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ASTM E2109-01(2021)

(Test Method)

Standard Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings

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.

General Information

Status
Published
Publication Date
31-Aug-2021
ICS
25.220.20 - Surface treatment
Technical Committee
E04 - Metallography
Drafting Committee
E04.14 - Quantitative Metallography
Current Stage
Ref Project

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ASTM E2109-01(2021) - Standard Test Methods for Determining Area Percentage Porosity in Thermal Sprayed CoatingsASTM E2109-01(2021) - Standard Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings
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ASTM E2109-01(2021) - Standard Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings
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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.
Designation: E2109 − 01 (Reapproved 2021)
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. Terminology
1.1 These test methods cover procedures to perform poros- 3.1 Definitions—For definitions of terms used in these test
ity ratings on metallographic specimens of thermal sprayed methods refer to Terminology E7.
coatings (TSCs) prepared in accordance with Guide E1920 by
3.2 Definitions of Terms Specific to This Standard:
direct comparison to standard images and via the use of
3.2.1 halo effect—unwanted detection of the perimeter of
automatic image analysis equipment.
one phase (due to a shared gray value at the phase boundary)
1.2 These test methods deal only with recommended mea- when setting the detection limits of another.
suring methods and nothing in them should be construed as
3.2.2 linear detachment, n—a region within a TSC in which
defining or establishing limits of acceptability for any mea-
two successively deposited splats of coating material have not
sured value of porosity.
metallurgically bonded.
1.3 This standard does not purport to address all of the
3.2.3 porosity, n—cavity type discontinuities (voids) or
safety concerns, if any, associated with its use. It is the
linear detachments within a sprayed coating.
responsibility of the user of this standard to establish appro-
3.2.4 splat, n—an individual globule of thermal sprayed
priate safety, health, and environmental practices and deter-
material that has been deposited on a substrate.
mine the applicability of regulatory limitations prior to use.
1.4 This international standard was developed in accor-
4. Significance and Use
dance with internationally recognized principles on standard-
4.1 TSCs are susceptible to the formation of porosity due to
ization established in the Decision on Principles for the
a lack of fusion between sprayed particles or the expansion of
Development of International Standards, Guides and Recom-
gases generated during the spraying process. The determina-
mendations issued by the World Trade Organization Technical
tion of area percent porosity is important in order to monitor
Barriers to Trade (TBT) Committee.
the effect of variable spray parameters and the suitability of a
2. Referenced Documents
coating for its intended purpose. Depending on application,
2
2.1 ASTM Standards: some or none of this porosity may be tolerable.
E3 Guide for Preparation of Metallographic Specimens
4.2 These test methods cover the determination of the area
E7 Terminology Relating to Metallography
percentage porosity of TSCs. Method A is a manual, direct
E562 Test Method for Determining Volume Fraction by
comparison method utilizing the seven standard images in
Systematic Manual Point Count
Figs. 1-7 which depict typical distributions of porosity in
E1245 Practice for Determining the Inclusion or Second-
TSCs.MethodBisanautomatedtechniquerequiringtheuseof
Phase Constituent Content of Metals byAutomatic Image
a computerized image analyzer.
Analysis
4.3 These methods quantify area percent porosity only on
E1920 Guide for Metallographic Preparation of Thermal
the basis of light reflectivity from a metallographically pol-
Sprayed Coatings
ished cross section. See Guide E1920 for recommended
metallographic preparation procedures.
1
These test methods are under the jurisdiction of ASTM Committee E04 on
Metallography and are the direct responsibility of Subcommittee E04.14 on
4.4 The person using these test methods must be familiar
Quantitative Metallography.
with the visual features of TSCs and be able to determine
Current edition approved Sept. 1, 2021. Published November 2021. Originally
differences between inherent porosity and oxides. The indi-
approved in 2000. Last previous edition approved in 2014 as E2109 – 01(2014).
DOI: 10.1520/E2109-01R21.
vidual must be aware of the possible types of artifacts that may
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
be created during sectioning and specimen preparation, for
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
example, pullouts and smearing, so that results are reported
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. only on properly prepared specimens. Examples of properly
...

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ASTM E1920-03(2021)(Guide)
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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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4.2 During the development of TSC procedures, metallographic information is necessary to validate the efficacy of a specific application.  
4.3 Cross sections are usually taken perpendicular to the long axis of the specimen and prepared to reveal information concerning the following:  
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4.3.8 The integrity of the interface between the coating and substrate, and,  
4.3.9 The integrity of the coating microstructure with respect to chemistry.
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.  
1.2 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.  
1.3 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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Standard Test Method for Evaluating and Comparing Transfer Efficiency of Spray Applied Coatings Under Laboratory Conditions

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5.1 Subject to the limitations listed above, the procedure can be used as a research tool to optimize spray equipment and paint formulations as well as to study the relative effect on transfer efficiency of changing operating variables, spray application equipment, and types of coatings.
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1.1 This test method covers the evaluation and comparison of the transfer efficiency of spray-applied coatings under controlled laboratory conditions.  
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Note 1: This laboratory procedure requires specific equipment and procedures. For those laboratories that do not have access to the type of equipment required a more general laboratory procedure is being prepared as Procedure B.  
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1.6 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 B136-23(Test Method)
Standard Test Method for Measurement of Stain Resistance of Anodic Coatings on Aluminum

ABSTRACT
This specification covers measurement of strain resistance of anodic coatings on aluminium and its alloys, that have undergone a sealing treatment and contact with an acidic solution, are stainproof or nonadsorptive with respect to dyes. The method comprises contacting the test area of the anodized specimen with nitric acid solution and, after rinsing and drying, applying a special dye solution followed by rinsing and rubbing the test area with pumice powder, drying, and visual examination of the test area for retention of dye stain. Coatings that exhibit no dye stain or change in color are considered to have passed the test. Reagent grade chemicals shall be used in all tests. A specified solution of nitric acid shall be prepared in distilled or deionized water. A specified volume of aluminium blue 2WL dye shall be dissolved in distilled or deionized water.
SIGNIFICANCE AND USE
3.1 This test method is intended to determine whether anodic oxide coatings on aluminum and its alloys have been properly sealed and as a result are resistant to absorbing dyes.
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1.1 This test method is intended to determine whether anodic oxide coatings on aluminum and its alloys, that have undergone a sealing treatment and contact with an acid solution, are stainproof or nonadsorptive with respect to dyes.  
1.2 Coatings that have been properly sealed should be proof against adsorption of coloring materials and, hence, “nonstaining” in many types of service.  
1.3 This test method is applicable to anodic coatings intended for applications where they are exposed to the weather, or for protective purposes in corrosive media, and where resistance to staining is important.
Note 1: Performance in this test is predictive only of susceptibility to stain by dyes. It is not intended to be predictive of other factors in service performance such as pitting or general corrosion.
Note 2: For Aluminum Association Class I and II architectural anodic coatings that are sealed in solutions containing less than 15 ppm silicates or 3 ppm phosphates, the acid pretreatment may be omitted.  
1.4 In the case of coatings colored in deep shades, where estimation of the intensity of any residual dye stain is difficult, interpretation of the test is based on whether or not the original color has been affected by the action of the test.  
1.5 This test method is not applicable to:  
1.5.1 Chromic acid type anodic coatings.  
1.5.2 Anodic coatings on aluminum alloys containing more than 2 mass % Cu or 4.5 mass % Si.  
1.5.3 Anodic coatings that have been sealed only in dichromate solutions.  
1.5.4 Anodic coatings that have undergone a treatment to render them hydrophobic.  
1.6 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
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ASTM D6529-22(Test Method)
Standard Test Method for Operating Performance of Continuous Electrodeionization Systems on Feeds from 50 μS/cm to 1000 μS/cm

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5.1 The CEDI devices can be used to produce deionized water from feeds of pretreated water. This test method permits the relatively rapid measurement of key performance capabilities of CEDI devices using standard sets of conditions. The data obtained can be analyzed to provide information on whether changes may have occurred in operating characteristics of the device independently of any variability in feed water characteristics or operating conditions. Under specific circumstances, this test method may also provide sufficient information for plant design.
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1.1 This test method covers the determination of the operating characteristics of continuous electrodeionization (CEDI) devices using synthetic feed solutions and is not necessarily applicable to natural waters. This test method is a procedure applicable to solutions with a conductivity range from approximately 50 μS/cm to 1000 μS/cm.  
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1.3.4 Performance on feed waters less than 50 μS/cm, particularly performance relating to organic solutes, colloidal or particulate matter, or biological or microbial matter.  
1.4 This test method, subject to the limitations previously described, can be applied as either an aid to predict expected deionization performance for a given feed water quality, or as a test method to determine whether performance of a given device has changed over some period of time. It is ultimately, however, the user's responsibility to ensure the validity of this test method for their specific applications.  
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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.  
1.1.3 These wire alloys have a nominal liquidus temperature not exceeding 850 °F (455 °C).  
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Standard Test Method for Hydrophobic Surface Films by the Water-Break Test

SIGNIFICANCE AND USE
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  
5.2 This test method is not quantitative and is typically restricted to applications where a go/no go evaluation of cleanliness will suffice.  
5.3 The test may also be used for the detection and control of hydrophobic contaminants in processing environments. For this application, a witness surface free of hydrophobic films is exposed to the environment and subsequently tested. The sensitivity of this test will vary with the level of airborne contaminant and the duration of exposure of the witness surface.  
5.4 For quantitative measurement of surface wetting, test methods that measure contact angle of a sessile drop of water or other test liquid may be used in some applications. Measurement methods based on contact angle are shown in Test Methods C813, D5946, and D7490; and Practice D7334.  
5.4.1 Devices for in situ measurement of contact angle are available. These devices are limited to a small measurement surface area and may not reflect the cleanliness condition of a larger surface. For larger surface areas, localized contact angle measurement, or other quantitative inspection, combined with water-break testing may be useful.  
5.5 For surfaces that cannot be immersed or doused with water, or where such immersion or dousing is impractical, such as previously coated large parts or assemblies, prior to the application of paints, primers or other organic coatings, Test Method F21 may be better suited for the evaluation of surface cleanliness than this test method.
Note 2: This test method is not appropriate where line o...
SCOPE
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.  
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 D1735-21(Practice)
Standard Practice for Testing Water Resistance of Coatings Using Water Fog Apparatus

SIGNIFICANCE AND USE
4.1 Water can cause the degradation of coatings, so knowledge of how a coating resists water is helpful in predicting its service life. Failure in water fog tests may be caused by a number of factors, including a deficiency in the coating itself, contamination of the substrate, or inadequate surface preparation. The test is therefore useful for evaluating coatings alone or complete coating systems.  
4.2 Water fog tests are used for research and development of coatings and substrate treatments, specification acceptance, and quality control in manufacturing. These tests usually result in a pass or fail determination, but the degree of failure may also be measured. A coating system is considered to pass if there is no evidence of water-related failure after a specified period of time.  
4.3 Results obtained from the use of water fog tests in accordance with this practice should not be represented as being equivalent to a period of exposure to water in the natural environment, until the degree of quantitative correlation has been established for the coating or coating system.  
4.4 The test apparatus is similar to that used in Practice B117, and the conversion of the apparatus from salt spray to water fog testing is feasible. Care should be taken to remove all traces of the salt from the cabinet and reservoir when converting from salt spray to water fog testing.
SCOPE
1.1 This practice covers the basic principles and operating procedures for testing water resistance of coatings in an apparatus similar to that used for salt spray testing.  
1.2 This practice is limited to the methods of obtaining, measuring, and controlling the conditions and procedures of water fog tests. It does not specify specimen preparation, specific test conditions, or evaluation of results.  
Note 1: Alternative practices for testing the water resistance of coatings include Practices D870, D2247, and D4585.  
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.  
1.5 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 D5162-21(Practice)
Standard Practice for Discontinuity (Holiday) Testing of Nonconductive Protective Coating on Metallic Substrates

SIGNIFICANCE AND USE
4.1 A coating/lining is applied to a metallic substrate to prevent corrosion or reduce product contamination, or both. The degree of coating continuity required is dictated by service conditions. Discontinuities in a coating/lining are frequently very minute and may not be readily visible. This practice provides a procedure for electrical detection of discontinuities in nonconductive coating systems.  
4.2 Electrical testing to determine the presence and number of discontinuities in a coating/lining is performed on a nonconductive coating/lining applied to an electrically conductive surface. The allowable number of discontinuities should be determined prior to conducting this test since the acceptable quantity of discontinuities will vary depending on film thickness, design, and service conditions.  
4.3 The low voltage wet sponge test equipment is generally used for detecting discontinuities in coatings/linings having a total thickness of 0.5 mm (20 mil) or less. High voltage spark test equipment is generally used for detecting discontinuities in coatings/linings having a total thickness of greater than 0.5 mm (20 mil).  
4.3.1 Coatings/linings less than 0.5 mm (20 mil) in thickness may be susceptible to damage if tested with high voltage spark testing equipment. However, coatings/linings greater than 0.25 mm (10 mil) and less than 0.5 mm (20 mil) may be tested with high voltage spark test equipment provided the voltage is calculated and set correctly, and the coating manufacturer approves its use.  
4.4 To prevent damage to a coating film when using high voltage test instrumentation, total film thickness and dielectric strength in a coating system shall be considered in determining the appropriate voltage for detection of discontinuities. Atmospheric conditions shall also be considered since the voltage required for the spark to gap a given distance in air varies with the conductivity of the air at the time the test is conducted. Table X1.1 in Appendix X1 cont...
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.  
1.5 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 E161-17(2021)(Specification)
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ABSTRACT
This specification covers the requirements for design and construction of electroformed sieves. These sieves are used to perform particle-size distribution analysis and in preparing narrowly designated particle-size fractions. They may also be used as reference standards when suitably calibrated. The material used in the manufacture of the sieve sheet shall be nickel or a metal suitable for electrodeposition in a firm crystalline structure. The sheet shall have square or round openings with straight uniform sides and smooth, flat surfaces except for a slight bevel along the edges of the openings. Frames for precision electroformed sieves shall be made from non-corrosive material such as brass or stainless steel, and constructed in such a manner as to be rigid.
SCOPE
1.1 This specification covers the technical requirements for design and construction of electroformed sieves and sieve material. These sieves are used to perform particle-size analysis and in preparing narrowly designated particle -size fractions. They may also be used as reference standards when suitably certified. The method of certifying these sieves is included in Annex A1.  
1.2 The values stated in SI units shall be considered standard for the dimensions of the electroformed mesh openings and the size of the line width in the electroformed mesh. The values stated in inch-pound units shall be considered standard with regard to the sieve frames and to lines per unit length, as in Table 1. The values given in parentheses are mathematical conversions that are provided for informational purposes only, and are not considered standard.  
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.

  • Technical specification
    4 pages
    English language
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