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ASTM E2109-01(2007)

(Test Method)

Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings

Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings

SCOPE
1.1 These test methods cover procedures to perform porosity ratings on metallographic specimens of thermal sprayed coatings (TSCs) prepared in accordance with Guide E 1920 by direct comparison to standard images and via the use of automatic image analysis equipment.
1.2 These test methods deal only with recommended measuring methods and nothing in them should be construed as defining or establishing limits of acceptability for any measured value of porosity.
1.3 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.

General Information

Status
Historical
Publication Date
30-Apr-2007
ICS
25.220.20 - Surface treatment
Technical Committee
E04 - Metallography
Drafting Committee
E04.14 - Quantitative Metallography
Current Stage
Ref Project

Relations

Replaces
ASTM E2109-01 - Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings
Effective Date
01-May-2007

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ASTM E2109-01(2007) - Test Methods for Determining Area Percentage Porosity in Thermal Sprayed CoatingsASTM E2109-01(2007) - Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings
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ASTM E2109-01(2007) - Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings
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NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
Designation: E2109 − 01(Reapproved 2007)
Standard Test Methods for
Determining Area Percentage Porosity in Thermal Sprayed
1
Coatings
This standard is issued under the fixed designation E2109; 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 3.2.1 halo effect—unwanted detection of the perimeter of
one phase (due to a shared gray value at the phase boundary)
1.1 These test methods cover procedures to perform poros-
when setting the detection limits of another.
ity ratings on metallographic specimens of thermal sprayed
coatings (TSCs) prepared in accordance with Guide E1920 by
3.2.2 linear detachment, n—a region within a TSC in which
direct comparison to standard images and via the use of two successively deposited splats of coating material have not
automatic image analysis equipment. metallurgically bonded.
1.2 These test methods deal only with recommended mea- 3.2.3 porosity, n—cavity type discontinuities (voids) or
suring methods and nothing in them should be construed as
linear detachments within a sprayed coating.
defining or establishing limits of acceptability for any mea-
3.2.4 splat, n—an individual globule of thermal sprayed
sured value of porosity.
material that has been deposited on a substrate.
1.3 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
4. Significance and Use
responsibility of the user of this standard to establish appro-
4.1 TSCs are susceptible to the formation of porosity due to
priate safety and health practices and determine the applica-
a lack of fusion between sprayed particles or the expansion of
bility of regulatory limitations prior to use.
gases generated during the spraying process. The determina-
tion of area percent porosity is important in order to monitor
2. Referenced Documents
the effect of variable spray parameters and the suitability of a
2
2.1 ASTM Standards:
coating for its intended purpose. Depending on application,
E3 Guide for Preparation of Metallographic Specimens
some or none of this porosity may be tolerable.
E7 Terminology Relating to Metallography
E562 Test Method for Determining Volume Fraction by 4.2 These test methods cover the determination of the area
Systematic Manual Point Count percentage porosity of TSCs. Method A is a manual, direct
E1245 Practice for Determining the Inclusion or Second- comparison method utilizing the seven standard images in
Phase Constituent Content of Metals byAutomatic Image Figs. 1-7 which depict typical distributions of porosity in
Analysis TSCs.MethodBisanautomatedtechniquerequiringtheuseof
E1920 Guide for Metallographic Preparation of Thermal a computerized image analyzer.
Sprayed Coatings
4.3 These methods quantify area percent porosity only on
the basis of light reflectivity from a metallographically pol-
3. Terminology
ished cross section. See Guide E1920 for recommended
3.1 Definitions—For definitions of terms used in these test
metallographic preparation procedures.
methods refer to Terminology E7.
4.4 The person using these test methods must be familiar
3.2 Definitions of Terms Specific to This Standard:
with the visual features of TSCs and be able to determine
differences between inherent porosity and oxides. The indi-
1
This test method is under the jurisdiction of ASTM Committee E04 on
vidual must be aware of the possible types of artifacts that may
Metallography and is the direct responsibility of Subcommittee E04.14 on Quanti-
be created during sectioning and specimen preparation, for
tative Metallography.
example, pullouts and smearing, so that results are reported
Current edition approved May 1, 2007. Published May 2007. Originally
only on properly prepared specimens. Examples of properly
approved in 2000. Last previous edition approved in 2001 as E2109 – 01. DOI:
10.1520/E2109-01R07.
preparedspecimensareshowninFigs.8-10.Iftherearedoubts
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
as to the integrity of the specimen preparation it is suggested
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
that other means be used to confirm microstructural features.
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. This may include energy dispersive spectroscopy (EDS),
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
1

---------------------- Page: 1 ----------------------
E2109 − 01 (2007)
FIG. 1 — 0.5 % Porosity
FIG. 2 — 1.0 % Porosity
wavelength dispersive spectroscopy (WDS)
...

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ASTM E2109-01(2021)(Test Method)
Standard Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings

SIGNIFICANCE AND USE
4.1 TSCs are susceptible to the formation of porosity due to a lack of fusion between sprayed particles or the expansion of gases generated during the spraying process. The determination of area percent porosity is important in order to monitor the effect of variable spray parameters and the suitability of a coating for its intended purpose. Depending on application, some or none of this porosity may be tolerable.  
4.2 These test methods cover the determination of the area percentage porosity of TSCs. Method A is a manual, direct comparison method utilizing the seven standard images in Figs. 1-7 which depict typical distributions of porosity in TSCs. Method B is an automated technique requiring the use of a computerized image analyzer.
FIG. 1 — 0.5 % Porosity  
FIG. 2 — 1.0 % Porosity  
FIG. 3 — 2.0 % Porosity  
FIG. 4 — 5.0 % Porosity  
FIG. 5 — 8.0 % Porosity  
FIG. 6 — 10.0 % Porosity  
FIG. 7 — 15.0 % Porosity  
4.3 These methods quantify area percent porosity only on the basis of light reflectivity from a metallographically polished cross section. See Guide E1920 for recommended metallographic preparation procedures.  
4.4 The person using these test methods must be familiar with the visual features of TSCs and be able to determine differences between inherent porosity and oxides. The individual must be aware of the possible types of artifacts that may be created during sectioning and specimen preparation, for example, pullouts and smearing, so that results are reported only on properly prepared specimens. Examples of properly prepared specimens are shown in Figs. 8-10. If there are doubts as to the integrity of the specimen preparation it is suggested that other means be used to confirm microstructural features. This may include energy dispersive spectroscopy (EDS), wavelength dispersive spectroscopy (WDS) or cryogenic fracture of the coating followed by analysis of the fractured surfaces with a scanning electron microscope (SEM).
FIG. 8 Ni/Al T...
SCOPE
1.1 These test methods cover procedures to perform porosity ratings on metallographic specimens of thermal sprayed coatings (TSCs) prepared in accordance with Guide E1920 by direct comparison to standard images and via the use of automatic image analysis equipment.  
1.2 These test methods deal only with recommended measuring methods and nothing in them should be construed as defining or establishing limits of acceptability for any measured value of porosity.  
1.3 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, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ASTM E1920-03(2021)(Guide)
Standard Guide for Metallographic Preparation of Thermal Sprayed Coatings

SIGNIFICANCE AND USE
4.1 TSCs are used in a number of critical industrial components. TSCs can be expected to contain measurable levels of porosity and linear detachment. Accurate and consistent evaluation of specimens is essential to ensure the integrity of the coating and proper adherence to the substrate.  
4.1.1 Example 1: By use of inappropriate metallographic methods, the apparent amount of porosity and linear detachment displayed by a given specimen can be increased, by excessive edge rounding, or decreased by smearing of material into voids. Therefore inaccurate levels of porosity and linear detachment will be reported even when the accuracy of the measurement technique is acceptable.  
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SCOPE
1.1 This guide covers recommendations for sectioning, cleaning, mounting, grinding, and polishing to reveal the microstructural features of thermal sprayed coatings (TSCs) and the substrates to which they are applied when examined microscopically. Because of the diversity of available equipment, the wide variety of coating and substrate combinations, and the sensitivity of these specimens to preparation technique, the existence of a series of recommended methods for metallographic preparation of thermal sprayed coating specimens is helpful. Adherence to this guide will provide practitioners with consistent and reproducible results. Additional information concerning standard practices for metallographic preparation can be found in Guide E3.  
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ABSTRACT
This specification covers zinc and tin alloy wire, including zinc-aluminum, zinc-aluminum-copper, zinc-tin, zinc-tin-copper an dtin-zinc, used as thermal spray wire in the electronics industry. The wire shall conform to the required chemical composition for cadmium, zinc, tin, lead, antimony, copper, aluminum, bismuth, arsenic, iron, nickel, and magnesium. The wire shall be clean and free of corrosion, adhering foreign material, scale, seams, nicks, burrs, and other defects which would interfere with the operation of thermal spraying equipment. The wire shall uncoil readily and be free of bends or kinks that would prevent its passage through the thermal spray gun. Sampling methodology should ensure that the sample slected for testing is representative of the matreial. The diameter of the wire shall be determines at the end and the beginning of each continuous wire.
SCOPE
1.1 This specification covers zinc and tin alloy wire, including zinc-aluminum, zinc-aluminum-copper, zinc-tin, zinc-tin-copper and tin-zinc, used as thermal spray wire in the electronics industry.  
1.1.1 Certain alloys specified in this standard are also used as solders for the purpose of joining together two or more metals at temperatures below their melting points, and for other purposes (as noted in Annex A1). Specification B907 covers Zinc, Tin and Cadmium Base Alloys Used as Solders which are used primarily for the purpose of joining together two or more metals at temperatures below their melting points and for other purposes (as noted in the Annex part of Specification B907). Specification B833 covers Zinc and Zinc Alloy Wire for Thermal Spraying (Metallizing) used primarily for the corrosion protection of steel (as noted in the Annex part of Specification B833).  
1.1.2 Tin base alloys are included in this specification because their use in the electronics industry is similar to the use of certain zinc alloys but different than the major use of the tin and lead solder compositions specified in Specification B32.  
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5.1 The water-break test as described in this test method is rapid, nondestructive, and may be used for control and evaluation of processes for the removal of hydrophobic contaminants. A water-break “free” test is commonly used for in-process verification of the absence of surface contaminants on metal surfaces that may interfere with subsequent surface treatments such as priming, conversion coating, anodizing, plating, or adhesive bonding  
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Note 2: This test method is not appropriate where line o...
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1.1 This test method covers the detection of the presence of hydrophobic (nonwetting) films on surfaces and the presence of hydrophobic organic materials in processing environments. When properly conducted, the test will enable detection of molecular layers of hydrophobic organic contaminants. On very rough or porous surfaces, the sensitivity of the test may be significantly decreased.  
1.2 Units—The values stated in SI units are to be regarded as standard. The values given in parentheses after SI units are provided for information only and are not considered standard.  
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SCOPE
1.1 This practice covers procedures for determining discontinuities using two types of test equipment:  
1.1.1 Test Method A—Low Voltage Wet Sponge, and  
1.1.2 Test Method B—High Voltage Spark Testers.  
1.2 This practice addresses metallic substrates. For concrete surfaces, refer to Practice D4787.  
1.3 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.  
1.4 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, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
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