Standard Practice for Measurement of Thickness of Applied Coating Powders to Predict Cured Thickness

SIGNIFICANCE AND USE
Many physical and appearance properties of the finished coating are affected by the film thickness. Film thickness can affect the color, gloss, surface profile, adhesion, flexibility, impact resistance and hardness of the coating. The fit of pieces assembled after coating can be affected when film thickness is not within tolerance. Therefore coatings must be applied within certain minimum and maximum film thickness specifications to optimize their intended use.
All procedures involve taking measurements of applied coating powders in the pre-cured, pre-gelled state to help insure correct cured film thickness. This enables the application system to be set up and fine-tuned prior to the curing process. In turn, this will reduce the amount of scrap and over-spray. Accurate predictions help avoid stripping and re-coating which can cause problems with adhesion and coating integrity.
Measurements of cured powder coating thickness can be made using different methods depending upon the substrate. Non-destructive measurements over metal substrates can be made with magnetic and eddy current coating thickness gages (see Practice D 7091). Non-destructive measurements over non-metal substrates can be made with ultrasonic coating thickness gages (see Test Method D 6132). Destructive measurements over rigid substrates can be made with cross-sectioning instruments (see Test Method D 4138).
SCOPE
1.1 This practice describes the thickness measurement of dry coating powders applied to a variety of substrates. Use of some of these procedures may require repair of the coating powder. This practice is intended to supplement the manufacturers instructions for the operation of the gages and is not intended to replace them. It includes definitions of key terms, reference documents, the significance and use of the practice, and the advantages and limitations of the instruments.
1.2 Three procedures are provided for measuring dry coating powder thickness:
1.2.1 Procedure A - Using rigid metal notched (comb) gages.
1.2.2 Procedure B - Using magnetic or eddy current coating thickness gages.
1.2.3 Procedure C - Using non-contact ultrasonic powder thickness instruments.
1.3 Coating powders generally diminish in thickness during the curing process. These procedures therefore require a reduction factor be established to predict cured film thickness of powder coatings.
1.4 Procedure A and Procedure B measure the thickness (height or depth) of the applied coating powders in the pre-cured, pre-gelled state. By comparing results to the measured cured powder thickness in the same location, a reduction factor can be determined and applied to future thickness measurements of the same coating powder.
1.5 Procedure C results in a predicted thickness value based on a calibration for typical coating powders. If the powder in question is not typical then a calibration adjustment can be made to align gage readings with the actual cured values as determined by other measurement methods.
1.6 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.
This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

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Publication Date
30-Jun-2007
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ASTM D7378-07 - Standard Practice for Measurement of Thickness of Applied Coating Powders to Predict Cured Thickness
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NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation:D7378–07
Standard Practice for
Measurement of Thickness of Applied Coating Powders to
1
Predict Cured Thickness
This standard is issued under the fixed designation D7378; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope responsibility of the user of this standard to establish appro-
priate safety and health practices and determine the applica-
1.1 This practice describes the thickness measurement of
bility of regulatory limitations prior to use.
dry coating powders applied to a variety of substrates. Use of
some of these procedures may require repair of the coating
2. Referenced Documents
powder. This practice is intended to supplement the manufac-
2
2.1 ASTM Standards:
turers’ instructions for the operation of the gages and is not
D4138 PracticesforMeasurementofDryFilmThicknessof
intended to replace them. It includes definitions of key terms,
Protective Coating Systems by Destructive, Cross-
reference documents, the significance and use of the practice,
Sectioning Means
and the advantages and limitations of the instruments.
D6132 Test Method for Nondestructive Measurement of
1.2 Three procedures are provided for measuring dry
Dry FilmThickness ofApplied Organic Coatings Using an
coating powder thickness:
Ultrasonic Gage
1.2.1 Procedure A—Using rigid metal notched (comb)
D7091 Practice for Nondestructive Measurement of Dry
gages.
Film Thickness of Nonmagnetic Coatings Applied to
1.2.2 Procedure B—Usingmagneticoreddycurrentcoating
Ferrous Metals and Nonmagnetic, Nonconductive Coat-
thickness gages.
ings Applied to Non-Ferrous Metals
1.2.3 Procedure C—Using non-contact ultrasonic powder
thickness instruments.
3. Terminology
1.3 Coating powders generally diminish in thickness during
3.1 Definitions of Terms Specific to This Standard:
the curing process. These procedures therefore require a
3.1.1 accuracy, n—the measure of the magnitude of error
reduction factor be established to predict cured film thickness
between the result of a measurement and the true thickness of
of powder coatings.
the item being measured.
1.4 Procedure A and Procedure B measure the thickness
3.1.2 adjustment, n—the physical act of aligning a gage’s
(height or depth) of the applied coating powders in the
thickness readings to match those of a known thickness sample
pre-cured, pre-gelled state. By comparing results to the mea-
(removal of bias) in order to improve the accuracy of the gage
sured cured powder thickness in the same location, a reduction
on a specific surface, within a specific portion of its measure-
factor can be determined and applied to future thickness
ment range or to specific operating conditions.
measurements of the same coating powder.
3.1.3 coating powders, n—finely divided particles of resin,
1.5 Procedure C results in a predicted thickness value based
either thermoplastic or thermosetting, generally incorporating
on a calibration for typical coating powders. If the powder in
pigments, fillers, and additives and remaining finely divided
question is not typical then a calibration adjustment can be
during storage under suitable conditions, which, after fusing
made to align gage readings with the actual cured values as
and possibly curing, give a continuous film.
determined by other measurement methods.
3.1.4 calibration, n—the high-level, controlled and docu-
1.6 The values stated in SI units are to be regarded as the
mented process of obtaining measurements on traceable cali-
standard. The values given in parentheses are for information
brationstandardsoverthefulloperatingrangeofthegage,then
only.
making the necessary gage adjustments (as required) to correct
1.7 This standard does not purport to address all of the
any out-of-tolerance conditions.
safety concerns, if any, associated with its use. It is the
3.1.4.1 Discussion—Calibration of coating thickness gages
is performed in a controlled environment using a documented
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This practice is under the jurisdiction of ASTM Committee D01 on Paint and
2
Related Coatings, Materials, and Applications and is the direct responsibility of For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Subcommittee D01.51 on Powder Coatings. contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Current edition approved July 1, 2007. Published July 2007. DOI: 10.1520/ Standards volume information, refer to the standard’s Document Summary page on
D7378-07. the ASTM website.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
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