

laboratories and

between replicate

specimens. Tin values

are found to be within

3% for the hydrobromic

acid-bromine solution

method.

* SI (metric) units are calculated because the original standard included only customary

units
127

ASTM A 428/A 428M 

Standard test Method for Weight (Mass) of Coating on Aluminum Coated Iron

or Steel Articles

General Description Data Produced

This Method describes techniques for

chemical stripping of aluminum from

iron and steel with mass of coating

determined by mass difference. The

Method includes details on reagents,

procedure calculation, sampling

and reporting.

Coating mass per unit area.

Intended Application Specimen Requirement Limits

Comparison with

specification

requirements.

Sheet- 2000 mm2 (3 in.2)

minimum;

Wire- 300 mm (12 in.)

minimum; 

Other articles- 2000 mm2

(3 in.2);

Threaded articlesportion without thread.

Repeatability=

9.5 g/m2 (0.031 oz/ft2)

for sheet

Reproducibility=

10.4 g.m2 (0.034 oz/ft2)

for sheet

Precision not determined.
128

ASTM A 630 

Standard Test Methods for Determination of Tin Coating Weights for

Electrolytic Tin Plate

General Description Data Produced

This document describes four

methods for the determination of tin

coating weights for electrolytic tin

plate. The methods remove the tin,

and/or its alloys by electrolytic or acid

dissolution. The four methods are:

A. Bendix Test Method which

determines tin coating weights on

steel plate by dissolution of tin from

a tin plate anode in a dilute HCl

solution. B. Constant Current,

Electrolytic Method referee method)

may be used to determine not only the

total tin coating weight but also that

part which is free tin and that which is

alloyed by stripping the tin anodically

at constant current in HCl electrolyte.

C. Stellar’s Method determines the

total weight of tin carried by a unit

area of tin plate by dissolution in HCl.

D. Titration Method determines tin

coating weight by dissolution of tin

in HCl which is hastened by placing

the sample in a platinum basket.

Procedures, reagents and calculations

for each method are provided.

Data produced varies with method.

Methods A, C, D require titration and

calculation of mass of dissolved tin.

Method B requires measurement of

time required for stripping at constant

current used to calculate mass.

Intended Application Specimen Requirement Limits

Specification

conformance and

process control.

Sheet samples:

Method A- disks

57.33 ± 0.02 mm

(2.257 ± 0.001 in.) in

diameter; Method BWilley & Kunze

procedure, same as

Method A; Stannomatic

procedure, disk at least

5.08 cm (1.50 in.) in

diameter; Method C- test

specimen area of

25.807 cm2 (4 in.2);

commonly used Method

D is same as Method A.

Methods have different

reported limits,

precluding comparison.
129

A 754/A 754M 

Standard Test Method for Coating Weight (Mass) of Metallic Coatings on Steel

by X-ray Fluoresence

General Description Data Produced

This Method covers the use of X-ray

fluoresence for on-line measurement

of mass of Sn, Zn, Al-Zn coatings

on steel sheet using X-ray tubes

and isotopes and includes: basic

principle, factors affecting accuracy

calibration, procedure.

Coating mass per unit area.

Intended Application Specimen Requirement Limits

On-line measurement of

coatings on continuous

production lines using

direct measurement of

intensity of fluoresecent

X-rays emitted by the

coating or attenuation of

fluorescent X-rays

emitted by the coating as

they pass through the

coating. This method is

used for evaluation of

PVD (physical vapor

deposited) coatings.

On-line processing. Requires calibration

curve of same materials,

adequate counting

time,ability of detector to

discriminate between

coating and substrate

signals.
130

ASTM B 137

Standard Test Method for Measurement of Coating Mass Per Unit Area on

Anodically Coated Aluminum

General Description Data Produced

This Method details the destructive

determination of the mass of anodic

coating on aluminum and its alloys.

The method consists of disolving the

coating from a known surface area

in a phosphoric-chromic acid

solution maintained at 100 °C

and measuring the weight loss.

Coating mass per unit area.

Intended Application Specimen Requirement Limits

Suitable for quality

control since the mass is

an approximation of

coating thickness when

the density of the

coating is known.

Clean surface about

75 mm square.

Uncertainty of less

than 10% possible.
131

ASTM B 767

Standard Guide for Determining Mass Per Unit Area of Electrodeposited and

Related Coatings by Gravimetric and Other Chemical Analysis Procedures

General Description Data Produced

This guide describes the general

method(s) for determining mass per

unit area of coatings which can be

removed from substrates. This is

not appropriate for thin coatings over

small areas. Method consists of

weighing sample before and after

removing coating and measuring area

from which coating is removed.

Guide includes apparatus, specimen

preparation, measurement of coated

area, gravimetric determination,

procedure and extensive list of

reagents for removal of metal layers.

Mass and area used to calculate

average mass per unit area.

Intended Application Specimen Requirement Limits

Acceptance testing. Specimens with sufficient

mass and area which

can be measured to give

adequate accuracy.

Procedures cannot be

used when coating

cannot be separated

from the substrate.
132

ASTM D 5723

Standard Practice for Determination of Chromium Treatment Weight on Metal

Substrates by X-ray Fluorescence

General Description Data Produced

This document describes the use of

X-ray fluorescence to determine the

weight of chromium coating on metal

substrates. The method consists of

exposing the sample to primary

radiation which causes the chromium

in the coating to fluoresce. The

fluorescence (secondary) radiation

intensity is a quantitative measure of

the mass of chromium. The measured

intensity of the secondary radiation

is compared to that obtained from

calibration samples of known mass

per unit area. The calibration samples

should span the expected values to

be measured. A commercial

instrument supplier is identified, as

are sources of calibration standards.

Chromium fluorescence intensity

readings which are used to calculate

coating weight.

Intended Application Specimen Requirement Limits

Generally, intended for

determination of coating

weight of chromium

treatments on metal

substrates.

Flat, clean specimens. Not specified.
133

ASTM E 1659

Standard Test Methods for Coating Weight and Chemical Analysis of

Zinc-Nickel Alloy Electrolytically Coated on Steel Sheet

General Description Data Produced

Methods are described for

determination of mass and nickel

content for zinc-nickel coatings on

steel. A gravimetric method where the

coating is removed with hydrochloric

acid is given for coating masses from

20 g/m2 to 45 g/m2. Atomic absorption

spectrometry analysis is conducted on

the solution used in the gravimetric

test and results compared with data

from a standard solution to determine

nickel concentrations from

11.0% to 13.5%.

Measurement of mass and instrument

data. 

Intended Application Specimen Requirement Limits

These are intended to be

referee methods for

specification compliance

testing.

Test pieces should be

obtained in accordance

with ASTM A 917. Test

specimens are 50 mm 

± 5 mm squares. One

specimen is required for

each side to be tested.

Multi-laboratory

comparisons of

gravimetric method for

20 g/m2 coating showed

a 2 standard deviation of

0.337 g/m2; 30 g/m2

showed a 2 standard

deviation value of

2.074 g/m2. Nickel

analysis on 20 g/m2

material showed a 2

standard deviation value

of 0.081% for an

average 11.34% nickel

material; 30 g/m2

showed a 2 standard

deviation of 0.141% for

an 11.76% average

nickel content.
134

ISO 2106

Anodizing of Aluminum and its Alloys – Determination of Mass per Unit Area

(Surface Density) of Anodic Oxide Coatings – Gravimetric Method

General Description Data Produced

This destructive method of

determination of anodized mass

consists of dissolving the anodized

coating from the substrate using a

mixture of phosphoric acid and

chromium trioxide at 100 °C for at

least 10 min and weighing the sample

before and after removal.

Mass per unit area.

Intended Application Specimen Requirement Limits

Coating thickness can be

calculated if density is

known. Coating density

can be calculated if

thickness is known.

Coating must be free of

oil and grease. Mass

should not exceed

100 g. Area should be

between 0.08 dm2 and

1 dm2.

Suitable for most

aluminum alloys except

those with copper

contents greater than

6%. Estimation of

thickness is more

accurate for coatings of

10 μm and less

in thickness.
135

ISO 3892

Conversion Coatings on Metallic Materials – Determination of Coating Mass

per Unit Area – Gravimetric Methods

General Description Data Produced

This Standard specifies gravimetric

methods for determination of mass

per unit area for: phosphate coatings

on iron and steel; phosphate coatings

on zinc and cadmium; phosphate

coatings on aluminum and its alloys;

chromate coatings on zinc and

cadmium; and, chromate coatings on

aluminum and its alloys. Reagents for

dissolution of coatings, specimen

surface areas required for adequate

accuracy, procedures and safety

warnings are provided.

Measured mass loss due to coating

dissolution and measured surface

area are used to calculate coating

mass per unit area.

Intended Application Specimen Requirement Limits

Determination of

conformity to product

specification.

Test pieces should have

a maximum mass of

200 g. Total surface

areas should be between

400 cm2 for expected

coating mass per unit

area of less than 1 g/m2

and 25 cm2 for expected

coating mass per unit

area of greater

than 50 g/m2.

Under optimum

conditions, the

measurement

uncertainty of the

methods is within 5%.

The methods do not

indicate the presence of

bare spots or sites with

thicknesses less than

specified. The values

obtained are mean

thicknesses over the

measured area.

The methods are

applicable to coatings

free of supplementary

coatings such as oil,

water or solvent-based

polymers, or wax.
136

8. Standards for Analysis of Microstructure

8.1 Metallography

ASTM B 797

Standard Test Method for Surface Finger Penetration Depth of Interparticle

Oxide Networks in Powder Forged (P/F) Steel Parts

General Description Data Produced

This Method describes the

metallographic examination of a

cross-section of the surface and

interior of powder forged steel parts.

Surface finger oxide penetration is

measured at 400x on polished but

unetched specimens. Interparticle

oxide network concentration is

measured at 200x to 400x on polished

and unetched specimens. The Method

includes sampling, procedure,

examples of metallographically

prepared oxide finger penetration

and oxide network concentration,

and reporting.

Metallographic images.

Intended Application Specimen Requirement Limits

Oxide finger penetration

and interparticle oxide

networks are used to

evaluate processing.

Results of tests may be

used to qualify parts.

Specimens should be

from each critical area

on a part. Polished

surfaces shall be parallel

to the forging direction.

Edge rounding is

to be avoided.

Not specified.
137

ASTM E 3

Standard Guide for Preparation of Metallographic Specimens 

General Description Data Produced

This Guide provides general

guidelines for preparation of

specimens for metallographic

examination of structure. It provides

guidance for coated materials and

identifies other pertinent ASTM

standards. The Guide includes

specimen selection, size and cutting;

cleaning and mounting; edge retention

methods; grinding and polishing;

procedures for porous or otherwise

unusual materials.

Visual image of microstructure.

Intended Application Specimen Requirement Limits

Study of structure and

composition of metals

and alloys by light or

electron microscopy.

Varies with subject of

analysis.

Not specified.
138

ASTM E 562

Standard Test Method for Determining Volume Fraction by Systematic Manual

Point Count

General Description Data Produced

This Method describes how to

manually count points in a polished

microstructure to enable the statistical

estimation of the volume fraction of

an identifiable constituent or phase.

Point grids are provided and the

procedure for using these grids or

eyepiece reticle. The Method includes

description of apparatus (including

grid configurations), sample selection

and preparation, procedure,

calculation of volume percentage

estimate and percent relative

accuracy, reporting,

precision and bias.

Count of grid points which can be

used to calculate volume fraction.

Intended Application Specimen Requirement Limits

Quantitative analysis

of microstructure.

Polished, opaque crosssection.Precision and relative

accuracy are a function

of the procedure

including sample

preparation, point

density of the grid,

magnification used and

calculation methods.
139

ASTM E 1920

Standard Guide for Metallographic Preparation of Thermal Sprayed Coatings

General Description Data Produced

This Guide provides guidance for

the preparation of thermal sprayed

coatings. The Guide is general and

does not address specific coating

or substrate materials. Selection of

specimens, sectioning, cleaning,

mounting, grinding, polishing and

reporting are included. Microstructural

features which this guide addresses

include: unmelted particles, linear

detachment, porosity, contamination,

coating thickness, interfacial

contamination and integrity.

Visual image of the microstructure.

Intended Application Specimen Requirement Limits

Evaluation to ensure

coating integrity and

adherence to substrate.

Specimens to be

mounted should be no

larger than 12 mm x

25 mm (0.50 in. x 1.0 in.)

Quantitative analysis can

be influenced by

preparation technique.
140

ISO 3057

Non-Destructive Testing – Metallographic Replica Techniques of Surface

Examination

General Description Data Produced

This Standard specifies techniques

of surface examination in which

transparent nitrocellulose varnish

or plastic material is used to record

metallurgical and mechanical in

homogeneities in a metal surface.

The Standard includes surface

preparation, including metallographic

preparation techniques, application of

the replicate, removal of the replicate,

mounting and examination.

Visual information.

Intended Application Specimen Requirement Limits

Analysis of

metallographic, fracture

and service effected

surfaces where access

is restricted.

Surface must be clean,

degreased and dry.

Not specified.
141

8.2 Porosity and Defect Measurement of Coatings

ASTM B 735

Standard Test Method for Porosity in Gold Coatings on Metal Substrates by

Nitric Acid Vapor

General Description Data Produced

This Method provides a means of

determining the amount of porosity in

gold coatings on electrical contacts.

It is a severe, destructive test,

applicable to curved surfaces.

Test materials are suspended in

a closed container which is at low

relative humidity (60% max) and

above a container of nitric acid.

Adequate specimen exposure to

nitric acid for times of over an hour,

depending on gold thickness, is

followed by oven drying and counting

corrosion product sites using 10x

magnification. Corrosion products are

the result of nitric acid fume reaction

with copper, nickel or their alloys

used as substrates.

Number of corrosion sites in a given

surface area for coatings less than

0.6 μm (25 μin.) in thickness. Gives

quantitative descriptions of pore

density up to about 100/cm2. 

Intended Application Specimen Requirement Limits

Designed to show if

porosity level is greater

or less than a value

considered acceptable

for a specific application.

Clean and dry complex

shapes are acceptable.

The test is too severe for

use on coatings less

than 0.6 μm (25 μin.) in

thickness. Not suitable

for coatings less noble

than gold or platinum,

such as palladium and

its alloys or gold-flashed

palladium or its alloys.

Not intended for

prediction of electrical

performance of contacts

unless correlation with

service performance is

established.

Tested parts are not to

be put into service.
142

ASTM B 741

Standard Test Method for Porosity in Gold Coatings on Metal Substrates by

Paper Electrography 

General Description Data Produced

This Method describes a technique

for determining the porosity of gold

coatings on electrical contacts which

are made of copper, nickel, or their

alloys. The test consists of pressing

dye transfer paper which has been

saturated with an appropriate

electrolyte against the test piece and

applying a low voltage across the

paper, coating and substrate.

Products of the reaction between the

substrate and the electrolyte, through

pores in the coating, stain the paper.

The test takes about one minute.

Procedures for preparing the

electrolyte are given. Reaction stains

on the paper are counted using 10x

magnification. Highly sensitive.

Indicated spots per unit area or

per contact. 

Intended Application Specimen Requirement Limits

Intended to show

whether the porosity

level is greater than a

level, which by

experience, is deemed

acceptable.

Clean and dry and

generally flat or gently

curved surfaces.

Intended to be

quantitative for pore

densities up to about

100/cm2; qualitative

above this level. Test is

destructive; specimens

should not be put

into service.
143

ASTM B 765 

Standard Guide for Selection of Porosity Tests for Electrodeposits and Related

Metallic Coatings

General Description Data Produced

This Guide provides general

information on ASTM Standards for

the detection, identification and

measurement of porosity. The tests

consist of exposing coated materials

to corrosive environments where

reaction of the corrodant with the

substrate (basis metal or interlayer)

through intrinsic porosity or gross

defects or mechanical damage in the

coating produces a corrosion product

at the defect site. Some of the

products occur on the coating and

others on a gel or paper coating.

Visual inspection is by unaided

eye or by 10x microscopy.

Visual indication of defect in coating. 

Intended Application Specimen Requirement Limits

Process control or

assessment of protection

afforded by the coating.

Intrinsic porosity test

methods apply to

coatings of gold, silver,

nickel, tin-nickel, tin, tinlead, copper, palladium

and chromium on

substrates of copper and

its alloys, nickel, iron or

steel and silver; although

not all coatings on all

substrates. Tests for

gross defects and

mechanical damage

apply to coatings of gold,

nickel, tin-nickel, tin, tinlead, palladium and

silver on copper and its

alloys, nickel, iron or

steel and aluminum;

although not all coatings

on all substrates.

Varies with method,

generally.

Clean surfaces.

Does not apply to

thermal sprayed,

sputtered, ion

bombardment or

processes where

particles are discretely

deposited on a

substrate.

Does not apply to

coatings with controlled

porosity.
144

ASTM B 798

Standard Test Method for Porosity in Gold or Palladium Coatings on Metal

Substrates by Gel-Bulk Electrography

General Description Data Produced

This Method is an electrographic

technique wherein the test piece is

made the anode in a cell containing

a semisolid electrolyte of gelatin,

conducting salts and an indicator.

Application of current causes

substrate metal ions to pass through

continuous pores in the coating.

Cation reaction with the indicator

produces a colored reaction productat

pore sites. Individual sites are counted

using low power magnification through

the clear gel in the cell. The test is

suitable for gold coatings on silver,

nickel, or copper and its alloys and

palladium on nickel, copper and its

alloys. The test procedure includes

electrolyte preparation. The test is

conducted for 20 s at a current

density of 0.78 mA/cm2 (5 mA/in.2),

2.0 V to 2.5 V, at 23 °C.

Count of pores per unit area or

per contact. 

Intended Application Specimen Requirement Limits

Intended for the

inspection of electrical

contacts by providing a

quantitative description

of porosity as number

of pores per unit area

or per contact.

Clean specimens free of

debris.

This is a destructive test.

Tested parts may not be

used in service. Not

sensitive to small pores.

Useful for pore densities

up to about 25/cm2.
145

ASTM B 799

Standard Test Method for Porosity in Gold and Palladium Coatings by

Sulfurous Acid/Sulfur-Dioxide Vapor

General Description Data Produced

This is a destructive test wherein test

pieces are exposed to sulfur dioxide

emitted from sulfurous acid above

which the pieces are suspended.

Reaction of the sulfur dioxide with the

substrate produces corrosion products

at pores in the coating. Spots are

counted with low power magnification.

The method is suitable for coatings

with greater than 95% gold or

palladium on substrates of copper,

nickel and their alloys. Tests should be

conducted in a fume hood. Exposures

of 2 h for gold thicknesses of 1.25 μm

or greater; 90 min for thicknesses less

than 1.25 μm. Exposures of 60 min

are required for palladium coatings.

Count of pores per unit area or

per contact. 

Intended Application Specimen Requirement Limits

Intended for the

inspection of electrical

contacts by providing a

quantitative description

of porosity as number

of pores per unit area

or per contact.

Clean specimens free of

debris.

Generally, corrosion

products less than

0.05 mm (0.002 in.)

in diameter are not

counted. Suitable for

pore densities up to

about 100/cm2.
146

ASTM B 809

Standard Test Method for Porosity in Metallic Coatings by Humid Sulfur Vapor

(“Flowers-of-Sulfur”)

General Description Data Produced

This Method describes methods

and equipment for determining

(qualitatively) the porosity of metallic

coatings on silver, copper or copper

alloys, where the pores penetrate to

the substrate. In this Method, the test

piece is suspended above a source

of sulfur vapor in an environment of

controlled humidity at 50 °C for hours

or days. Reaction of the sulfur with the

substrate, at locations where coating

porosity allows penetration, produces

“flowers of sulfur”. Visual examination

is conducted at 10x magnification.

Pore sizes less than 0.05 mm

(0.002 in.) in diameter are

not counted.

Visible indications of defects. 

Intended Application Specimen Requirement Limits

Intended for

determination of coating

quality and thus as a

measure of deposition

process control.

Particularly intended for

determination of quality

of underplates of nickel

or nickel alloy in finish

systems with 1.2 μm

(50 μin.) thick or less top

layers above the nickel.

Clean surfaces. Highly sensitive to

exposed copper but

nickel underplates are

not attacked below

100 °C and if free of

pores will not allow

identification of pores in

an overplate. Not

recommended for

product performance

prediction unless

correlation with service

experience is

established.
147

ASTM E 2109

Test Methods for Determining Area Percentage Porosity in Thermal Sprayed

Coatings

General Description Data Produced

This document gives procedures

for conducting porosity ratings on

metallographic specimens of thermal

sprayed coatings using both direct

visual comparison to standard images

and automatic image analysis

equipment. Specimens are prepared

per ASTM E 1920 without

specification of coating or substrate

material. Visual comparison images

are provided together with

descriptions of apparatus, sampling,

specimen preparation, test

procedures, statistical analysis

methods, reporting,

precision and bias.

Images analyzed manually or

by automated techniques. 

Intended Application Specimen Requirement Limits

Intended for monitoring

effects of process

variables and suitability

for purpose.

Specimens should

include approximately

25 mm (1.0 in.) of

coating length. Multiple

specimens may be

prepared to evaluate

homogeneity.

Precision and bias can

be affected by specimen

preparation and analysis

technique.
148

9. Standards for Measurement of Composition and Crystal Structure

9.1 Composition

ASTM E 673

Standard Terminology Relating to Surface Analysis

General Description Data Produced

This is a compilation of definitions

of over 150 terms used in surface

analysis. The terms apply to Auger

electron spectroscopy, X-ray

photoelectron spectroscopy, ionscattering spectroscopy, secondary

ion mass spectrometry and

energetic ion analysis.

Not specified.

Intended Application Specimen Requirement Limits

Surface analysis,

generally.

Not specified. Not specified.
149

ASTM E 1127

Standard Guide for Depth Profiling in Auger Electron Spectroscopy

General Description Data Produced

This Guide gives detailed instructions

for chemical analysis as a function

of depth from a surface using Auger

electron spectroscopy (AES).

Guidelines are given for depth

profiling using ion sputtering,

angle lapping and cross-sectioning.

Mechanical cratering and nondestructive depth profiling

are described.

Chemical composition as a function

of distance from the surface.

Intended Application Specimen Requirement Limits

Chemical analysis

generally.

Instrument dependent

size requirements, 

cleanliness.

Destructive analysis is

conducted by ion

sputtering for depths less

than 1μm or angle

lapping or mechanical

cratering for depths

greater than about 1 μm

and subsequently using

Auger Electron

Spectroscopy (AES)

at different distances

from the surface.

Nondestructive depth

profiling with AES is

based on varying the

effective electron escape

depth from the test piece

and is limited to the

outermost 2 nm to 5 nm.
150

ASTM E 1438

Standard Guide for Measuring Widths of Interfaces in Sputter Depth Profiling

Using SIMS

General Description Data Produced

This Guide provides a method for

determining the width of interfaces

from SIMS (secondary ion mass

spectroscopy) sputtering data.

Interface widths are calculated from

plots of SIMS secondary ion intensity

versus time. Procedure and

apparatus are included.

SIMS intensity versus ion

bombardment time where the time

required for the signal of one of the

major elements of the layer overlying

the interface to be reduced from 84%

to 16% of its average intensity in the

overlying layer is used to

calculate thickness.

Intended Application Specimen Requirement Limits

Primarily intended to

provide a method for

checking on proper or

consistent instrument

performance.

Not specified. This method does not

apply to analyses of data

from specimens without

interfaces such as ionimplanted material.
151

ISO 14606

Surface Chemical Analysis – Sputter Depth Profiling – Optimization Using

Layered Systems as Reference Materials

General Description Data Produced

This document gives guidance on the

optimization of sputter depth profiling

parameters using appropriate single

layered and multilayered reference

materials to optimize depth resolution

in Auger electron spectroscopy (AES),

X-ray photoelectron spectroscopy

(XPS) and secondary ion mass

spectroscopy (SIMS).

Instrument specific.

Intended Application Specimen Requirement Limits

Chemical analysis,

generally.

Not specified. Not specified.

ISO 14707

Surface chemical analysis – Glow discharge optical emission spectrometry

(GD-OES) – Introduction to use

General Description Data Produced

This document provides guidelines

applicable to bulk and depth profiling

GD-OES analyses. Principle of

operation, apparatus description,

procedure, steps for determination of

quantitative analysis are included.

Instrument specific.

Intended Application Specimen Requirement Limits

Chemical analyses as

a function of depth.

Flat round or rectangular

specimens with a width

of 10 mm to 100 mm.

The specimen area

analyzed is typically

2.5 mm to 8 mm.

Layer thicknesses

amenable to GD-OES

depth profiling range

from a few nanometers

to approximately

100 μm.
152

9.2 Crystal Structure

ASTM F 2024

Standard Practice for X-ray Diffraction Determination of Phase Content of

Plasma Sprayed Hydroxyapatite Coatings

General Description Data Produced

This Practice provides detailed

guidance for the use of the Reference

Intensity External Standard Model

to determine the weight percent of

the crystalline phases hydroxyapatite

(HA), beta-tricalcium phosphate

(B-TCP) and calcium oxide (CaO)

in plasma sprayed HA on metallic

substrates. The Practice was

developed for plasma sprayed

coatings with HA contents of at least

50% of the total coating. The Practice

includes a description of the external

standard technique, experimental

procedure, reporting,

precision and bias.

X-ray diffraction pattern which is

compared to an external standard

to quantitatively determine

phase content.

Intended Application Specimen Requirement Limits

For detailed analysis of

the form and purity of

calcium phosphate to

enable reproducible

clinical trials of biological

implants and for

determination of effects

of phases on

biocompatibility.

Specimens for X-ray

diffraction analysis

should be flat, 2.5 cm x

2.5 cm x 0.6 cm (1 x 1 x

0.125 in.) to be analyzed

on a substrate.

The coating should be

at least 44 μm thick to

ensure opaqueness to

the X-ray beam.

Effective particle size

and variation in surface

roughness in the alphacorundum external

standard must be

less than 5 μm.

Reproducibility is of the

order of ± 3% for HA

content of plasma

sprayed coatings.
153

10. Standards for Residual Stress and Hardness Measurement

10.1 Residual Stress Measurement

ASTM E 837

Standard Test Method for Determining Residual Stresses by the Hole-Drilling

Strain Gage Method

General Description Data Produced

This Method gives the procedure for

determining the residual stresses

near the surface of an isotropic,

linear-elastic material by measuring

changes in strain, using a strain gage

rosette, as affected by drilling a small

hole in the material in the center of

the rosette. Drilled hole diameters

and depths are a function of rosette

size. Procedure, instrumentation,

stress calculation, specimen

preparation, reporting, precision

and bias are included.

Instrument readings converted

to strain and via elastic modulus

to stress.

Intended Application Specimen Requirement Limits

Determination of residual

stresses which can affect

the performance of a

component or structure.

A clean, degreased

surface for strain gage

attachment. Abrading or

grinding the surface may

alter surface stresses.

Stresses should not vary

significantly with depth

and not exceed one-half

the yield strength. Bias

can be expected to not

exceed ± 10% if

conditions specified

herein are followed. If a

significant non-uniform

stress distribution is

unrecognized the error

may be more than 10%,

usually an under

estimate of the maximum

stress. Round robin

testing showed a

standard deviation of

14 MPa (2.0 ksi) for

carbon steel and 12 MPa

(1.7 ksi) for stainless

steel, both about the

mean values measured.
154

ASTM E 1426

Standard Test Method for Determining the Effective Elastic Parameter for

X-ray Diffraction Measurements of Residual Stress 

General Description Data Produced

This Method describes how to

determine the effective elastic

parameter, Eeff, using mechanical

loading techniques. Eeff is related

to Poisson’s ratio and relates

macroscopic stress to the strain

measured in a particular

crystallographic direction in

polycrystalline samples. The Method

includes apparatus and specimen

descriptions, calibration of the

specimen, X-ray diffraction technique,

calculation of Eeff, precision and bias.

Diffraction data related to stress

through calculation.

Intended Application Specimen Requirement Limits

Used in the X-ray

diffraction measurement

of residual and

applied stress.

Test specimens should

be fabricated from

material with

microstructure as similar

as possible to the

material in which

residual stress is to be

measured. Guidelines for

length to width to

thickness ratios are

provided for rectangular

specimens in tensile or

bending. Surfaces may

be electropolished or

as-rolled sheet or plate

and of a size to

accommodate

strain gage(s).

Precisions of 2% to 3%

were reported in a three

laboratory round robin.
155

10.2 Indentation Hardness Measurements

ASTM A 833

Standard Practice for Indentation Hardness of Metallic Materials

General Description Data Produced

This practice consists of using a

hammer to manually strike a

calibration bar which in turn strikes a

Brinell ball that makes an impression

in the test piece. The impact force on

the calibration bar is assumed to be

the same as the impact force on the

test piece. The size of the Brinell ball

indentation on the test piece and the

calibration bar are compared to

ascertain the hardness of the test

piece. The hardness of the calibration

bar is determined independently in

a hardness testing machine. The

Practice includes apparatus, test

parts, verification of apparatus and

calibration of comparative bars,

procedure and reporting.

The diameter of the impression is

measured with a microscope and

used to calculate hardness.

Intended Application Specimen Requirement Limits

This Practice is intended

for measurement of the

hardness of large parts

or stationary structures

not suitable for hardness

testing machine use.

The specimen should be

of sufficient thickness

such that a bulge does

not form on the side

opposite the impression,

and that the test piece

be stable with a surface

sufficiently smooth to

measure the impression

with a microscope.

The comparative bar

impression should not

exceed 4.2 mm.

Accuracy can be

improved if the

comparative bar has a

hardness within thirty

Brinell (HB) numbers

of the part tested.
156

ASTM B 277 

Standard Test Method for Hardness of Electrical Contact Materials

General Description Data Produced

This Method identifies other ASTM

standards suitable for measurement

of hardness of electrical contacts.

Those standards include E 10, E 18,

E 384. Aspects of those standards

which affect measurement of electrical

contacts are identified. The Method

includes sampling, procedure,

reporting, precision and bias.

Hardness numbers read from a

testing machine.

Intended Application Specimen Requirement Limits

Measurement of

hardness of metallic

electrical contacts.

Specimens should be

thick enough to not flow

during indentation or of

phase sizes sufficiently

large that microhardness

measurements do not

represent an average

hardness.

Precision and bias are

as identified in

referenced standards.
157

ASTM B 294

Standard Test Method for Hardness Testing of Cemented Carbides

General Description Data Produced

This Method addresses measurement

of hardness of cemented carbides

using the Rockwell A scale in the

range of Rockwell A80 and above.

This generally follows ASTM E 18.

The Method includes apparatus, test

specimens, procedure, reporting,

precision and bias, and information

of standard test blocks and

indenter selection.

Hardness numbers read from

a testing machine.

Intended Application Specimen Requirement Limits

Measurement of

hardness as an

indication of wear

resistance and

toughness.

Minimum thickness of

1.6 mm (0.0625 in.),

surface roughness with

Ra less than or equal to

0.2 μm (8 μin.), surfaces

flat and parallel to one

part per hundred for

general practice, radius

of curvature not less

than 15 mm.

Mounted carbides are

to be removed from

steel bodies.

The repeatability limit is

0.3 HRA (Hardness,

Rockwell A scale). The

repeatability standard

deviation is 0.1 HRA.

The reproducibility limit

between or among

laboratories is 0.4 HRA.

The reproducibility

standard deviation

is 0.14 HRA.
158

ASTM B 578

Standard Test Method for Microhardness of Electroplated Coatings

General Description Data Produced

This Method provides guidance for the

measurement of microhardness of the

cross-section of electroplated metallic

coatings using a Knoop indenter at

test loads of 0.245 N (25 gf) or

0.981 N (100 gf), for soft (50 to

300 HK) and hard (greater than

300 HK) coatings. The Method

includes special requirements,

preparation of test specimens,

procedure (based on ASTM E 384),

reporting, use of test coupons and

precision and bias.

Measurement of indent diagonals

interpreted as microhardness.

Intended Application Specimen Requirement Limits

Property measurement

for acceptance or

suitability for purpose.

Metallographic specimen

with 38 μm thick (min)

soft coating and 25 μm

thick (min) hard coating

overplated with 12 μm

coating of similar

hardness as test coating.

Precision and bias are

not provided. Reference

hardness specimens of

electroformed nickel with

certified hardness

readings are available

from the National

Institute of Standards

and Technology (NIST).
159

ASTM B 647

Standard Test Method for Indentation Hardness of Aluminum Alloys by Means

of a Webster Hardness Gage

General Description Data Produced

This method addresses the use of the

Webster, Model B, portable handheld

hardness gage. This gage provides a

numerical hardness value reflecting

the penetration of a hardened steel

indenter into the test piece.

The Method includes apparatus, test

parts or specimens, calibration of the

device, procedure, reporting, precision

and bias. The device is operated

like a pair of pliers.

Webster hardness number as

read from gage.

Intended Application Specimen Requirement Limits

Intended for the in-situ

determination of

hardness of fabricated

parts and test specimens

for production control.

Material between 1 mm

(0.040 in.) and 6 mm

(0.250 in.) in thickness

and with a clear flat area

of 25 mm x 25 mm

(1 in. x 1 in.) at an edge,

with surfaces essentially

parallel, clean and

lightly polished and

3 mm (0.125 in.) from

edge of part or

specimen.

Useful for material in the

range of 3003-0 to

7075-T6;

e.g., Rockwell 5 HRE

(Hardness Rockwell E

scale) to 110 HRE.
160

ASTM B 648

Standard Test Method for Indentation Hardness of Aluminum Alloys by Means

of a Barcol Impressor

General Description Data Produced

This Method addresses the use of

a Barcol Impressor, Model 934-1,

a portable device, to measure the

hardness of aluminum alloys. The

device is operated by applying hand

pressure on the housing and

measuring the penetration of a

hardened steel indenter into the test

piece. The Method includes

apparatus, test parts or specimens,

calibration, procedure, reporting, effect

of curvature and precision and bias.

Barcol hardness number as read

from gage.

Intended Application Specimen Requirement Limits

Intended for the in-situ

determination of

hardness of fabricated

parts and test specimens

for production control.

Test material should be

clean and smooth at

least 1.5 mm (0.0625 in.)

thick and large enough

to ensure a minimum

distance of 3 mm

(0.125 in.) in any

direction from the

indenter point

to the edge.

Greater variation than

standard fixed frame

hardness testers.

Three readings on

homogeneous materials

are needed to maintain a

variance-of-average of

0.28 at an 80 Barcol

reading. Six readings at

a 50 Barcol reading are

required for the same

variance-of-average.
161

ASTM B 724

Standard Test Method for Indentation Hardness of Aluminum Alloys by Means

of a Newage, Portable, Non-Caliper-Type Instrument 

General Description Data Produced

This Method addresses the use of a

Newage portable hardness instrument

which provides readout values

numerically equivalent to Rockwell B

scale as determined by ASTM E 18.

The depth of penetration of a carbide

tipped indenter between preload and

full load is an indication of the

hardness value. The Method includes

apparatus, hazards, test piece

requirements, instrument calibration,

test procedure, interpretation of

results, precision and bias.

Hardness numbers are read from the

instrument and are related to but not

necessarily identical to Rockwell B

when conducted in accordance with

ASTM E 18. Values obtained with the

Newage instrument are reported as

HRBN (Hardness Rockwell BN scale).

Intended Application Specimen Requirement Limits

Intended for quality

assurance and

production control.

It is not intended to

be an independent

material-acceptance

test.

Intended for thicknesses

greater than 1.50 mm

(0.0625 in.) which does

not deflect during test

and which does not

produce a bulge on its

reverse side. Surface

should be clean, free of

mechanical damage or

processing defects. A

surface finish of 3.2 μm

or finer is recommended.

Single operator, single

instrument, same day

relative precision for

HRBN of aluminum alloy

with HRB of 55 was

± 1.4, with HRB of 75 it

was ± 1.1, and with HRB

of 84 it was ± 0.8. More

extensive repeatability

and reproducibility

information are

included.
162

ASTM C 1326

Standard Test Method for Knoop Indentation Hardness of Advanced Ceramics

General Description Data Produced

This Method, in great detail, describes

the measurement of the Knoop

hardness of advanced ceramics

using a calibrated machine to force

a diamond indenter into a polished

surface of the material and measuring

the long diagonal of the indentation

with an optical microscope. The

Knoop indentation is shallower than a

Vickers indentation and may be useful

in evaluating coating hardness. The

Method includes identification of

factors which can interfere with the

measurement, apparatus and

specimen descriptions, indentation

measurement, hardness calculation,

reporting, precision and bias.

Hardness calculated from the ratio

of the applied load to the projected

area of the permanent impression

in the test piece.

Intended Application Specimen Requirement Limits

One of many properties

used to characterize

ceramics.

Specimens should have

a surface roughness less

than 0.1 μm rms and be

ten times as thick as the

indentation depth,

generally at least

0.50 mm. Porosity can

affect the measurement.

Precision and bias

depend on adherence to

the procedure and

instrument and

material factors.
163

ASTM C 1327

Standard Test Method for Vickers Indentation Hardness of Advanced Ceramics

General Description Data Produced

This Method provides detailed

guidance on the measurement of

the Vickers hardness of advanced

ceramics, complementing ASTM

C-1326-99 which addresses the use

of a Knoop indenter. The Method

includes descriptions of apparatus,

factors which affect measurements,

specimen requirements, procedure

and measurement, hardness

calculation, illustrations of acceptable

and unacceptable indentations,

reporting, precision and bias.

Hardness calculated from the ratio

of the applied load to the area of

contact of the four faces of the

undeformed indenter.

Intended Application Specimen Requirement Limits

Measurement of one

property used to

characterize advanced

ceramics.

Generally, specimens

should be over 0.50 mm

thick with a surface

roughness of less than

0.1 μm rms, unless

examination of surface

treatment or coating

precludes grinding

and polishing.

Precision and bias

depend on adherence to

procedure, material and

instrument factors.

Within laboratory

hardness repeatabilities

of indentations made at

9.81 N on tungsten

carbide test blocks

showed 1.2% coefficient

of variation and between

laboratory repeatabilities

of 6.1% for indents made

by the organizing

laboratory.
164

ASTM E 10

Standard Test Method for Brinell Hardness of Metallic Materials

General Description Data Produced

The Brinell hardness number (HBW)

is determined by measuring the

indentation of a tungsten carbide

ball of known diameter at a specified

load into the test piece using a testing

machine. The method is suitable for

materials with a Brinell hardness

(HBW) not exceeding 650. Three test

methods are included: Test Method

A- test procedure; Test Method

B- verification of testing machines;

Method C- calibration of

standardized test blocks.

Hardness is calculated from and

is proportional to the quotient

obtained by dividing the test force

by the curved surface area of

the indentation.

Intended Application Specimen Requirement Limits

Provides empirical data

which can be correlated

with strength, wear

resistance or other

properties and may be

useful in quality control

and material selection.

The test piece should

not exhibit bulging on the

reverse side opposite the

indentation; generally

interpreted as requiring a

thickness of ten times

the indentation depth.

The center of the

indentation should be at

least 2.5 times the

diameter of the

indentation and the

surface should be

smooth enough to

see the edge of

the indentation.

Precision and bias for

the test method are not

specified. Conversion to

other hardness scales

is to be avoided.
165

ASTM E 18

Standard Test Methods for Rockwell Hardness and Rockwell Superficial

Hardness of Metallic Materials

General Description Data Produced

The Rockwell hardness of a material

is determined by measuring the

indentation of a diamond

spheroconical or tungsten carbide

or steel spherical indenter under

specified conditions into a surface in

two operations (loads) and to measure

the difference in depth of the

indentation under the specified

conditions of preliminary and total test

forces. The Rockwell superficial

hardness test is the same but with

lower loads. Three test methods are

included: Test Method A- General

Description and Test Procedure; Test

Method B- Verification of Machines;

Method C- Calibration of

Standardized Test Blocks.

Hardness number read from

testing machine.

Intended Application Specimen Requirement Limits

This is an empirical test

which provides hardness

data which may correlate

with strength or other

properties and may be

useful in quality control

and material selection.

This test is considered

satisfactory for

acceptance of

commercial shipments.

Information is provided

on test piece thickness

and surface condition.

Generally, thickness

should be greater than

ten times the depth of

indentation with a

diamond indenter and

15 times the depth of

indentation with a

ball indenter.

None specified.
166

ASTM E 92

Standard Test Method for Vickers Hardness of Metallic Materials

General Description Data Produced

The Vickers hardness is determined

using a calibrated machine to force

a square base diamond pyramid

indenter into the test piece with a

predetermined force and measuring

the diagonals of the impression with

an optical microscope after the force

is removed. The Vickers hardness

number, HV, is related to the applied

force and the surface area of the

permanent impression. Three test

methods are included:

Method A – General Method and Test

Procedure; Method B – Verification

of Testing Machine; Method C –

Calibration of Standard

Hardness Test Blocks.

Hardness number calculated

from applied force and

measured impression.

Intended Application Specimen Requirement Limits

This test provides

hardness data which

may be used for

correlations with material

properties.

The thickness of the test

piece should be at least

1.5 times the length of

the diagonal. The

surface shall be

prepared such that the

ends of the diagonals

are clearly defined. The

center of an indentation

shall not be closer than

2.5 times the diagonal of

the impression from the

test piece edge.

Under optimum

conditions of procedure

and equipment, the

accuracy can be

expected to be the

equivalent of 4% of the

Vickers hardness

number of the

standardized reference

test blocks.
167

ASTM E 103 

Standard Test Method for Rapid Indentation Hardness Testing of Metallic

Materials

General Description Data Produced

This Method is an alternative to ASTM

E 10 and employs commercially

available portable testers. This is

not considered a standard Brinell

hardness test method. The Method

includes: Part A – General Description

and Test Procedure;

Part B – Verification of Testing

Machines; Part C – Calibration of

Reference Test Blocks.

Varies with device.

Intended Application Specimen Requirement Limits

The method is used

where hardness

measurements must be

made rapidly; as in

inspection of production

output.

The thickness of the test

piece must be at least

10 times the depth of

the indentation and the

surface must be clean

and in such condition

that test results are not

compromised. The

center of the indentation

should be at least

2.5 times the depth of

the indentation from the

edge of the test piece.

Test results are not

comparable between

equipment from different

manufacturers.
168

ASTM E 110 

Standard Test Method for Indentation Hardness of Metallic Materials by

Portable Hardness Testers

General Description Data Produced

This is a short, general description of

portable devices which attach to the

test piece and use spring or hydraulic

force, rather than dead weights, to

apply the load necessary to make

a Brinell, Rockwell or Vickers

type indentation.

Varies with device.

Intended Application Specimen Requirement Limits

These devices are used

principally for testing

articles too large or

awkward to be evaluated

in conventional,

stationary hardness

testing machines.

Not specified. Precision of the method

is not established

because of the wide

variety of portable

testers. Precision of

a given test can

be determined.
169

ASTM E 140

Standard Hardness Conversion Tables for Metals Relationship Among Brinell

Hardness, Vickers Hardness, Rockwell Hardness, Superficial Hardness, Knoop

Hardness and Scleroscope Hardness

General Description Data Produced

This document contains nine

conversion tables relating hardness

scales for steels (primarily), stainless

steels, copper, cartridge brass,

unalloyed white cast iron and

wrought aluminum alloys.

Equations for conversion

between scales are included.

Varies with method, generally read

off instrument.

Intended Application Specimen Requirement Limits

These tables should be

used when it is

impossible to test a

material under the

conditions specified.

Varies with method. Converted values should

be considered

approximate.
170

ASTM E 384 

Standard Test Method for Microindentation Hardness of Materials

General Description Data Produced

E 384 is the Standard Test Method

on which several other methods are

based. It provides the basic

information for Knoop and Vickers

indentation tests at loads in the range

of 1 gf to 1000 gf. This method

includes formulas for calculation of

hardness numbers, description of

apparatus, specimen requirements,

procedure, reporting, factors affecting

precision and bias, verification

methods for testing machines and

indenters, calibration of standardized

hardness test blocks, results of

interlaboratory tests of

microindentation measurement,

recommendations for light force

testing, HK and HV values for

a 1 gf test load.

Optical measurement of diagonal

used with applied force to

calculate hardness.

Intended Application Specimen Requirement Limits

Hardness can be

correlated with material

properties such as

strength and wear

resistance.

Microindentation tests

can be applied to test

pieces too small for

conventional macroindentation tests or for

the examination of

phases or aspects

of a material.

Preferably flat polished

specimens free of

defects or material which

can affect measurement

of indentation diagonals,

particularly tips.

Specimens should be

prepared in accordance

with ASTM E 3.

Precision and bias

depend on adherence

to test procedure,

instrumental and

material factors and

measurement errors.

The Method includes

results of interlaboratory

tests and analysis of test

parameter variations

which produce a 1%

error in hardness.
171

ISO 3878

Hardmetals – Vickers Hardness Test

General Description Data Produced

This is a succinct Standard describing

the method for determining the

Vickers hardness of hardmetals.

Hardmetals are not defined. The test

force applied shall be in the range of

9.807 N (HV 1) to 490.3 N (HV 50),

the preferred force being 294.2 N

(HV 30). 

Optical measurements of indentation

dimensions (diagonals) used to

calculate a hardness number.

Intended Application Specimen Requirement Limits

Hardness

measurements,

generally.

Polished, clean surface

free of contaminants,

lubricants and oxides.

The test piece shall be at

least 1 mm thick and the

thickness of material

removed from the

surface shall not be less

than 0.2 mm.

The device for diagonal

(d) measurement shall

have the following

accuracy:

d < 100 μm; ± 0.2μm

100 m < d < 200 μm;

± 1.0μm

d > 200 μm; ± 0.5 μm

The arithmetical mean

of the hardness values

measured shall be

reported to the

nearest 10 HV.
172

ISO 4498-2

Sintered Metal Materials, Excluding Hard Metals – Determination of

Apparent Hardness

Part 2: Case-hardened ferrous materials, surface enriched by carbon or

carbon and nitrogen

General Description Data Produced

This brief Standard specifies methods

of hardness testing surfaces of

sintered metals which have nonuniform hardness to a depth of 5 mm

below the surface and “therefore

applies to materials in which the

hardness is obtained essentially by

surface enrichment by carbon and

nitrogen, for example by carburizing,

carbonitriding, nitrocarburizing or

sulphidizing.” Vickers (HV 5) or

Rockwell (HR 15 N) hardness tests

are specified. Five indentations are to

be made and reported hardness shall

be the arithmetical mean of the four

highest readings rounded to the

nearest whole number.

Readings as obtained for Vickers or

Rockwell hardness measurements

specified in ISO/ R 146, Verification of

Vickers hardness testing machines;

ISO/R 1024, Rockwell superficial

hardness test (N and T scales) for

steel; and ISO 6507/1, Metallic

materials-Hardness test-Vickers

test-Part 1: HV 5 to HV 100.

Intended Application Specimen Requirement Limits

Not specified. The sintered metal

surface shall be clean,

smooth and flat.

Not specified.
173

ISO 4545

Metallic Materials – Hardness Test – Knoop Test

Part 1: Test method

General Description Data Produced

This Standard specifies the method

for conduct of a Knoop hardness test

for metallic materials at forces up to

and including 9.807 N. The document

accompanies ISO 4546, Metallic

materials-Hardness test-Verification of

Knoop hardness testing machines and

ISO 10250 Metallic materials- Tables

of Knoop hardness values for use in

tests made on flat surfaces.

Descriptions of apparatus, test pieces,

test procedure and reporting

are included.

Optical measurements of indentation

dimensions used to calculate

a hardness number.

Intended Application Specimen Requirement Limits

Microhardness

measurements,

generally.

Polished, clean surface

free of contaminants and

oxides.

There is no general

process of accurately

converting Knoop

hardness values into

other hardness scales or

tensile strength. A strict

comparison of hardness

values is only possible

at identical test forces.
174

ISO 6507-1

Metallic Materials – Vickers Hardness Test

Part 1: Test method

General Description Data Produced

This Standard specifies the method

for conduct of a Vickers hardness test

at test forces of: greater than or equal

to 49.03 N; greater than or equal to

1.961 N and less than 49.03 N; and,

greater than or equal to 0.09807 N

and less than 1.961 N. This Standard

accompanies ISO 6507-2 Metallic

materials – Vickers hardness test –

Part 2: Verification of testing machines

and ISO 6507-3, Metallic materials –

Vickers hardness test –Part 3:

Calibration of reference blocks.

Optical measurements of indentation

dimensions used to calculate

a hardness number.

Intended Application Specimen Requirement Limits

Microhardness

measurements where

lengths of indentation

diagonals are between

0.020 mm and

1.400 mm.

Polished, clean surface

free of contaminants

and oxides.

Uncertainty is dependent

on two categories of

parameters, the testing

machine and the

application of the

method. Uncertainty

may approach 10%

of the measured

hardness value.
175

ISO 14577-1

Metallic Materials – Instrumented Indentation Test for Hardness and

Materials Parameters

Part 1: Test method

General Description Data Produced

ISO 14577 – Part 1 specifies the

method for instrumented indentation

measurement of Martens hardness

(HM), indentation hardness (HIT),

indentation modulus (EIT), indentation

creep (CIT), indentation relaxation

(RIT), plastic and elastic parts of the

indentation work. In this method,

displacement of the indenter

(indentation) and force are measured

during the complete cycle of increasing

and removal of the load. Optical

measurement of the indent is not

necessary. Ranges of application

are: macro (2N ≤ F ≤ 30 kN), micro

(2N ≥ F; h ≥ 0.2 μm), nano (h ≤ 0.2 μm),

where F is the applied force and h is

the depth of the indent. This Standard

is accompanied by Part 2 – Verification

and calibration of testing machines and

Part 3 – Calibration of testing blocks.

Indentation force and indenter

displacement with time used to

calculate material properties.

Intended Application Specimen Requirement Limits

Determination of

material properties.

The contact area should

be free of fluids or

lubricants and dust

particles. Surface finish

has a significant effect on

test results due to asperity

contact at very shallow

indentation depths. The

standard provides

guidelines of permissible

roughness for different

materials and test forces.

The test piece thickness

should be at least 10x the

indentation depth or 3x

the indentation diameter,

whichever is greater.

Coating thickness should

be considered to be the

test piece thickness.

Type A uncertainties

include: zero point

assignation, measurement

of force and displacement,

fitting of the force removal

curve, thermal drift rate,

and contact area due to

surface roughness.

Type B uncertainties

include force and

displacement, testing

machine compliance,

indenter area function

calibration values,

calibration drift due to

uncertainty in temperature

of testing machine and

time since last calibration,

and tilt of test surface.
176

ISO 14705

Fine Ceramics (Advanced Ceramics, Advanced Technical Ceramics) – Test

Method for Hardness of Monolithic Ceramics at Room Temperature

General Description Data Produced

This Standard describes the methods

for determining the Vickers or Knoop

hardness of monolithic fine ceramics

at room temperature by microscopical

measurement of diagonals of indentations

made with diamond indenters using a

loading device which controls appliedload

and load duration. The Standard includes

definitions and physical principles for each

method; sample calculations based on

applied load and measured indentation

diagonal lengths, diamond indenter

requirements, measurement procedures

including examples of acceptable and

unacceptable indentations, and

illustrations of crosshair measurements

of indentation diagonals.

Optical measurements of indentation

dimensions used with the measured

indentation load to calculate a

hardness number.

Intended Application Specimen Requirement Limits

Intended for measurement

of hardness of ceramics

where indentation is formed

by micro cracking and

micro fracture, besides

plastic deformation.

Polished, smooth, clean

surface free of

contaminants and oxides.

Vickers and Knoop test

piece thickness shall be

at least 0.5 mm; and, for

Vickers, at least 1.5 times

the diagonal of the

indentation and 2 times

the crack length. 

Vickers indentations are

less likely to cause cracks

in fine ceramics than Knoop

indentations. Conversion

between these hardness

scales shall not be made.

Distance between centers

of Vickers indentations and

the test piece edge shall be

at least 2.5 times the mean

diagonal of the indentation

and 5 times the mean

length of the crack from

indentation tips. The distance

between the centers of

adjacent indentations shall

be at least 4 times the

mean diagonal of the

indentation and 5 times the

mean length of the crack.

Five valid indentations are

required. Knoop indentations

should be at least 1.5 times

the long diagonal distance

from the test piece edge.

Knoop indentations should

be separated by at least

1.5 times the long

diagonal length. 
177

SAE J417 

Hardness Tests and Hardness Number Conversions 

(SAE Information Report)

General Description Data Produced

Approximate conversion values giving

relationships between Vickers, Brinell,

Rockwell, and Scleroscope hardness

values and approximate

corresponding tensile strengths of

steels are included. Information on

surface preparation, specimen

thickness, effect of curved surfaces

and recommendations for Rockwell

surface hardness testing for case

hardened parts are also included.

Test methods for Vickers, Brinell,

Rockwell, Rockwell Superficial

and Shore are provided.

See ASTM E 140-02.

Data may be read from instrument test

to enable calculation of hardness.

Intended Application Specimen Requirement Limits

Material evaluation,

generally.

Requirements for

surface smoothness and

cleanliness, specimen

thickness, proximity to

edges and surface

treatment vary

with method.

Conversion from one

hardness scale to

another should be

conducted with caution,

particularly for surface

treated materials.
178

10.3 Other Hardness Measurement Methods

ASTM G 171

Standard Test Method for Scratch Hardness of Materials Using a Diamond Stylus

General Description Data Produced

This method describes determination

of the scratch hardness, the resistance

of a solid surface to penetration by a

moving stylus of given tip radius under

a constant normal force and speed. The

method is applicable to metals, ceramics,

polymers and coated materials and may

be indicative of resistance to surface

damage. It is not intended to measure

coating adhesion or for use with other

than the specific hemispherically tipped

conical styli described. Included are

apparatus, calibration, procedure,

calculation of scratch hardness number

and stylus drag coefficient, reporting,

and factors affecting precision and bias.

Measurement of the scratch width and

the normal force applied to the stylus

are used to calculate the “scratch

hardness number”.

Scratch width is measured and with

normal force used to calculate

scratch hardness number.

Intended Application Specimen Requirement Limits

Intended to complement

quasi-static hardness

measurements. In

principle, it is a more

appropriate measure

of the resistance of a

material to damage

processes like two

body abrasion.

The surface of the test

piece should not be such

that scratch edges are

indistinct or such that the

stylus skips. The surface

should be free of

preparation artifacts.

Surfaces of 0.02 μm to

0.05 μm Ra are typical

of polished surfaces.

Interlaboratory tests on

repeatability and

reproducibility showed

between laboratory

scratch hardness of brass

to be 1.13 (± 0.08) GPa

with 200 g load and

200 μm radius diamond

stylus. Does not measure

a single material property.

Correlations of scratch

hardness number with

other material

characteristics depends

on the extent to which the

response of the surface in

use is controlled by the

same combination of

properties which

determine the scratch

hardness number.
179

ASTM E 448

Standard Practice for Scleroscope Hardness Testing of Metallic Materials

General Description Data Produced

This Practice describes the scleroscope

apparatus for measuring hardness and

the procedure for its use. The practice

applies to Scleroscope Models C and D

manufactured by the Shore Instrument

and Manufacturing Company. Basic

operation consists of dropping a

diamond-tipped “hammer” onto the

test piece and measuring the rebound

of the hammer. The rebound height is

a measure of hardness, reported as a

Scleroscope hardness number HSc or

HSd. The Practice includes: Part A –

General Description of Instruments and

Test Procedure; Part B – Verification of

Scleroscope Hardness Instruments;

Part C – Calibration of Standardized

Hardness Test Blocks.

A Scleroscope hardness number is read

from the instrument. The instrument

scale is determined by dividing into

100 units the rebound of the hammer

from a quenched to maximum hardness

and untempered tool steel test block

of AISI W-5.

Intended Application Specimen Requirement Limits

The Scleroscope can be

used in situations where

instrument portability

is required.

Small specimens may be

evaluated by clamping in

a stand. Large specimens

may be evaluated by

mounting the instrument

in a stand. Thin strips

0.13 mm to 0.38 mm

(0.005 in. to 0.015 in.),

depending on the material

may be tested in the

stand. Model C may be

used free hand for testing

specimens with a

minimum mass of 2.3 kg

(5 lb.). Surface finish is

important. A No. 125

machined surface,

minimum, is required for

metals of “intermediate”

hardness. Indentations

can be made within

6 mm (0.250 in.) of an

edge when proper

clamping is used. Test

should not be made on

magnetized material.

Under optimum

conditions, accuracy can

be expected to be

3 Scleroscope points

from the mean of the

spread in Scleroscope

hardness numbers

marked on standardized

reference test blocks.
180

SAE J864

Surface Hardness Testing with Files 

(SAE Recommended Practice)

General Description Data Produced

This Practice describes the technique

for subjective evaluation of the

hardness of iron and steel parts. The

Practice includes required apparatus,

condition of the surface to be tested,

procedure and sources of files.

Subjective feel of operator.

Intended Application Specimen Requirement Limits

The method is useful in

production control for

identification of

inconsistent surface

conditions and where

conventional indentation

testing of hardness of

sintered parts is

inappropriate.

Smoothness of test

piece and “prover”

(standard for

comparison) should

be same.

Not quantitative.
181

11. Standards for Mechanical Properties and Adhesion of Coatings

11.1 Mechanical Properties

ASTM B 489

Standard Practice for Bend Test for Ductility of Electrodeposited and

Autocatalytically Deposited Metal Coatings on Metals

General Description Data Produced

This Practice describes a test

procedure for determination of the

ductility of electrodeposited or

autocatalytically deposited metal

coatings on metal substrates by

bending strips of test material over

round mandrels of successively

smaller diameter. Mandrel diameters

are from 6 mm to 50 mm, in 3 mm

steps. Mandrels are held in a vise and

specimens bent with coating outward

until legs are parallel. If examination

at 10x does not reveal cracks in the

coating, a new specimen is bent

over the next smaller mandrel.

Elongation is calculated from

measured deposit and substrate

thickness and diameter of smallest

diameter mandrel which did

not cause cracking.

Intended Application Specimen Requirement Limits

Intended to determine

coating resistance

to cracking during

distortion.

Flat 10 mm wide and not

less than 150 mm long,

cut from plated or coated

article, no closer than

25 mm from edges.

Alternative substrates

allowed where base

metal thickness and

temper affect

bending test.

Largest source of error

is detection of crack

initiation.
182

ASTM B 490

Standard Practice for Micrometer Bend Test for Ductility of Electrodeposits

General Description Data Produced

This Practice describes a method

of measuring the ductility of

electrodeposits with low ductility.

This is a semi-quantitative method

wherein a foil of the test material

is bent between the closing jaws

of a micrometer until cracks

appear or fracture occurs.

Elongation is calculated from

measured foil thickness and

distance between jaws when

cracks are formed.

Intended Application Specimen Requirement Limits

A useful method for

controlling some

electroplating solutions

and evaluating response

to moderate stress, as in

bolting parts together.

Deposits are removed

from a substrate and are

typically 25 μm to 40 μm

thick foils. Specimens

are cut from the center

of the foil removed

from the substrate.

Elongations calculated

using either formula

provided bears no simple

relation to ductility

obtained from tension

or other tests.
183

ASTM F 1044

Standard Test Method for Shear Testing of Calcium Phosphate Coatings and

Metallic Coatings

General Description Data Produced

This Method describes shear testing

of calcium phosphate and metallic

coatings applied to metallic

substrates. It assesses adhesion of

coatings to substrates or the cohesive

strength of a coating, parallel to the

substrate surface. Two tests are

described: (1) for calcium phosphate

or metal coatings- a coated and an

uncoated surface bonded together by

thermo- mechanical means or by a

polymeric adhesive are loaded in

shear using a tensile machine; (2) for

metal coatings only-a lap shear test

on porous coated area utilizing

polymeric adhesive or bone cement

and a test jig in a tensile machine.

Gripping device details are included.

Load at separation is used to calculate

adhesive or cohesive strength.

Intended Application Specimen Requirement Limits

Recommended for shear

testing under uniaxial

stress. Useful for

comparative evaluations

and for certain quality

control. Aids

development of load

bearing medical implant

applications.

Aligned interface test

method substrates

should have a nominal

cross-sectional area of

2.84 cm2. Lap shear

specimens should have

substrates 7.62 cm x

2.54 cm (3 in. x 1 in.)

with a 2.54 cm x

2.54 cm (1 in. x 1 in.

overlap test area).

Does not provide

intrinsic property values

for utilization directly in

making calculations.

Minimum bulk shear

strength of 34.5 MPa

(5000 psi) is required.

Testing to be conducted

at room temperature.

Repeatability testing of

plasma sprayed titanium

alloy with mean shear

strength of 29.6 MPa

(4292 psi) was found to

have a standard

deviation of 4.81 MPa

(698 psi). Reproducibility

standard deviation was

found to be 5.03 MPa

(729 psi).
184

ASTM F 1147

Standard Test Method for Tension Testing of Calcium Phosphate and

Metallic Coatings

General Description Data Produced

This Method addresses tension testing

of calcium phosphate and metallic

porous coatings on dense metal

substrates. It assesses adhesion to

substrates or internal cohesion of a

coating in tension normal to the surface

plane. A coated specimen is bonded

to an uncoated grip with polymeric

adhesive (calcium phosphate and metal)

or by sintering (metal). Loading is

performed in a testing machine and

an axial force pulls the parallel faces

of specimen substrates apart. 

Similar to ASTM C 633.

Load at separation is used to calculate

adhesive or cohesive strength.

Intended Application Specimen Requirement Limits

Useful for comparing

adhesive or cohesive

strengths of coatings or

effects of processing

methods.

Substrates should have a

nominal cross-sectional

area of 5.07 cm2.

Does not provide an

intrinsic material value

for utilization directly in

making calculations.

Polymeric adhesive must

have a minimum bulk

tensile strength of

34.5 MPa (5000 psi).

Sintered Co-Cr-Mo

coatings on the same

substrate alloy

demonstrated a mean

tensile strength of

29.8 MPa (4325 psi).

These coatings had a

repeatability standard

deviation of 4.23 MPa

(613 psi) and a

reproducibility standard

deviation of 5.32 MPa

(772 psi).Test intended for

room temperature use.

Eccentric loading

introduces bending

stresses in the coating.
185

ASTM F 1160

Standard Test Method for Shear and Bending Fatigue Testing of

Calcium Phosphate

General Description Data Produced

This test method describes the

determination of the shear and

bending fatigue performance of

plasma sprayed coatings intended for

medical implants. The procedure was

developed and is pertinent to plasma

sprayed titanium and plasma sprayed

hydroxyapatite coatings. The shear

fatigue mode evaluates the cohesive

and adhesive properties of the coating

on the metallic substrate. The bending

mode evaluates adhesion as well as

the effect of the coating on the

substrate. The Method includes

descriptions of test equipment and

specimens, adhesives for bonding

coating to test fixture (shear), test

procedure, stress calculations,

reporting precision and bias.

Cycles to failure at a predetermined

stress, a predetermined number of

visible cracks at a specified

magnification, a crack of certain

dimensions, or complete separation

of the coating from substrate.

Intended Application Specimen Requirement Limits

To aid in the

development of material

for use in load bearing

implant applications as

a guide to the selection

of coated materials

under conditions of

repeated stress.

Shear test specimens

must have a crosssectional area of

nominally 2.85 cm2

(0.44 in.2) to which the

coating is applied.

Bending fatigue

specimens of various

designs are allowed but

general requirements

pertaining to failure in

the test section and

constant stress in flat

tapered beam designs.

Not intended for

evaluation of

components

or devices.
186

ASTM F 1501

Standard Test Method for Tension Testing of Calcium Phosphate Coatings

General Description Data Produced

This Method is very similar to

F 1147-99, differing in that it does

not include metallic coatings.

Load at separation is used to calculate

adhesion or cohesion strength.

Intended Application Specimen Requirement Limits

Intended to provide a

comparative evaluation

of cohesive or adhesive

properties or quality

control.

Cross-section of

specimen to which

coating is applied should

be nominally 5.07 cm2

(0.78 in.2). Coating

thickness, substrate

composition, surface or

other features should be

representative of the

intended application.

The Method does not

provide an intrinsic value

for utilization directly in

making calculations such

as determining the ability

of a coating to withstand

specified environmental

stresses.
187

11.2 Adhesion

ASTM B 571 

Standard Practice for Qualitative Adhesion Testing of Metallic Coatings

General Description Data Produced

This Practice provides general

guidance for evaluating the adhesion

of, primarily, electroplated coatings

to substrates. Methods described

include: bend tests, burnishing tests,

chisel-knife tests, draw tests, file tests,

grind-saw tests, heat-quench tests,

impact tests, peel tests and scribe-grid

tests. A table of adhesion tests

appropriate for various coating

materials is provided as well as a

temperature test guide for various

coatings and substrates.

Varies with test method.

Intended Application Specimen Requirement Limits

Production control and

acceptance inspection.

Varies with test method,

but generally should

reflect condition of

material in intended

application.

Qualitative nature of the

tests precludes precision

and bias statements.
188

ASTM C 633

Standard Test Method for Adhesion or Cohesion Strength of

Thermal Spray Coatings

General Description Data Produced

This Method describes the

measurement of the degree of

adhesion of a coating to a substrate

or the cohesive strength of a coating

when subjected to a tensile force

normal to the surface. The test

consists of adhesively bonding test

fixtures to the underside of the

substrate and to the top side of the

coating and applying tensile loading

in a testing machine. The test is

performed at ambient temperatures

due to elevated strength limitations of

common adhesives. The degree of

cohesion or adhesion is calculated by

dividing the maximum load sustained

by the cross-sectional area of the

specimen. The Method includes

testing machine and fixture

descriptions, adhesive material and

test specimen requirements,

procedure, calculation and

interpretation of results and reporting.

Adhesive or cohesive strength.

Intended Application Specimen Requirement Limits

Recommended for

quality control,

acceptance testing,

process/procedure and

material development.

Not intended to provide

an intrinsic value for

calculation purposes.

Coatings should be at

least 0.38 mm (0.015 in.)

thick applied to test

fixtures of not less than

23 mm (0.9 in.) and not

more than 25 mm

(1.0 in.) in diameter.

Application of this test

should have tolerances

and interpretation of

adherence set and

agreed upon by

purchaser and

manufacturer.
189

ASTM D 4541

Standard Test Method for Pull-Off Strength of Coatings Using

Portable Adhesion Testers

General Description Data Produced

This Method covers the measurement

of the force and, by calculation, the

stress (pull-off strength) of coatings.

A loading fixture is affixed to a coating

on a substrate using an adhesive. The

fixture, with adhesive bonded coating

attached, is pulled from the substrate

using a portable device which can be

mechanically or hydraulically loaded.

The device gradually applies force

normal to the surface until the coating

is detached. The pull-off strength is

calculated based on the maximum

indicated load, instrument calibration

data and original surface stressed.

Four commercially available

instruments are described.

The Method includes: Apparatus,

Test Preparation, Test Procedure,

Calibration and Interpretation of

Results, Reporting, Precision and

Bias. The principle of operation

is similar to ASTM C 633.

Pull-off strength calculated from

instrument readings and measured

area of separation.

Intended Application Specimen Requirement Limits

Intended to determine

acceptance per specified

properties as measured

by this method.

The Method is not

specifically intended for

a given material. 

Referenced documents

address testing of paints

and varnishes.

Nature of failure must be

reported, i.e., whether in

adhesive, coating

system or substrate.

Precision of

measurements

determined in intra- and

inter- laboratory studies

show coefficient of

variation of types I, II,

and III instruments to be

12.2% for intralaboratory

measurement and 20.6%

for interlaboratory

measurement.
190

Industry Standard Scratch Adhesion Test

General Description Data Produced

This Practice provides a quantitative

value of coating adhesion for standard

PVD (physical vapor deposition)

coatings. A diamond stylus 0.2 mm in

diameter is run against the surface at

fixed speed of 100 mm/min and a load

increasing at the rate of 100 N/min.

Two values are recorded: the load at

which delamination of the coating is

first observed, and the load at which

the coating is completely removed

from the wear track.

Quantitative adhesion.

Intended Application Specimen Requirement Limits

Production control and 

acceptance inspection.

Flat, highly polished

sample.

Results are very

dependent on

substrate.
191

12. Standards for Measurement of Corrosion, Wear and Thermal

Properties

12.1 Bare

ASTM C 177

Standard Test Method for Steady-State Heat Flux Measurements and Thermal

Transmission Properties by Means of the Guarded-Hot-Plate Apparatus

General Description Data Produced

This Method establishes the criteria

for measurement of the one

dimensional steady state heat flux

through flat, homogeneous

specimens. General guidelines for

design of the apparatus and testing

are given The test consists of heating

one side of a flat specimen with a

resistance heater in a carefully

insulated arrangement and limiting

heat flux to the thickness of the

specimen with temperatures

measured on both sides of the

specimen. This is a primary method of

measurement. ASTM C 1043, C 1044

and C 1045 accompany this Method.

The apparatus may be designed to

operate in controlled environments or

at elevated or reduced temperatures.

Heat input and specimen

temperatures are measured

and used to calculate thermal

transmission properties per

ASTM C 1045.

Intended Application Specimen Requirement Limits

Laboratory measurement

of heat flux which

enables calculation

of conductivity.

Specimen size is

determined by heater

size and other

experimental

considerations.

Specimen conductance

should be less than

16 W/(m2K). Layer

structures with

inhomogeneities normal

to the heat flux direction

can be measured.

Inhomogeneities in the

heat flux direction can

yield results that are

location specific and are

inappropriate for

this apparatus.
192

ASTM C 1043

Standard Practice for Guarded-Hot-Plate Design Using Circular

Line-Heat Sources

General Description Data Produced

This Practice covers the design of a

circular line-heat-source guarded hot

plate for use in accordance with

ASTM test Method C 177-Test

Method for Steady State Heat Flux

Measurements and Thermal

Transmission Properties by Means of

the Guarded Hot Plate Apparatus.

The Practice provides: guidance in

determining the mean temperature

of the meter plate, information and

calculation procedures for (1) control

of edge heat loss or gain, (2) location

and installation of line-heat sources,

(3) design of the gap between the

meter and guard plates, (4) location

of heater leads for the meter plate.

Provides detailed design data for

fabrication of a device which performs

in accordance with ASTM C 177.

Intended Application Specimen Requirement Limits

Supports fabrication of a

guarded hot plate for

measurement of thermal

transmission properties.

Specimen size is

determined by heater

size and other

experimental

considerations.

The line-heat-source

guarded hot plate has

been used over a mean

temperature range of

-10 °C to +65 °C with

circular metal plates and

a single line-heat source

in the meter plate.

However, the practice

does not preclude

(1) lower or higher

temperatures, (2) lineheat sources other than

circular, (3) plate

geometries other than

circular, (4) the use of

plated fabricated from

ceramics, composites or

other materials, (4) the

use of multiple line-heat

sources in both the

meter and guard plates.
193

ASTM C 1044

Standard Practice for using a Guarded-Hot-Plate Apparatus or Thin-Heater

Apparatus in the Single-Sided Mode

General Description Data Produced

This Practice covers the determination

of the steady-state heat flow through

the meter section of a specimen when

a guarded hot plate apparatus or

thin-heater apparatus is used in the

single-sided mode. This Practice

supplements ASTM C 177 or

ASTM C 1114 for testing a single

specimen. Procedure, heat flow

calculation, and sources of

experimental error are included.

Thermal transmission properties

are determined in accordance

with ASTM C 177.

Intended Application Specimen Requirement Limits

Supports operation of

the guarded hot plate

apparatus in the single

sided mode for the

determination of thermal

transmission properties.

Specimen size is

determined by heater

size and other

experimental

considerations.

The Practice requires

that the cold plates of

the apparatus have

independent temperature

controls.
194

ASTM C 1045

Standard Practice for Calculating Thermal Transmission Properties Under

Steady-State Conditions

General Description Data Produced

This Practice gives a uniform

procedure for calculating thermal

transmission properties of a material

or system from data generated by

steady state, one dimensional test

methods used to determine heat flux

and surface temperatures. It is

intended to eliminate the need for

similar calculation sections in

ASTM C 177 and other Standards and

allow concentration on measurement

details rather than calculation details.

Apparent thermal conductivity is

obtained as a function of temperature

with data obtained from ASTM C 177

or other test methods.

Intended Application Specimen Requirement Limits

Supports operation of

the guarded hot plate

apparatus in the single

sided mode for the

determination of thermal

transmission properties.

Specimen size is

determined by heater

size and other

experimental

considerations.

ASTM C 177 shall be

considered the final

authority for materials

having flat geometry;

C 335 shall be used for

materials having a

cylindrical geometry.
195

ASTM E 1461

Standard Test Method for Thermal Diffusivity by the Flash Method

General Description Data Produced

This comprehensive test Method

details measurement of thermal

diffusivity using the laser flash

method. In brief, the material of

concern is heated on one side (front

face) with a laser or flash lamp and

the temperature rise on the opposite

side (back face) is measured.

Thermal conductivity can be

calculated using diffusivity results,

specific heat capacity and density.

Document includes interferences,

detailed description of apparatus

requirements, specimen requirements,

calibration and verification, procedure,

calculation, precision and bias

statement. Measurements may be

conducted at elevated temperature

or in other non-ambient conditions

using an appropriate environmental

chamber.

Temperature and time data measured

on the back face of the specimen is

used to calculate thermal diffusivity.

Intended Application Specimen Requirement Limits

General measurement of

thermal diffusivity of

homogeneous solids.

The method has been

used for composite and

layered materials.

Specimens are typically

a circular disk with a

front face area less than

the energy beam, usually

6 mm to 18 mm in

diameter. Thicknesses

are typically 1 mm to

6 mm. Sample faces

should be flat and

parallel within 5% of their

thickness with uniform

surfaces. Translucent or

reflective materials may

be coated.

Non-homogenous

materials may have heat

flow patterns which may

render diffusivity values

inaccurate, but still

useful for limited

comparisons. Precision

of ± 5% can be attained

for diffusivity.
196

ISO 8302

Thermal Insulation – Determination of Steady-State Thermal Resistance and

Related Properties – Guarded-Hot-Plate Apparatus

General Description Data Produced

This is an extensive Standard detailing the

use of the guarded hot plate to measure

the steady-state heat transfer through flat

slab specimens and the calculation of heat

transfer properties. This is an absolute,

or primary, method of measurement since

only measurements of length; temperature

and electrical power are required. A flat

specimen, which may be layered, is

heated on one side and temperature

on the opposite side is measured. All

measurements are conducted in an

apparatus which controls heat flow.

The technique is sensitive to specimen

dimensions, finish and homogeneity.

The limit for thermal resistance may be

as low as 0.02 m2 K/W but accuracy over

the full range may not be achieved.

The Standard includes detailed information

on instrumentation and calculation of heat

transfer properties. Temperature limits

are not specified.

Test data consists of measured specimen

dimensions, temperatures on either side

of the test specimen and electrical power

input. These data are used to calculate

thermal resistance. 

Intended Application Specimen Requirement Limits

The Standard is intended

to provide the means for

determining the steady

state heat transfer

properties of flat slab

specimens.

Specimen size

requirements may

limit the utility of this

method for evaluation

of materials typically

manufactured for some

high temperature

applications.

Specimens should typically

be homogeneous.

Homogeneous porous

specimens should have

inhomogeneities smaller

than one-tenth of the

specimen thickness.

Specimen dimensions

should be 0.2 m to 1 m

diameter or square.

Samples should be

representative of the bulk

material, which may

determine specimen size.

Specimen flatness is

important. Specimen

thickness is limited by

contact resistances and

thickness measurement

accuracy.

Accuracy is a function

of apparatus design,

instrumentation and

specimen type. When this

standard is followed, the

method is capable of

measuring heat transfer

properties accurate to

within ± 2% when the

mean temperature of the

test is near room

temperature. Accuracy

of ± 5% should be

obtainable anywhere

within the full operating

range of the apparatus.

Reproducibility should

be better than ± 1%.
197

SAE AMS-STD-753

Corrosion-Resistant Steel Parts: Sampling, Inspection and Testing for

Surface Passivation

(Aerospace Material Specification)

General Description Data Produced

This Standard is adopted from

Mil-STD-753C. It describes methods

of sampling and testing for surface

passivity of steels with chromium

contents in excess of 10.5%.

Five test methods are listed for the

determination of free iron or other

anodic surface contaminants: water

immersion, high humidity, copper

sulfate, potassium ferricyanide-nitric

acid solution and salt spray

(ASTM B 117). Determination

of presence of free iron is

by visual inspection.

Evidence or indication of no

surface contaminants.

Intended Application Specimen Requirement Limits

The standard is intended

to test for the

effectiveness or need

for passivation.

No surface

contaminants.

The copper sulfate test

is not recommended for

use on martensitic 400

series alloys or lower

chromium grades (less

than 16%) of ferritic 400

series alloys.The

potassium ferricyanide

test is more sensitive to

the presence of free iron

than the copper sulfate

test and is

recommended for use

only on austenitic AISI

200 and 300 series

alloys when the

determination of trace

amounts of free iron

is required.
198

12.2 Coated

ASTM B 651

Standard Test Method for Measurement of Corrosion Sites in Nickel Plus

Chromium or Copper Plus Nickel Plus Chromium Electroplated Surfaces with

Double-Beam Interference Microscope

General Description Data Produced

This Method allows the measurement

of average dimensions and number of

corrosion sites in decorative coatings

electroplated onto steel. Corrosion pit

lateral dimensions are measured

optically with magnifiers or

microscopes. Depths are measured

with an interference microscope.

Coating thickness is measured on a

metallographically prepared crosssection. The Method includes

descriptions of the apparatus,

specimen preparation, procedures

for measurement of crack and pit

depth and average number,

reporting, precision and bias.

Numeric values for number of pits

and cracks as well as pit and

crack dimensions.

Intended Application Specimen Requirement Limits

For comparing the

relative corrosion

resistance of different

electroplating systems

and for comparing the

corrosiveness of different

environments.

Clean surfaces. Precision can be as

good as ± 1μm. Bias can

be as good as ± 1μm.
199

ASTM F 326

Standard Test Method for Electronic Measurement for Hydrogen Embrittlement

from Cadmium-Electroplating Processes

General Description Data Produced

This Method describes the use of a

metal-shelled vacuum probe to

evaluate electrodeposited cadmium

characteristics, principally porosity,

relative to hydrogen permeation.

The Method includes detailed

descriptions of the apparatus,

reagents, preparation and calibration

of the apparatus, procedure and

calculations. It is useful particularly

when hydrogen embrittlement, as of

high strength steels, may be an issue

due to limits of hydrogen bake-out

after plating caused by cadmium

plate low permeability.

Hydrogen pressure and cell current

used to calculate hydrogen

permeability of cadmium plate.

Intended Application Specimen Requirement Limits

The test provides a

quantitative “control

number” for cadmium

plate porosity which can

be used as a process

control or as a process

development research

tool. This method is used

in conjunction with stress

rupture or other tests

when intended to control

a critical process.

Unpainted bare steel

prepared as in

production process

of interest.

The Method specifies an

“acceptable zone” of

time in seconds for

hydrogen pressure to

drop to half its value

during post plate baking.
200

ASTM F 1978

Standard Test Method for Measuring Abrasion Resistance of Metallic Thermal

Spray Coatings by Using the Taber Abraser

General Description Data Produced

This Method quantifies the loss of

mass of plasma sprayed coatings

when evaluated on the Taber Abraser

with a 250 g mass. The specimen

is rotated under a pair of abrasive

wheels which gives rolling and rubbing

wear. The Method includes description

of the apparatus and supplier,

specimen, procedure, calculation

of mass loss per rotational cycle,

reporting and information on

precision and bias determined

in an interlaboratory study.

Cumulative mass loss.

Intended Application Specimen Requirement Limits

Characterizing coatings

used on surgical

implants.

Flat specimens either

round with a 10 cm

diameter and at least

0.16 cm (0.0625 in.)

thick; or 10 cm (4 in.)

squares, same

thickness, both with a

0.64 cm (0.250 in.) hole

in the center. Coatings

representative of that

used in the intended

implant. Six specimens,

generally, required

per material.

Flat, rigid specimens

which do not react

significantly with rinsing

water and do not have

phase transformations

or chemical reactions

between room

temperature and 100 °C

in air. An interlaboratory

study (ILS) of a 100

cycle test showed a

repeatability of 0.012 g

and a reproducibility of

0.017 g for a material

with an average weight

loss of 0.504 g.

More extensive ILS

data is provided.
201

ISO 4536

Metallic and Non-Organic Coatings on Metallic Substrates – Saline Droplets

Corrosion Test (SD Test)

General Description Data Produced

This standard describes the procedure

for evaluation of coatings, particularly

conversion coatings, to ascertain

corrosion resistance. A spray of

aqueous saline solution is applied to

test specimens to create discrete

droplets on the surface. Specimens

are evaluated visually after exposure

in a chamber with relative humidity

controlled according to a specification.

Data produced may be visual

appearance after test or after removal

of corrosion product, number and

distribution of corrosion defects, time

lapsed before signs of corrosion are

observed.

Intended Application Specimen Requirement Limits

Intended for the

evaluation of corrosion

resistance where the

droplets may be a more

severe condition than a

continuous moving

moisture film.

Clean specimens which

can be of complex

shapes.

Criteria for evaluation of

test results will be given

in a product

specification. Results of

this test should not be

regarded as a guide to

corrosion resistance in

all environments.
202

ISO 4538 

Metallic coatings – Thioacetamide Corrosion Test (TAA test)

General Description Data Produced

This Standard is intended to assess

the corrosion resistance of metal

surfaces in atmospheres containing

volatile sulphides. Test specimens are

exposed to vapors from thioacetimide

in an atmosphere of 75% relative

humidity maintained by the presence

of a saturated solution of sodium

acetate. The test is conducted in a

chamber for a duration of generally

less than 2 weeks with visual

inspection hourly or daily.

Descriptions of apparatus and

procedures are included.

Product specifications determine

evaluation criteria which may be

appearance after test, time to first

signs of corrosion, or number and

distribution of corrosion defects.

Methods for assessment of defects

are specified in ISO 1462.

Intended Application Specimen Requirement Limits

Intended to accompany

a coating or product

specification for

assessment of tarnishpreventing treatments

on silver or copper

and the detection of

discontinuities in

precious metal coatings

on these materials.

Product specification

may specify test sample

or product to be tested.

Samples shall be clean

and cut edges protected.

Type and number of test

specimens, exposure

period, failure criteria are

not included in this

Standard but should be

included in the product

specification.
203

ISO 8993

Anodized Aluminum and Aluminum Aloys – Rating System for the Evaluation

of Pitting Corrosion – Chart Method

General Description Data Produced

This Standard describes the method

for a rating system that defines levels

of pitting corrosion. Test materials are

cleaned to reveal corrosion pits.

Cleaned surfaces are compared to

illustrative charts included in the

standard. Seven alphabetic levels of

percentage of area of defects are

illustrated in the charts, each with six

sub-levels. Designations range from

an “A” rating for no defects to an “H1”

to “H6” rating for greater than 0.5%

area of defects. This Standard is

similar in purpose to ISO 8994.

Data consists of a visual or electronic

comparison with charts included in

the Standard.

Intended Application Specimen Requirement Limits

The rating system is

applicable to pitting

corrosion resulting from

accelerated tests,

exposure to corrosive

environments and

practical service tests.

Corrosion products or

deposits are removed

from the subject surface

by abrasion with a fine

pumice slurry, dipping in

30% nitric acid for 5 min

to 10 min, or by

dissolving the anodic

coating in a hot

phosphoric acid-chromic

acid mixture.

Only accounts for pitting

corrosion of the basis

metal resulting from

penetration of the

protective anodic

coating.
204

ISO 8994

Anodized Aluminum and Aluminum Alloys – Rating System for the Evaluation

of Pitting Corrosion – Grid Method

General Description Data Produced

This Standard describes the method

for a rating system that defines levels

of pitting corrosion. Test materials are

cleaned to reveal corrosion pits.

A transparent grid of at least

5,000 mm2 with 5 mm x 5 mm grid

squares is placed over the area of

interest and the percentage of

squares containing a pit determined.

The percent containing pits is

converted to a rating number. Grid

ratings range from 0 for no grid

squares with pits to 40 for 5.01% and

greater of grid squares with defects.

This Standard

Data consists of a count to determine

percent of grid squares with defects.

Intended Application Specimen Requirement Limits

The rating system is

applicable to pitting

corrosion resulting from

accelerated tests,

exposure to corrosive

environments and

practical service tests.

The system is frequently

used for rating short

term corrosion tests of

thin anodic coatings

used in the automotive

industry.

Corrosion products or

deposits are removed

from the subject surface

by abrasion with a fine

pumice slurry, dipping in

30% nitric acid for 5 min

to 10 min, or by

dissolving the anodic

coating in a hot

phosphoric acid-chromic

acid mixture. 

Only accounts for pitting

corrosion of the basis

metal resulting from

penetration of the

protective anodic

coating.
205

ISO 4540

Metallic Coatings – Coatings Cathodic to the Substrate – Rating of

Electroplated Test Specimens Subjected to Corrosion Tests

General Description Data Produced

This Standard specifies a method of

evaluating the condition of

electroplated test specimens that

have been exposed to corrosive

environments for test purposes.

The method is applicable only to

decorative and protective coatings

that are cathodic to the substrate;

i.e., nickel plus chromium or copper

plus nickel plus chromium on steel

or zinc die castings. The method

provides a rating system that assigns

a rating which (a) describes the

appearance as affected by corrosion

of the substrate and, (b) describes

the appearance as affected by

corrosion of the coating itself.

Levels of protection rating from 10

(no defects) to 0 (greater than 50%

area covered with defects) are

assigned by comparing the test piece

with dot charts and photographs

included in the standard.

Visual examination and comparison

with included charts and photographs

gives numeric ratings. The rating

number assigned to the ability to

protect the substrate is called the

“protection” rating. The number

assigned to describe the overall

appearance is called the

“appearance” rating.

Intended Application Specimen Requirement Limits

Intended to describe the

condition of electroplated

coatings.

Specimens are typically

10 cm x 15 cm test

panels. Specimens

should not be cleaned

before inspection

if possible.

Not intended for use with

anodic sacrificial

coatings such as zinc

and cadmium on steel.

Defects to be taken into

account include only

those that can be seen

by the unaided eye.
206

ISO 4541

Metallic and Other Non-Organic Coatings – Corrodkote Corrosion Test

(CORR test)

General Description Data Produced

This Standard provides guidance on

assessment of corrosion resistance of

metallic coatings by the Corrodkote

procedure. The procedure consists of

preparing a slurry of copper nitrate

trihydrate, iron chloride hexahydrate

and ammonium chloride with ceramic

grade kaolin. The saturated kaolin is

brushed onto the test surface.

The slurry layer (0.08 mm to 0.2 mm

thick) is allowed to dry before the

test specimen is placed in a humidity

chamber with temperature controlled to

38 °C. Test cycle time is typically 16 h.

Slurry is reapplied after each cycle.

After humidity chamber exposure,

specimens are cleaned, removing

corrosion products.

The points of coating failure are

identified by exposure to a medium

which is corrosive to the basis metal,

such as ISO 3768, but not the coating.

Evaluation typically consists of visual

appearance after testing, appearance

after removal of corrosion products,

number and distribution of corrosion

defects assessed per ISO 1462,

for example.

Descriptions of appearance of surface

and quantitative evaluation by a

method such as ISO 1462.

Intended Application Specimen Requirement Limits

The method and

evaluation criteria may be

used in product or

purchase specifications.

The method is primarily

applicable to coppernickel-chromium or

nickel- chromium

electroplated parts.

Type and number of

specimens are

determined by relevant

product or purchase

specification. Specimens

should be solvent

cleaned before testing

with a material which is

non-corrosive and does

not create a protective

film. Specimens may be

cut from sheet material

but cut edges should

be protected.

Test results should not be

regarded as a direct

guide to the corrosion

resistance of the tested

materials in all

environments.

Relative ranking in

the test may not be

the same as ranking

in service.
207

ISO 9227

Corrosion Tests in Artificial Atmospheres – Salt Spray Tests 

General Description Data Produced

This Standard specifies the procedure for

determining the corrosion resistance of

metallic materials, including those with

inorganic or organic coatings. The test

consists of spraying neutral salt solution

(NSS), or acetic acid salt (ACSS) solution,

or copper accelerated acetic acid solution

(CASS) on specimens in a salt spray

cabinet with controlled temperature and

determining extent of corrosion after a

predetermined exposure time. The

Standard provides details of solution

preparation and a salt spray cabinet

design. Reference specimens are required

for each test. Supercedes ISO 3768.

Test data consists of appearance before

and after removing corrosion products,

number and distribution of corrosion

defects which may be assessed by ISO

1462 or ISO 4540, elapsed time before

appearance of corrosion, mass change,

change in mechanical properties,

alteration revealed by microscopic

examination.

Intended Application Specimen Requirement Limits

The Standard is intended

to assess the corrosion

resistance of metallic

materials with or without

permanent or temporary

corrosion protection. The

Standard may be included

in a specification. Useful

for detecting discontinuities

such as pores and other

defects in certain metallic,

anodic oxide and

conversion coatings.

The NSS applies to metals

and their alloys, certain

metallic coatings (anodic

and cathodic), certain

conversion coatings, certain

anodic oxide coatings, and

organic coatings on metallic

materials. The AASS is

useful for testing decorative

coatings of copper+nickel+

chromium or nickel+

chromium. The CASS is

useful for testing decorative

coatings of copper+nickel+

chromium or nickel+

chromium. It is also useful

for testing anodic coatings

on aluminum.

Detailed requirements for

reference specimens of

CR4 grade steel according

to ISO 3574 are provided.

Test specimen number,

size, shape and

arrangement in the spray

cabinet shall be agreed

upon by participating

parties. Specimens shall

be cleaned in such a way

as to remove contaminants

but not affect the surface

adversely.

Test results shall not be

regarded as a direct guide

to the corrosion resistance

of tested materials in all

environments. Test

performance should not

be taken as a direct guide

to performance in service.
208

ISO 10289

Methods for Corrosion Testing of Metallic and Other Inorganic Coatings on

Metallic Substrates – Rating of Test Specimens and Manufactured Articles

Subjected to Corrosion Tests

General Description Data Produced

This Standard supersedes ISO 1460

and provides guidance for rating

coatings that provide corrosion

protection to a substrate or provide

visual effects. The performance rating

includes a protection rating and an

appearance rating. The protection

rating is a simple numerical rating

while the appearance rating may

include specific defects along with

a numerical rating designating the

intensity. Types of defects are

identified, the method of inspection

of defects are identified.

Visual observation of corrosion sites

or products which are given

numeric values.

Intended Application Specimen Requirement Limits

Intended for evaluation

of the condition of test

materials or articles

exposed to corrosive

test conditions or

other purposes.

Product specification

may specify test sample

or product to be tested.

Samples shall be clean

and cut edges protected.

Generally qualitative

assessment.
209

SAE J400 

Test for Chip Resistance of Surface Coatings 

(SAE Recommended Practice)

General Description Data Produced

This Practice describes the use of a 

“Gravelometer” which projects sized

gravel against a flat test panel to

assess the resistance to chipping of

organic surface coatings used in 

automotive applications. Equipment is

described and equipment supplier

identified. Test procedure including

evaluation based on an SAE Chipping

Rating Standard (EA-400) is provided.

Assessment of coating

material damage.

Intended Application Specimen Requirement Limits

This test provides a

means of evaluating

automotive coatings

and coating systems

and has been

correlated with

field results.

Test panels should be

10.16 cm x 30.48 cm

(4 in. x 12 in.) and

typically 20 gage

(0.091 cm (0.0359 in.))

material with typical

preliminary surface

treatment such as

phosphatizing

or anodizing.

Exact counting and

visual comparison

techniques are used to

establish a rating which

should not differ by

more than one

number-letter

rating in a test

sequence.
210

13. Surface Engineering Measurement Standards

13.1 ASME (American Society of Mechanical Engineers) Standards

B46.1 Surface Texture (Surface Roughness, Waviness, 63

and Lay) American National Standard

13.2 ASTM International (American Society for Testing and Materials)

Standards

A 90/A 90M Standard Test Method for Weight (Mass) of Coating on 125

Steel Articles with Zinc or Zinc-Alloy Coatings

A 309 Standard Test Method for Weight and Composition of 126

Coating on Terne Sheet by the Triple Spot Test

A 428/A 428M Standard Test Method for weight (Mass) of Coating on 127

Aluminum Coated Iron or Steel Articles

A 630 Standard Test Methods for Determination of Tin Coating 128

Weights for Electrolytic Tin Plate

A 754/A 754M Standard Test Method for Coating Weight (Mass) of 129

Metallic Coatings on Steel by X-ray Fluoresence

A 802/A 802M Standard Practice for Steel Castings, Surface 57

Acceptance Standards, Visual Examination

A 833 Standard Practice for Indentation Hardness of 155

Metallic Materials

A 896 Standard Practice for Conducting Case Studies on 75

Galvanized Structures

A 902 Standard Terminology Relating to Metallic Coated Steel 10

Products

B 137 Standard Test Method for Measurement of Coating Mass 130

Per Unit Area on Anodically Coated Aluminum

B 244 Standard Test Method for Measurement of Thickness of 99

Anodic Coatings on Aluminum and of Other Nonconductive 

Coatings on Nonmagnetic Basis Metals with Eddy-Current

Instruments

B 277 Standard Test Method for Hardness of Electrical 156

Contact Materials
211

B 294 Standard Test Method for Hardness Testing of 157

Cemented Carbides

B 487 Standard Test Method for Measurement of Metal and 100

Oxide Coating Thickness by Microscopical 

Examination of a Cross-Section

B 489 Standard Practice for Bend Test for Ductility of 181

Electrodeposited and Autocatalytically Deposited 

Metal Coatings on Metals

B 490 Standard Practice for Micrometer Bend Test for 182

Ductility of Electrodeposits

B 499 Standard Test Method for Measurement of Coating 101

Thickness by the Magnetic Method: Nonmagnetic 

Coatings on Magnetic Basis Metals

B 504 Standard Test Method for Measurement of Thickness of 102

Metallic Coatings by the Coulometric Method

B 530 Standard Test Method for Measurement of Coating 103

Thickness by the Magnetic Method: Electrodeposited 

Nickel Coatings on Magnetic and Nonmagnetic Substrates

B 555 Standard Guide for Measurement of Electrodeposited 104

Metallic Coating Thickness by the Dropping Test

B 556 Standard Guide for Measurement of Thin Chromium 105

Coatings by Spot Test

B 567 Standard Test Method for Measurement of Coating 106

Thickness by the Beta Backscatter Method

B 568 Standard Test Method for Measurement of Coating 107

Thickness by X-ray Spectrometry

B 571 Standard Practice for Qualitative Adhesion Testing of 187

Metallic Coatings

B 578 Standard Test Method for Microhardness of 158

Electroplated Coatings

B 588 Standard Test Method for Measurement of Thickness of 108

Transparent or Opaque Coatings by Double-Beam 

Interference Microscope Technique
212

B 602 Standard Test Method for Attribute Sampling of 21

Metallic and Inorganic Coatings

B 647 Standard Test Method for Indentation Hardness of 159

Aluminum Alloys by Means of a Webster Hardness Gage

B 648 Standard Test Method for Indentation Hardness of 160

Aluminum Alloys by Means of a Barcol Impressor

B 651 Standard Test Method for Measurement of Corrosion Sites 198

in Nickel Plus Chromium or Copper Plus Nickel Plus

Chromium Electroplated Surfaces with Double-Beam 

Interference Microscope

B 659 Standard Guide for Measuring Thickness of Metallic and 109

Inorganic Coatings

B 681 Standard Test Method for Measurement of Anodic Coatings 110

on Aluminum and Other Transparent Coatings on Opaque

Surfaces Using the Light-Section Microscope

B 697 Standard Guide for Selection of Sampling Plans for 22

Inspection of Electrodeposited Metallic and 

Inorganic Coatings

B 721 Standard Test Method for Microhardness and Case 88

Depth of Powder Metallurgy (P/M) Parts 

B 724 Standard Test Method for Indentation Hardness of 161

Aluminum Alloys by Means of a Newage, Portable, 

Non-Caliper-Type Instrument 

B 735 Standard Test Method for Porosity in Gold Coatings on 141

Metal Substrates by Nitric Acid Vapor

B 741 Standard Test Method for Porosity in Gold Coatings on 142

Metal Substrates by Paper Electrography

B 762 Standard Test Method of Variables Sampling of 23 

Metallic and Inorganic Coatings

B 765 Standard Guide for Selection of Porosity Tests for 143

Electrodeposits and Related Metallic Coatings

B 767 Standard Guide for Determining Mass Per Unit Area of 131

Electrodeposited and Related Coatings by Gravimetric

and Other Chemical Analysis Procedures
213

B 797 Standard Test Method for Surface Finger Penetration 136

Depth of Interparticle Oxide Networks in 

Powder Forged (P/F) Steel Parts

B 798 Standard Test Method for Porosity in Gold or 144

Palladium Coatings on Metal Substrates by 

Gel-Bulk Electrography

B 799 Standard Test Method for Porosity in Gold and Palladium 145

Coatings by Sulfurous Acid/Sulfur-Dioxide Vapor

B 809 Standard Test Method for Porosity in Metallic Coatings 146

by Humid Sulfur Vapor (“Flowers-of-Sulfur”)

B 866 Standard Test Method for Gross Defects and 25

Mechanical Damage in Metallic Coatings by

Polysulfide Immersion

B 874 Standard Specification for Chromium Diffusion 80

Coating Applied by Pack Cementation Process

B 875 Standard Specification for Aluminum Diffusion 81

Coating Applied by Pack Cementation Process

B 877 Standard Test Method for Gross Defects and 26

Mechanical Damage in Metallic Coatings by the

Phosphomolybdic Acid (PMA) Method

C 177 Standard Test Method for Steady-State Heat Flux 191

Measurements and Thermal Transmission Properties by

Means of the Guarded-Hot-Plate Apparatus

C 536 Standard Test Method for Continuity of Coatings in 85

Glassed Steel Equipment by Electrical Testing

C 537 Standard Test Method for Reliability of Glass Coatings on 86

Glassed Steel Reaction Equipment by High Voltage

C 633 Standard Test Method for Adhesion or Cohesion 188

Strength of Thermal Spray Coatings

C 664 Standard Test Methods for Thickness of Diffusion Coating 111

C 743 Standard Test Method for Continuity of 87

Porcelain Enamel Coatings
214

C 1043 Standard Practice for Guarded-Hot-Plate Design 192

Using Circular Line-Heat Sources 

C 1044 Standard Practice for using a Guarded-Hot-Plate 193

Apparatus or Thin-Heater Apparatus in the

Single-Sided Mode

C 1045 Standard Practice for Calculating Thermal Transmission 194

Properties Under Steady-State Conditions

C 1326 Standard Test Method for Knoop Indentation 162

Hardness of Advanced Ceramics

C 1327 Standard Test Method for Vickers Indentation 163

Hardness of Advanced Ceramics

D 4417 Standard Test Methods for Field Measurement of 51

Surface Profile of Blast-Cleaned Steel

D 4541 Standard Test Method for Pull-Off Strength of 189

Coatings Using Portable Adhesion Testers

D 5723 Standard Practice for Determination of Chromium 132

Treatment Weight on Metal Substrates by

X-ray Fluorescence

E 3 Standard Guide for Preparation of Metallographic Specimens 137

E 10 Standard Test Method for Brinell Hardness of 164

Metallic Materials 

E 18 Standard Test Methods for Rockwell Hardness and 165

Rockwell Superficial Hardness of Metallic Materials

E 92 Standard Test Method for Vickers Hardness of 166

Metallic Materials

E 103 Standard Test Method for Rapid Indentation Hardness 167

Testing of Metallic Materials

E 110 Standard Test Method for Indentation Hardness of 168

Metallic Materials by Portable Hardness Testers 

E 140 Standard Hardness Conversion Tables for Metals 169

Relationship Among Brinell Hardness, Vickers Hardness, 

Rockwell Hardness, Superficial Hardness,

Knoop Hardness and Scleroscope Hardness
215

E 376 Standard Practice for Measuring Coating Thickness by 112

Magnetic-Field or Eddy-Current (Electromagnetic) 

Examination Methods

E 384 Standard Test Method for Microindentation 170

Hardness of Materials

E 430 Standard Test Methods for Measurement of Gloss of 52

High-Gloss Surfaces by Goniophotometry

E 448 Standard Practice for Scleroscope Hardness 179

Testing of Metallic Materials

E 562 Standard Test Method for Determining Volume Fraction by 138

Systematic Manual Point Count

E 673 Standard Terminology Relating to Surface Analysis 148

E 837 Standard Test Method for Determining Residual Stresses by 153

the Hole-Drilling Strain Gage Method

E 1077 Standard Test Methods for Estimating the Depth of 89

Decarburization of Steel Specimens

E 1127 Standard Guide for Depth Profiling in Auger 149

Electron Spectroscopy

E 1182 Standard Test Method for Measurement of Surface 113

Layer Thickness by Radial Sectioning

E 1418 Standard Test Methods for Visible Penetrant 53

Examination Using the Water-Washable Process

E 1426 Standard Test Method for Determining the Effective Elastic 154

Parameter for X-ray Diffraction Measurements of

Residual Stress 

E 1438 Standard Guide for Measuring Widths of Interfaces in 150

Sputter Depth Profiling Using SIMS

E 1461 Standard Test Method for Thermal Diffusivity by the 195

Flash Method

E 1659 Standard Test Methods for Coating Weight and Chemical 133

Analysis of Zinc-Nickel Alloy Electrolytically Coated on

Steel Sheet
216

E 1813 Standard Practice for Measuring and Reporting 62

Probe Tip Shape in Scanning Probe Microscopy

E 1920 Standard Guide for Metallographic Preparation of 139

Thermal Sprayed Coatings

E 2109 Test Methods for Determining Area Percentage Porosity in 147

Thermal Sprayed Coatings

F 326 Standard Test Method for Electronic Measurement for 199

Hydrogen Embrittlement from CadmiumElectroplating Processes

F 788/F 788M Standard Specification for Surface Discontinuities of 42

Bolts, Screws, and Studs, Inch and Metric Series

F 812/F812M Standard Specification for Surface Discontinuities of 43

Nuts, Inch and Metric Series

F 1044 Standard Test Method for Shear Testing of Calcium 183

Phosphate Coatings and Metallic Coatings

F 1147 Standard Test Method for Tension Testing of Calcium 184

Phosphate and Metallic Coatings

F 1160 Standard Test Method for Shear and Bending Fatigue 185

Testing of Calcium Phosphate

F 1438 Standard Practice for Determination of Surface 66

Roughness by Scanning Tunneling Microscopy for

Gas Distribution System Components

F 1501 Standard Test Method for Tension Testing of 186

Calcium Phosphate Coatings

F 1978 Standard Test Method for Measuring Abrasion 200

Resistance of Metallic Thermal Spray Coatings by

Using the Taber Abraser

F 2024 Standard Practice for X-ray Diffraction Determination 152

of Phase Content of Plasma Sprayed Hydroxyapatite

Coatings

G 171 Standard Test Method for Scratch Hardness of 178

Materials Using a Diamond Stylus
217

13.3 ISO (International Organization for Standards) Standards

1456 Metallic Coatings – Electrodeposited Coatings of Nickel Plus 76

Chromium and of Copper Plus Nickel Plus Chromium

1458 Metallic Coatings – Electrodeposited Coatings of Nickel 77

1460 See 10289 208

1463 Metallic and Oxide Coatings – Measurement of 114

Coating Thickness – Microscopical Method

2063 Metallic and Other Inorganic Coatings – Thermal Spraying – 83

Zinc, Aluminum and Their Alloys

2064 Metallic and Other Inorganic Coatings – Definitions and 124

Conventions Concerning the Measurement of Thickness

2079 Surface Treatment and Metallic Coatings – 10

General Classification of Terms

2080 Electroplating and Related Processes – Vocabulary 11

2081 Metallic Coatings – Electroplated Coatings of Zinc on 78

Iron or Steel

2082 Metallic Coatings – Electroplated Coatings of Cadmium on 79

Iron or Steel

2106 Anodizing of Aluminum and its Alloys – Determination of 134

Mass per Unit Area (Surface Density) of Anodic Oxide

Coatings – Gravimetric Method 

2128 Anodizing of Aluminum and its Alloys – Determination of 115

Thickness of Anodic Oxide Coatings – Non-Destructive

Measurement by Split Beam Microscope

2177 Metallic Coatings – Measurement of Coating Thickness – 116

Coulometric Method by Anodic Dissolution

2178 Nonmagnetic Coatings on Magnetic Substrates – 117

Measurement of Coating Thickness – Magnetic Method

2361 Electrodeposited Nickel Coatings on Magnetic and 118

Nonmagnetic Substrates – Measurement of

Coating Thickness – Magnetic Method
218

2639 Steels – Determination and Verification of the Depth of 90

Carburized and Hardened Cases

3057 Non-Destructive Testing – Metallographic Replica 140

Techniques of Surface Examination

3274 Geometrical Product Specifications (GPS) – Surface 27

Texture: Profile Method – Nominal Characteristics of

Contact (Stylus) Instruments

3497 Metallic Coatings – Measurement of Coating Thickness – 119

X-ray Spectrometric Methods

3543 Metallic and Nonmetallic Coatings – Measurement of 120

Thickness – Beta Backscatter Method

3613 Chromate Conversion Coatings on Zinc, Cadmium, 73

Aluminum-Zinc Alloys and Zinc-Aluminum Alloys – 

Test Methods

3754 Steel – Determination of Effective Depth of Hardening After 91

Flame or Induction Hardening

3868 Metallic and Other Non-Organic coatings – Measurement of 121 

Coating Thickness – Fizeau Multiple-Beam Interferometry Method

3878 Hardmetals – Vickers Hardness Test 171

3892 Conversion Coatings on Metallic Materials – Determination of 135

Coating Mass per Unit Area – Gravimetric Methods

4042 Fasteners – Electroplated Coatings 44

4287 Geometrical Product Specifications (GPS) – Surface Texture: 64

Profile Method – Terms, Definitions and Surface Texture Parameters

4288 Geometrical Product Specification (GPS) – Surface Texture: 28

Profile Method – Rules and Procedures for the 

Assessment of Surface Texture

4498-2 Sintered Metal Materials, Excluding Hard Metals – 172

Determination of Apparent Hardness 

Part 2: Case-hardened ferrous materials, surface enriched

by carbon or carbon and nitrogen

4518 Metallic Coatings – Measurement of Coating Thickness – 122

Profilometric Method
219

4519 Electrodeposited Metallic Coatings and Related Finishes – 24

Sampling Procedures for Inspection by Attributes

4520 Chromate Conversion Coatings on Electroplated 74

Zinc and Cadmium Coatings

4522-1 Metallic Coatings – Test Methods for Electrodeposited Silver 123

and Silver Alloy Coatings

Part 1: Determination of coating thickness

4536 Metallic and Non-Organic Coatings on Metallic Substrates – 201

Saline Droplets Corrosion Test (SD Test)

4538 Metallic Coatings – Thioacetamide Corrosion Test (TAA Test) 202

4540 Metallic Coatings – Coatings Cathodic to the Substrate – Rating of 205

Electroplated Test Specimens Subjected to Corrosion Tests

4541 Metallic and Other Non-Organic Coatings – Corrodkote 206

Corrosion Test (CORR Test)

4545 Metallic Materials – Hardness Test – Knoop Test 173

Part 1: Test method

4970 Steel – Determination of Total or Effective Thickness of 92

Thin Surface-Hardened Layers

6157-1 Fasteners – Surface Discontinuities 45

Part 1: Bolts, screws and studs for general requirements

6157-2 Fasteners – Surface Discontinuities 46

Part 2: Nuts

6157-3 Fasteners – Surface Discontinuities – 47

Part 2: Bolts, screws and studs for special requirements

6507-1 Metallic Materials – Vickers Hardness Test 174

Part 1: Test method 

7599 Anodizing of Aluminum and its Alloys – General Specifications 72

for Anodic Coatings on Aluminum

8302 Thermal Insulation- – Determination of Steady-State Thermal 196

Resistance and Related Properties – Guarded-Hot-Plate Apparatus

8501-1 Preparation of Steel Substrates Before Application of Paints and 64

Related Products – Visual Assessment of Surface Cleanliness
220

8502-1 Preparation of Steel Substrates Before Application of Paints and 29

Related Products – Tests for the Assessment of Surface Cleanliness

Part 1: Field test for soluble iron corrosion products

8502-2 Preparation of Steel Substrates Before Application of Paints and 29

Related Products – Tests for the Assessment of Surface Cleanliness 

Part 2: Laboratory determination of chloride on cleaned surfaces

8502-3 Preparation of Steel Substrates Before Application of Paints and 29

Related Products – Tests for the Assessment of Surface Cleanliness 

Part 3: Assessment of dust on steel surfaces prepared for 

painting (pressure-sensitive tape method)

8502-4 Preparation of Steel Substrates Before Application of Paints and 29

Related Products – Tests for the Assessment of Surface Cleanliness 

Part 4: Guidance on the estimation of the probability of 

condensation prior to paint application

8502-5 Preparation of Steel Substrates Before Application of Paints and 29

Related Products – Tests for the Assessment of Surface Cleanliness 

Part 5: Measurement of chloride on steel surfaces prepared for

painting (ion detection tube method)

8502-6 Preparation of Steel Substrates Before Application of Paints and 30

Related Products – Tests for the Assessment of Surface Cleanliness

Part 6: Extraction of soluble contaminants for analysis – 

The Bresle method

8502-8 Preparation of Steel Substrates Before Application of Paints and 30

Related Products – Tests for the Assessment of Surface Cleanliness

Part 8: Field method for the refractometric determination

of moisture

8502-9 Preparation of Steel Substrates Before Application of Paints and 30

Related Products – Tests for the Assessment of Surface Cleanliness

Part 9: Field method for the conductometric determination of

water-soluble salts

8502-10 Preparation of Steel Substrates Before Application of Paints and 30

Related Products – Tests for the Assessment of Surface Cleanliness

Part 10: Field method for the titimetric determination of 

water-soluble chloride

8502-12 Preparation of Steel Substrates Before Application of Paints and 30

Related Products – Tests for the Assessment of Surface Cleanliness

Part 12: Field method for the titimetric determination of

water soluble ferrous ions
221

8503-1 Preparation of Steel Substrates Before Application of Paints and 67

Related Products – Surface Roughness Characteristics of

Blast-Cleaned Steel Substrates

Part 1: Specifications and definitions for ISO surface profile

comparators for the assessment of abrasive blast-cleaned surfaces

8503-2 Preparation of Steel Substrates Before Application of Paints and 68

Related Products – Surface Roughness Characteristics of

Blast-Cleaned Steel Substrates

Part 2: Method for the grading of surface profile of abrasive

blast-cleaned steel – Comparator procedure

8503-3 Preparation of Steel Substrates Before Application of Paints and 69

Related Products – Surface Roughness Characteristics of

Blast-Cleaned Steel Substrates

Part 3: Method for the calibration of ISO surface profile

comparators and for the determination of surface profile –

Focusing microscope procedure

8503-4 Preparation of Steel Substrates Before Application of Paints and 70

Related Products – Surface Roughness Characteristics of

Blast-Cleaned Steel Substrates

Part 4: Method for the calibration of ISO surface profile

comparators and for the determination of surface profile –

Stylus instrument procedure

8503-5 Preparation of Steel Substrates Before Application of Paints and 71

Related Products – Surface Roughness Characteristics of

Blast-Cleaned Steel Substrates

Part 5: Replica tape method for the determination of the

surface profile

8785 Geometrical Product Specification (GPS) – Surface 31

Imperfections – Terms, Definitions and Parameters

8993 Anodized Aluminum and Aluminum Alloys – Rating System for 203

the Evaluation of Pitting Corrosion – Chart Method

8994 Anodized Aluminum and Aluminum Alloys – Rating System for 204

the Evaluation of Pitting Corrosion – Grid Method

9227 Corrosion Tests in Artifical Atmospheres – Salt Spray Tests 207

10289 Supersedes 1460 208

Methods for Corrosion Testing of Metallic and Other Inorganic 

Coatings on Metallic Substrates – Rating of Test Specimens and

Manufactured Articles Subjected to Corrosion Tests
222

11562 Geometrical Product Specifications (GPS) – Surface Texture: 32

Profile Method – Metrological Characteristics of Phase Correct Filters

11971 Visual Examination of Surface Quality of Steel Castings 57

12085 Geometrical Product Specification (GPS) – Surface Texture: 33

Profile Method – Motif Parameters

13565-1 Geometrical Product Specifications (GPS) – Surface Texture: 34

Profile Method; Surfaces Having Stratified Functional Properties – 

Part 1: Filtering and general measurement conditions

13565-2 Geometrical Product Specifications (GPS) – Surface Texture: 35

Profile Method; Surfaces Having Stratified Functional Properties –

Part 2: Height characterization using the linear material ratio curve

13565-3 Geometrical Product Specifications (GPS) – Surface Texture: 36

Profile Method; Surfaces Having Stratified Functional Properties – 

Part 3: Height characterization using the material probability curve

13665 Seamless and Welded Steel Tubes for Pressure Purposes – 59

Magnetic Particle Inspection of the Tube Body for the

Detection of Surface Imperfections

14104 Gears – Surface Temper Etch Inspection After Grinding 58

14577-1 Metallic Materials – Instrumented Indentation Test for 175

Hardness and Materials Parameters

Part 1: Test method

14606 Surface Chemical Analysis – Sputter Depth Profiling – 151

Optimization Using Layered Systems as Reference Materials

14705 Fine Ceramics (Advanced Ceramics, Advanced Technical 176

Ceramics) – Test Method for Hardness of Monolithic

Ceramics at Room Temperature

14707 Surface Chemical Analysis – Glow Discharge Optical Emission 151

Spectrometry (GD-OES) – Introduction to use

13.4 Military and Industry Standards

MIL-STD-1687A (SH) Thermal Spray Processes for Naval Ship 84

Machinery Applications

Industry Standard Scratch Adhesion Test 190
223

13.5 SAE (Society of Automotive Engineers) Standards

J121 Decarburization in Hardened and Tempered Unified 48

Thread Fasteners (SAE Recommended Practice)

J122 Surface Discontinuities on Nuts (SAE Recommended Practice) 49

J123 Surface Discontinuities on Bolts, Screws, and Studs in 49 

Fatigue Applications (SAE Recommended Practice)

J349 Detection of Surface Imperfections in Ferrous Rods, 59

Bars, Tubes and Wires (SAE Information Report)

J358 Nondestructive Tests (SAE Information Report) 37

J359 Infrared Testing (SAE Information Report) 37

J400 Test for Chip Resistance of Surface Coatings 209

(SAE Recommended Practice)

J417 Hardness Tests and Hardness Number Conversions 177

(SAE Information Report)

J419 Methods of Measuring Decarburization 93

(SAE Recommended Practice)

J420 Magnetic Particle Inspection (SAE Information Report) 38

J423 Methods of Measuring Case Depth (SAE Standard) 94

J425 Electromagnetic Testing by Eddy-Current Methods 38 

(SAE Information Report)

J426 Liquid Penetrant Test Methods (SAE Information Report) 39

J428 Ultrasonic Inspection (SAE Information Report) 40

J448a Surface Texture (SAE Standard) 65

J449a Surface Texture Control (SAE Recommended Practice) 65

J810 Classification of Common Surface Imperfections in 54

Sheet Steel (SAE Information Report)

J864 Surface Hardness Testing with Files 180

(SAE Recommended Practice)
224

J911 Surface Roughness and Peak Count Measurement of 55

Cold Rolled Steel Sheet (SAE Recommended Practice)

J1061 Surface Discontinuities on General Application Bolts, 50

Screws, and Studs (SAE Recommended Practice)

J1242 Acoustic Emission Test Methods (SAE Information Report) 40

AMS 2440A Inspection of Ground, Chromium Plated Steel Parts 41

(Aerospace Material Specification)

AMS 2444A Coating, Titanium Nitride Physical Vapor Deposition 82

(Aerospace Material Specification)

AMS 2633B Ultrasonic Inspection (Aerospace Material Specification) 60

AMS 2647B Fluorescent Penetrant Inspection Aircraft and Engine 61

Component Maintenance (Aerospace Material Specification)

AMS 2649B Etch Inspection of High Strength Steel Parts 56

(Aerospace Material Specification)

AMS-STD-753 Corrosion-Resistant Steel Parts: Sampling, Inspection and 197

Testing for Surface Passivation

(Aerospace Material Specification)

ARP 1341 Determining Decarburization and Carburization in Finished 95

Parts of Carbon and Low-Alloy Steels 

(Aerospace Recommended Practice)

ARP 1820 Chord Method of Evaluating Surface Microstructural 96

Characteristics (Aerospace Recommended Practice)

AS 4194 Sheet and Strip Surface Finish Nomenclature 11

(Aerospace Standard)

AS 7101 National Aerospace and Defense Contractors Accreditation 12

Program (NADCAP) General Requirements for Materials Test

Laboratory Accreditation Program (Aerospace Standard)

AS 7109 National Aerospace and Defense Contractors Accreditation 13

Program Requirements for Coatings (Aerospace Standard)

AS 7109-1 National Aerospace and Defense Contractors Accreditation 14

Program Requirements for Thermal Spray

(Aerospace Standard)
225

AS 7109-2 National Aerospace and Defense Contractors Accreditation 15

Program Requirements for Vapor Deposit 

(Aerospace Standard)

AS 7109-3 National Aerospace and Defense Contractors Accreditation 16

Program Requirements for Cementation 

(Aerospace Standard)

AS 7109-4 National Aerospace and Defense Contractors Accreditation 17

Program requirements for Stripping (Aerospace Standard)

AS 7109-5 National Aerospace and Defense Contractors Accreditation 18

Program Requirements for Coating Evaluation Laboratory 

Practices (Aerospace Standard)

AS 7109-6 National Aerospace and Defense Contractors Accreditation 19

Program Requirements for Plating of Coated Parts Laboratory 

Practices (Aerospace Standard)

AS 7109-7 National Aerospace and Defense Contractors Accreditation 20

Program Requirements for Heat Treating for Suppliers of 

Coatings (Aerospace Standard)
226

14. Index

Subject Standard Page

A

Abrasion resistance

Thermal spray metallic coatings ASTM F 1978 200

Accreditation

Cementation SAE AS 7109-3 16

Coating evaluation laboratory practices SAE AS 7109-5 18

Coating stripping SAE AS 7109-4 17

Coating supplier SAE AS 7109 13

Materials test laboratory SAE AS 7101 12

Plating coated parts SAE AS 7109-6 19

Thermal spray SAE AS 7109-1 14

Vapor deposit SAE AS 7109-2 15

Acedic Acid Salt Solution (ACSS) ISO 9227 207

Adhesion testing of coatings

Adhesion strength ASTM C 633 188

Grid test ISO 2063 83

Portable testers ASTM D 4541 189

Qualitative measurement ASTM B 571 187

Paper Test ISO 3613 73

Scribe (grid) ISO 2063 83

Tape test SAE AMS 2444A 82

Aluminizing, See Aluminum diffusion coating

Aluminum 

Anodically coated, 

mass measurement ASTM B 137 130

Anodically coated,

specifications ISO 7599 72

thickness measurement ASTM B 244 99

Transparent anodic coating thickness ASTM B 681 110

Aluminum diffusion coating 

Standard specification ASTM B 875 81 

Supplier accreditation SAE AS 7109-3 16

Aluminum hardness 

Webster ASTM B 647 159

Barcol Impressor ASTM B 648 160

Newage non-caliper ASTM B 724 161
227

Aluminum-zinc coating 

Mass of, on steel ASTM A 754 129

Anodic coating 

Corrosion evaluation ISO 8993 203

ISO 8994 204

ISO 9227 207

Mass ASTM B 137 130

ISO 2106 134

Thickness ASTM B 244 99

Transparent, thickness ASTM B 681 110

ISO 2128 115

Appearance rating, coatings ISO 10289 208

ISO 4540 205

Attribute sampling, Metallic and inorganic coatings ASTM B 602 21

Auger electron spectroscopy (AES) ASTM E 1127 149

Autocatalytically deposited coatings, ductility of ASTM B 489 181

B

Bend test

Metal coating ductility ASTM B 489 181

Electrodeposited foil ductility ASTM B 490 182

Bendix test method, electrolytic tin

coating weight ASTM A 630 128

Beta backscatter, coating thickness measurement ASTM B 567 106

ISO 3543 120

Blast cleaned steel, See also Geometrical Product Specification

Surface profile ISO 8503-2 71

Bond strength, See also Adhesion testing of coatings

Thermal spray coatings ASTM C 633 188

Bresle method

for extraction of soluble surface contaminants ISO 8502-6 30

Brinell hardness, See Hardness

Metals ASTM E 10 164
228

C

Cadmium coating, 

Thickness measurement ASTM B 555 104

Hydrogen embrittlement from ASTM F 326 199

Calcium phosphate coating

Shear testing ASTM F 1044 183

Tension testing ASTM F 1147 184

ASTM F 1501 186

Phase content by X-ray diffraction ASTM F 2024 152

Carburization 

Depth measurement SAE ARP 1341 95

ISO 2639 90

Case depth 

Powder metallurgy parts ASTM B 721 88

Methods of measurement SAE J423 94

Steel, carburized and hardened cases ISO 2639 90

ISO 3754 91

ISO 4970 92

Case studies, galvanized structure ASTM A 896 75

Castings, steel, visual examination of surface quality ISO 11971 57

Cathodic coatings ISO 4540 205

Cemented carbides, hardness ASTM B 294 157

Ceramic, See also Calcium phosphate, Hydroxyapatite

Hardness, Knoop ASTM C 1326 162

ISO 14705 176

Hardness, Vickers ASTM C 1327 163

ISO 14705 176

Chart method of corrosion evaluation ISO 8993 203

Chemical and compositional analysis, See also Surface analysis

Depth profiling, AES ASTM E 1127 149

Interface width using SIMS ASTM E 1438 150

Terne sheet ASTM A 309 126

Zinc-nickel on steel sheet, nickel by 

Atomic absorption ASTM E 1659 133
229

Chemical vapor deposition Supplier accreditation, See Accreditation

Chip resistance of surface coatings SAE J400 209

Chloride on surface measurement

Bresle method ISO 8502-6 30

Conductometric ISO 8502-9 30

Ion detection tube method ISO 8502-5 29

Laboratory determination ISO 8502-2 29

Titrimetric Method ISO 8502-12 30 

Chromate conversion coating ISO 3613 73

ISO 4520 74 

Chromium coating

Pack cementation,

Accreditation SAE AS 7109-3 16

Specification ASTM B 874 80

Plated and ground, inspection SAE AMS 2440A 41

Thickness, electrodeposited ASTM B 556 105

Weight, by X-ray fluorescence ASTM D 5723 132

Chromizing, See also Chromium coating, Pack cementation 

Classification, conversion coatings ISO 4520 74

Coating, supplier accreditation SAE AS 7109 13

Coating adhesion strength, See Adhesion testing of coatings 

Coating attribute sampling ASTM B 602 21

Coating continuity

Glassed steel ASTM C 536 85

Porcelain enamel ASTM C 743 87

Coating ductility 

Metal coating ASTM B 489 181

Metal foil ASTM B 490 182

Coating evaluation, laboratory practices SAE AS 7109-5 18

Coating mass determination 

Anodically coated aluminum ASTM B 137 130

ISO 2106 134

Beta backscatter method ASTM B 567 106

Chromate coating ISO 3613 73
230

Chromium treatment on metal substrate,

X-ray fluorescence method ASTM D 5723 132

Conversion coatings ISO 3892 135

Electrolytic tin plate ASTM A 630 128

Metallic coating on steel, X-ray fluorescence,

on-line ASTM A 754 129

Terne sheet ASTM A 309 126

Zinc-nickel alloy on steel sheet,

chemical stripping ASTM E 1659 133

Zinc, zinc alloy on iron and steel ASTM A 90 125

Coating stripping, See also Accreditation,

Coating mass, Coating thickness

Coating thickness measurement

Anodic coatings on aluminum on opaque surfaces,

light section microscope ASTM B 681 110

Anodic coatings on aluminum,

Eddy-current method ASTM B 244 99

Split-beam microscope ISO 2128 115

Cadmium on iron or steel ISO 2082 79

Chromium over nickel and stainless steel,

spot test ASTM B 556 105

Coating on metallic substrate, magnetic-field or

eddy-current methods ASTM E 376 112

Definitions and conventions ISO 2064 124

Diffusion coating, micrometer and

microscopical ASTM C 664 111

Electrodeposited silver and silver alloys ISO 4522-1 123

Electrodeposited zinc, cadmium, copper and

tin coatings, dropping test ASTM B 555 104

Fasteners-electroplated coatings ISO 4042 44

Galvanized structures ASTM A 896 75

Metal and oxide, microscopical method ASTM B 487 100

ISO 1463 114

Metallic, coulometric method

anodic solution,electrochemical stripping ASTM B 504 102

ISO 2177 116

Metallic and inorganic coatings, standard guide ASTM B 659 109

Metallic and non-metallic,

beta backscatter method ASTM B 567 106

ISO 3543 120

Metallic and non-Organic,

Fizeau multiple-beam Interferometry ISO 3868 121

Metallic and some nonmetallic coatings,

X-ray spectrometry method ASTM B 568 107

ISO 3497 119
231

Nickel on magnetic and nonmagnetic

substrates, magnetic method ASTM B 530 103

ISO 2361 118

Nonmagnetic on magnetic metals,

magnetic method ASTM B 499 101

ISO 2178 117

Transparent metal oxide and metallic coatings,

double beam interference microscope ASTM B 588 108

ISO 2128 115

Zinc, electroplated ISO 2081 78

Cohesion strength, thermal spray coatings ASTM C 633 188

Cold shuts, See Surface discontinuities 

Composition, See Chemical and compositional analysis 

Conductometric determination of water soluble salts ISO 8502-9 30

Constant current test method for tin coating mass ASTM A 630 128

Conversion coating, chromate ISO 3613 73

ISO 4520 74

Mass per unit area ISO 3892 135

Copper Accelerated Acedic Acid Test (CASS) ISO 9227 207

Copper, coating thickness measurement ASTM B 555 104

Copper, electroplated

corrosion site measurement ASTM B 651 198

Coulometric method, thickness measurement ASTM B 504 102

Coating composition, See Chemical and compositional analysis 

Corrodkote corrosion test ISO 4541 206

Corrosion evaluation,

anodized aluminum ISO 8993 203

ISO 8994 204

ISO 9227 207

grid method ISO 8994 204

Corrosion rating, coatings ISO 10289 208
232

Corrosion site measurement, See also Electrography 

Electroplated surfaces ASTM B 651 198

Corrosion test,

metallic substrates ISO 4536 201

metallic coatings ISO 4538 202

ISO 4541 206

ISO 10289 208

salt spray ISO 9227 207

Cracks, See Surface discontinuities

Crystallographic phase, See Phase content

D

Decarburization depth

Steel ASTM E 1077 89

Threaded fasteners SAE J121 48 

Methods of measuring SAE J419 93

SAE ARP 1341 95

Depth profiling

Auger electron spectroscopy ASTM E 1127 149 

Depth of hardening, steel, flame or

induction hardened ISO 3754 91

Designation, electroplated coatings ISO 1456 76

Diffusion coating 

Aluminum specification ASTM B 875 81

Chromium specification ASTM B 874 80

Thickness measurement ASTM C 664 111

Dimensions, See also Coating thickness, Case depth, 

Decarburization depth, Surface roughness, 

Surface texture 

Ductility

Metal coatings ASTM B 489 181

Metal foils ASTM B 490 182

Dust, on steel ISO 8502-3 29
233

E

Eddy current measurement 

Coating Thickness ASTM B 244 99

ASTM E 376 112

Testing Generally SAE J425 38

Electrolytic tin plate ASTM A 630 128

Electrical contact materials,

Hardness measurement ASTM B 277 156

Electrodeposited coatings, See also Porosity measurement, 

Corrosion tests ISO 4540 205

ISO 4541 206

Designation ISO 1456 76

Ductility ASTM B 489 181

Gross defects ASTM B 765 143

Mass per unit area ASTM B 767 131

Mechanical damage ASTM B 765 143

Porosity test selection ASTM B 765 143

Requirements ISO 1456 76

ISO 1458 77

ISO 2081 78

ISO 2082 79

Stripping methods ASTM B 767 131

Thickness ASTM B 530 103

Vocabulary ISO 2080 11

Electrography

Paper ASTM B 741 142

Gel-bulk ASTM B 798 144

Electrical testing

Glassed steel coating continuity ASTM C 536 85

Porcelain enamel continuity ASTM C 743 87

Etch inspection 

Steel, after grinding and machining SAE AMS 2649B 56

Gears, after grinding ISO 14104 58

F

Fasteners-electroplated coatings ISO 4042 44
234

Field testing and measurement, See also Case studies, Portable

Hardness testing, Replica

Adhesion, coating, portable testing ASTM D 4541 189

Glassed steel coating continuity ASTM C 536 85

Surface profile ASTM D 4417 51

Fizeau multiple-beam interferometry for

coating thickness ISO 3868 121

Flame hardening depth ISO 3754 91

Flash method for thermal diffusivity ASTM E 1461 195

Flowers of sulfur, coating porosity test ASTM B 809 146

Fluorescent penetrant inspection SAE AMS 2647B 61

G

Galvanized structures ASTM A 896 75

Gears, surface temper etch inspection 

after grinding ISO 14104 58

Gel-bulk electrography, for 

porosity measurement ASTM B 798 144

Geometrical product specification (GPS)

Surface imperfections, terms,

definitions parameters ISO 8785 31

Surface texture: profile method

Metrological characteristics of

phase correct filters ISO 11562 32

Motif parameters ISO 12085 33

Rules and procedures for 

assessment of texture ISO 4288 28

Stylus characteristics ISO 3274 27

Terms, definitions, surface 

texture parameters ISO 4287 64

Surfaces having stratified functional propertiesPart 1-filtering and general

measurement conditions ISO 13565-1 34

Part 2- height characterization using

linear material ratio curve ISO 13565-2 35

Part 3- height characterization using

the material probability curve ISO 13565-3 36
235

Glassed steel

Coating continuity ASTM C 536 85

Reliability by high voltage ASTM C 537 86

Gloss measurement by goniophotometry ASTM E 430 52

Gold coating, porosity tests ASTM B 735 141

ASTM B 741 142

ASTM B 798 144

ASTM B 799 145

Goniophotometry, for gloss measurement ASTM E 430 52

Gouges, See Surface discontinuities

Grid method of corrosion evaluation ISO 8994 204

Grinding damage, chromium plated steel SAE AMS 2440A 41

Gross defects in coatings, test for ASTM B 765 143

ASTM B 866 25

ASTM B 877 26

Guarded hot plate ASTM C 177 191

H

Hardness 

Carburization SAE ARP1341 95

Conversion tables, metallic materials ASTM E 140 169

SAE J417 177

Decarburization measurement SAE J419 93

SAE ARP1341 95

Method

Barcol Impressor, aluminum alloys ASTM B 648 160

Brinell, metallic materials ASTM E 10 164

Files, testing with SAE J864 180

Instrumented ISO 14577 175

Knoop

Advanced ceramics ASTM C 1326 162

ISO 14705 176

Electroplated coatings ASTM B 578 158

Metallic materials ISO 4545 173

Martens ISO 14577 175 

Microindentation ASTM E 384 170
236

Newage non-caliper type, aluminum alloys ASTM B 724 161

Portable indentation, metallic materials ASTM E 110 168

Rapid indentation, metallic materials ASTM E 103 167

Rockwell 

Cemented carbides ASTM B 294 157

Electrical contact materials ASTM B 277 156

Metallic materials ASTM E 18 165

Superficial, metallic materials ASTM E 18 165

Scleroscope, metallic materials ASTM E 448 179

Scratch ASTM G 171 178

Vickers

Advanced ceramics ASTM C 1327 163

ISO 14705 176

Hard metals ISO 3878 171

Metallic materials ASTM E 92 166

Metallic materials, method ISO 6507-1 174

Webster Hardness Gage, aluminum alloys ASTM B 647 159

Hole drilling, residual stress analysis ASTM E 837 153

Humid sulfur vapor porosity test ASTM B 809 146

Hydrogen embrittlement, from cadmium electroplating ASTM F 326 199 

Hydrogen detection, in cadmium electroplating ASTM F 326 199

Hydroxyapitite, see calcium phosphate

Phase content by X-ray diffraction ASTM F 2024 152

I

Indentation hardness, See Hardness 

Induction hardening, steel ISO 3754 91

Infrared testing SAE J359 37

Inspection 

Electrodeposited coatings, inspection

by attributes ISO 4519 24 

Etch of high strength steel parts SAE AMS 2649B 56

Metallic and inorganic coatings, 

attribute sampling ASTM B 602 21

Metallic and inorganic coatings, 

sampling plan selection ASTM B 697 22
237

Instrumented Indentation Hardness, See Hardness

Interference microscope ASTM B 588 108

Interferometry, Fizeau ISO 3868 121

Interparticle oxide networks, 

powder forged steel ASTM B 797 136

Ion detection tube, for measurement of chloride ISO 8502-5 29

Ion sputtering ASTM E 1127 149

K

Knoop hardness, See Hardness

L

Laps, See Surface discontinuities

Lay, See Surface texture

Lead-tin coating ASTM A 309 126

Liquid penetrant testing ASTM E 1418 53

SAE J426 39

M

Magnetic method, coating thickness ASTM B 499 101

ASTM E 376 112

Magnetic particle inspection 

Discontinuities SAE J420 38

Steel tube imperfections ISO 13665 59

Martens Hardness, See Hardness

Mass per unit area, See Coating mass measurement

Gravimetric procedure ASTM B 767 131
238

Mechanical damage of coatings, tests for ASTM B 765 143

ASTM B 866 25

ASTM B 877 26 

Metallic coatings terminology ASTM A 902 10

Metallographic specimen preparation 

General ASTM E 3 137

Replica techniques ISO 3057 140

Thermal spray coatings ASTM E 1920 139

Microhardness

Decarburization measurement, 

threaded fasteners SAE J121 48

Electroplated coatings ASTM B 578 158

Microindentation hardness ASTM E 384 170

Powder metallurgy parts case depth ASTM B 721 88

Surface hardened layer thickness ISO 4970 92

Microscopical measurement, thickness ASTM B 487 100

Microstructure, See also Metallographic specimen preparation

Area percentage porosity, 

thermal spray coatings ASTM E 2109 147

Chord method for surface microstructure SAE ARP1820 96

Decarburization depth, steel ASTM E 1077 89

SAE J419 93

SAE ARP1341 95

Decarburization measurement, 

threaded fasteners SAE J121 48

Metallographic preparation,

thermal spray coatings ASTM E 1920 139

Point count analysis ASTM E 562 138

Replica techniques ISO 3057 140

Surface hardened layer thickness ISO 4970 92

Volume fraction determination ASTM E 562 138

Moisture,

Condensation on steel ISO 8502-4 29

Refractometric determination ISO 8502-8 30

N

NADCAP (National Aerospace and Defense Contractors

Accreditation Program), See Accreditation
239

Neutral Salt Solution (NSS) ISO 9227 207

Nickel, electrodeposited

Coating thickness ASTM B 530 103

Corrosion site measurement ASTM B 651 198

Requirements ISO 1458 77

Nicks, See Surface discontinuities

Nitric acid vapor test for porosity ASTM B 735 141

Nomenclature

Sheet and strip surface finish SAE AS 4194 11 

Nondestructive examination (NDE)

Acoustic emission SAE J1242 40

Fluorescent penetrant SAE AMS 2647B 61

Infrared testing SAE J359 37

Magnetic particle inspection SAE J420 38

ISO 13665 59

Nondestructive tests SAE J358 37

Surface defects by visible penetrants ASTM E 1418 53

SAE J426 39

Ultrasonic inspection SAE J428 40

Nonmagnetic coating thickness measurement ASTM B 499 101

Nonmetallic coating thickness measurement ASTM B 567 106

ASTM B 568 107

O

On-line coating mass measurement ASTM A 754 129

Oxide coating thickness ASTM B 487 100

ISO 1463 114

Oxide finger penetration, powder forged steel ASTM B 797 136

P

Pack cementation

Aluminum, specification ASTM B 875 81

Chromium, specification ASTM B 874 80

Supplier accreditation SAE AS 7109-3 16
240

Paint, chip resistance SAE J400 209

Painted steel ISO 8502 29

Palladium coating

Porosity ASTM B 798 144

ASTM B 799 145

Paper electrography for porosity measurement ASTM B 741 142

Performance rating, coating ISO 10289 208

Phase content, hydroxyapatite ASTM F 2024 152

Physical vapor deposition

Coating thickness 

Profilometry ISO 4518 122

Radial sectioning ASTM E 1182 113

Supplier accreditation SAE AS 7109-2 15

X-ray spectroscopy ISO 3497 119

Pitting corrosion evaluation, anodized aluminum ISO 8993 203

ISO 8994 204

Plating porosity, See Porosity 

Plating supplier accreditation SAE AS 7109-6 19

Phosphomolybdic acid (PMA) test B 877 26

Pits, See Surface discontinuities

Point count, systematic, microstructural analysis E 562 138

Polysulfide immersion test B 866 25

Porosity

Flowers of sulfur method ASTM B 809 146

Gold coatings, nitric acid vapor ASTM B 735 141

Gold coatings, paper electrography ASTM B 741 142

Gold and palladium coatings, 

gel-bulk electrography ASTM B 798 144

humid sulfur vapor method ASTM B 809 146

phosphomolybdic acid, (PMA) method ASTM B 877 26

polysulfide immersion method ASTM B 866 25

sulfurous acid/sulfur-dioxide vapor ASTM B 799 145

surface, isolated, visible penetrant examination ASTM E 1418 53
241

test selection for coatings ASTM B 765 143

thermal spray coatings, area percentage ASTM E 2109 147

Pore corrosion test ASTM B 735 141

ASTM B 799 145

ASTM B 809 146

Portable hardness testing 

Barcol Impressor ASTM B 648 160

Indentation ASTM E 110 168

Newage non-caliper ASTM B 724 161

Webster ASTM B 647 159

Powder metallurgy parts

Case depth ASTM B 721 88

Oxide finger penetration ASTM B 797 136

Protection rating, coating ISO 10289 208

Pull-off strength, See Adhesion testing

R

Rapid indentation hardness, See Hardness

Metallic materials ASTM E 103 167

Reliability

Glass coatings on steel ASTM C 537 86

Replica

Surface profile measurement ASTM D 4417 51

Metallographic examination ISO 3057 140

Reflection, See Gloss

Residual stress

Hole-drilling strain-gage method ASTM E 837 153

X-ray diffraction method, effective elastic parameter ASTM E 1426 154

Rockwell, See Hardness

Roughness, See Surface texture
242

S

Saline droplets test ISO 4536 201

Salt spray tests ISO 9227 207

Sampling

Coating attribute ASTM B 602 21

Electrodeposited coating, inspection by

attribute ISO 4519 24

For surface passivation SAE AMS-STD-753 197

Selection of sampling plan ASTM B 697 22

Variables sampling ASTM B 762 23

Scanning probe microscopy, tip shape ASTM E 1813 62

Scanning tunneling microscopy, 

surface roughness by ASTM F 1438 66

Scleroscope hardness, See Hardness

Scratches, See Surface discontinuities

Scratch hardness, See Hardness

Seams, See Surface discontinuities

Stellar’s test method, See also Coating mass ASTM A 630 128

Shear testing

Calcium phosphate and metallic coatings ASTM F 1044 183

SIMS, secondary ion mass spectrometry ASTM E 1438 150

Soluble contaminants analysis ISO 8502-6 30

Specifications

Aluminum diffusion coating ASTM B 875 81

Anodized aluminum ISO 7599 72

Chromium diffusion coating ASTM B 874 80

Specimen preparation 

Metallographic ASTM E 3 137

Sputter depth profiling ASTM E 1127 149

ASTM E 1438 150

ISO 14606 151
243

Standards

ASME, The American Society of Mechanical Engineers

B46.1 63

ASTM, the American Society for Testing and Materials

A 90/A 90M 125

A 309 126

A 428/A 428M 127

A 630 128

A 754/A 754M 129

A 802/A 802M 57

A 833 155

A 896 75

A 902 10 

B 137 130

B 244 99

B 277 156

B 294 157

B 487 100

B 489 181

B 490 182

B 499 101

B 504 102

B 530 103

B 555 104

B 556 105

B 567 106

B 568 107

B 571 187

B 578 158

B 588 108

B 602 21

B 647 159

B 648 160

B 651 198

B 659 109

B 681 110

B 697 22

B 721 88

B 724 161

B 735 141

B 741 142

B 762 23

B 765 143

B 767 131

B 797 136

B 798 144
244

B 799 145

B 809 146

B 866 25

B 874 80

B 875 81

B 877 26

C 177 191

C 536 85

C 537 86

C 633 188

C 664 111

C 743 87

C 1043 192

C 1044 193

C 1045 194

C 1326 162

C 1327 163

D 4417 51

D 4541 189

D 5723 132

E 3 137

E 10 164

E 18 165

E 92 166

E 103 167

E 110 168

E 140 169

E 376 112

E 384 170

E 430 52

E 448 179

E 562 138

E 673 148

E 837 153

E 1077 89

E 1127 149

E 1182 113

E 1418 53

E 1426 154

E 1438 150

E 1461 195

E 1659 133

E 1813 62

E 1920 139

E 2109 147

F 326 199

F 788 42
245

F 812/F812M 43

F 1044 183

F 1147 184

F 1160 185

F 1438 66

F 1501 186

F 1978 200

F 2024 152

G 171 178

Industry Standard Scratch Adhesion Test 190

ISO, International Organization for Standardization

1456 76

1458 77

1460, See 10289 208

1463 114

2063 83

2064 124

2079 10

2080 11

2081 78

2082 79 

2106 134

2128 115

2177 116

2178 117

2361 118

2639 90

3057 140

3274 27

3497 119

3543 120

3613 73

3754 91

3868 121

3878 171

3892 135

4042 44

4287 64

4288 28

4498 172

4518 122

4519 24

4520 74

4522-1 123

4536 201
246

4538 202

4540 205

4541 206

4545 173

4970 92

6157-1 45

6157-2 46

6157-3 47

6507-1 174

7599 72

8302 196

8501-1 64

8502-1 29

8502-2 29

8502-3 29

8502-4 29

8502-5 29

8502-6 30

8502-8 30

8502-9 30

8502-10 30

8502-12 30

8503-1 67

8503-2 68

8503-3 69

8503-4 70

8503-5 71

8785 31

8993 203

8994 204

9227 207

10289, supersedes 1460 208

11562 32

11971 57

12085 33

13565-1 34

13565-2 35

13565-3 36

13665 59

14104 58

14577-1 175

14606 151

14705 176

14707 151

Military Standard

MIL-STD-1687A (SH) 84
247

SAE, Society of Automotive Engineers

J121 48

J122 49

J123 49

J349 59

J358 37

J359 37

J400 209

J417 177

J419 93

J420 38

J423 94

J425 38

J426 39

J428 40

J448a 65

J449a 65

J810 54

J864 180

J911 55

J1061 50

J1242 40

AMS 2440A 41

AMS 2444A 82

AMS 2633B 60

AMS 2647B 61

AMS 2649B 56

AMS-STD-753 197

ARP 1341 95

ARP 1820 96

AS 4194 11

AS 7101 12

AS 7109 13

AS 7109-1 14

AS 7109-2 15

AS 7109-3 16 

AS 7109-4 17

AS 7109-5 18

AS 7109-6 19

AS 7109-7 20 

Steel castings

Visual examination, surface

acceptance standards ASTM A 802 57

Visual examination of surface quality ISO 11971 57
248

Steel, hardened cases 

Depth of ISO 2639 90

Total effective thickness of ISO 4970 92

Steel substrates ISO 8502 29ff

Stress analysis by hole drilling ASTM E 837 153

Stylus, characteristics for surface texture

Measurement ISO 3274 27 

Sulfurous acid/sulfur-dioxide vapor test

for porosity ASTM B 799 145

Surface analysis (chemistry, composition)

Depth profiling ASTM E 1127 149

Glow discharge optical emission 

Spectrometry (GD-OES) ISO 14707 151

Interface width using SIMS ASTM E 1438 150

Sputter depth profiling ISO 14606 151

Terminology ASTM E 673 148

Surface cleanliness

Chloride on surfaces ISO 8502-2,5,6,10 29, 30

Dust ISO 8502-3 29

Ferrous ions ISO 8502-12 30

Moisture measurement ISO 8502-8 30

Moisture condensation ISO 8502-4 29

Soluble iron ISO 8502-1 29

Visual assessment ISO 8501-1 64

Water soluble salts ISO 8502-9,10,12 30

Surface density, See Coating mass

Surface discontinuities

Ferrous rods, bars, tubes, wires SAE J349 59

Imperfection classification, sheet steel SAE J810 54

Imperfections in seamless and welded steel 

tubes, magnetic particle inspection ISO 13665 59

Specification for bolts, screws, studs 

ASTM F 788 42

SAE J123 49

SAE J1061 50

ISO 6157-1 45

ISO 6157-3 47

Specification for nuts ASTM F 812 43

SAE J122 49

ISO 6157-2 46
249

Ultrasonic inspection for SAE J428 40

Visible penetrant examination ASTM E 1418 53

Surface hardened layers, See Steel, hardened cases

Surface passivation SAE AMS-STD-753 197

Surface finger oxides ASTM B 797 136

Surface imperfections, See Surface discontinuities, Geometrical Product Specification

Surface morphology, See Surface roughness, Surface texture

Surface profile measurement, See also Surface texture

Steel, blast cleaned, field measurement ASTM D 4417 51

Scanning probe microscopy tip for ASTM E 1813 62

Surface quality

Visual examination, steel castings ISO 11971 57

Visual examination, acceptance standards ASTM A802 57

Surface roughness, See Surface texture 

Blast cleaned steel, surface profile determination

Comparator specifications and

definitions ISO 8503-1 67

Comparator procedure for 

surface profile ISO 8503-2 68

Comparator calibration, 

focusing microscope ISO 8503-3 69

Comparator calibration, 

stylus procedure ISO 8503-4 70

Replica tape method ISO 8503-5 71

Cold rolled steel sheet SAE J911 55

Scanning tunneling microscopy for ASTM F 1438 66

Surface standards, steel castings ASTM A 802 58

Surface temper, etch inspection after grinding ISO 14104 58

Surface texture, ASME B46.1 63

See also Geometrical product specification ISO 4287 64

ISO 4288 28

SAE J448a 65 

Surface texture control SAE J449a 65
250

T

Tape, pressure sensitive for dust on steel ISO 8502-3 29

Terminology, 

General classification of terms ISO 2079 10

Metallic coatings ASTM A 902 10

Sheet and strip surface finish SAE AS4194 11

Surface analysis ASTM E 673 148

Vocabulary, electroplating ISO 2080 11

Tension testing

Calcium phosphate and metallic coatings ASTM F 1147 184

Calcium phosphate coatings ASTM F 1501 186

Terne sheet, See Coating mass measurement 

Texture, See Surface profile, Surface texture

Thermal conductivity ASTM C 177 191

ASTM C 1043 192

Thermal diffusivity ASTM E 1461 195

Thermal resistance ASTM C 177 191

ASTM C 1043 192

ASTM C 1044 193

ASTM C 1045 194

ISO 8302 196

Thermal spray coatings 

Abrasion resistance, Taber Abraser ASTM F 1978 200

Adhesion/cohesion measurement ASTM C 633 188

Metallographic preparation ASTM E 1920 139

Military standard MIL-STD-1687A(SH) 84

Percentage porosity determination ASTM E 2109 147

Phase content, hydroxyapatite ASTM F 2024 152

Supplier accreditation, See Accreditation

Zinc, aluminum and their alloys ISO 2063 83

Thickness, See Coating thickness 

Thioacetamide corrosion test (TAA) ISO 4538 202

Tin coating, mass measurement ASTM A 754 129

Tin plate, mass measurement ASTM A 630 128
251

Titanium nitride,

physical vapor deposition specification SAE AMS 2444A 82

Titration test method for coating mass ASTM A 630 128

Titrimetric determination 

Ferrous ions ISO 8502-12 30

Chloride ISO 8502-10 30

Triple spot test for coating mass ASTM A 309 126

U

Ultrasonic inspection for surface discontinuities SAE J428 40

V

Variables sampling of metallic and 

inorganic coatings ASTM B 762 23

Vickers hardness

Advanced ceramics ASTM C 1327 163

Metallic materials ASTM E 92 166

Hard metals ISO 3878 171

Test method ISO 6507-1 174

Visual inspection, 

Surface, steel castings ASTM A 802 57

Comparison, surface profile ASTM D 4417 51

Vocabulary, See Terminology

Volume fraction, microstructural constituent ASTM E 562 138

W

Waviness, See Surface texture

Webster Hardness Gage ASTM B 647 159
X

X-ray diffraction

Effective elastic parameter for residual 

stress measurement ASTM E 1426 154

Phase content, hydroxyapatite ASTM F 2024 152

X-ray fluorescence 

Mass of metallic coating on steel ASTM A 754 129

Coating thickness by X-ray spectrometry ISO 3497 119

Chromium treatment weight ASTM D5723 132

X-ray spectrometry, 

Coating thickness measurement ASTM B 568 107

ISO 3497 119

Coating mass measurement by

X-ray fluoresence ASTM A 754 129

Z

Zinc, zinc alloys on steel 

Mass, acid stripping ASTM A 90 125

Mass, X-ray fluorescence ASTM A 754 129

Mass, composition ASTM E 1659 133

Specifications ISO 2081 78

Thermal spray ISO 2063 83

Thickness ASTM B 555 104

252

April 2005