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EP06 view

THICKNESS TESTING OF ELECTROPLATED AND RELATED COATINGS

by G. P. RAY

Pages--170; Tables--14; Figures--70; References--82.
ISBN 0 901150 27 4

Code: EP26

Contents of this page:

Description
Some Worldwide Reviews
About the Editor
Table of Contents

Description

The purpose of this book is to describe the methods which can be used to measure the thickness of electrodeposited and ‘electroless’ (autocatalytic) coatings on both metallic and non-metallic substrates, conversion and hot-dipped coatings on metallic substrates, vitreous enamel coatings on metals, anodic coatings on aluminium and other metals and chemical replacement coatings on metallic substrates. Many of the methods, especially some of those based on non-destructive techniques, are equally applicable to organic coatings deposited on metallic substrates. The book attempts to give sufficient details of the test methods for them to be carried out without reference to any of the literature, apart from the instruction supplied by the instrument manufacturers for their particular instruments.

The first part of the book deals with ‘Destructive Testing Methods’ such as Microscopical examination of the cross-sections, Coulometric, Jet test and Strip and Weigh methods. The second part describes ‘Non-destructive methods’: Magnetic, Beta backscatter, X-Ray Spectrometry, Eddy current and Breakdown voltage methods. Profilometric and Optical methods, which may be described as almost ‘non-destructive’ techniques, are included in the second part of the book. A brief list of some well-known instrument manufacturers has been included for guidance purposes. The book concludes with a list of current international (ISO), British (BS) and US (ASTM) Standards to assist both metal finishers and the users of their products.

Some Worldwide Reviews

"The subject matter is well presented with a practical, down to earth approach. It seems clear that the book has been written with the needs of people in industry firmly in mind, and to such people I would have no hesitation in recommending it."

Hybrid Circuits (UK)

About the Editor

After obtaining his professional membership of the Institution of Metallurgists (now Institute of Materials), Dr Ray attended Sir John Cass School of Science and Technology, City of London Polytechnic, gaining an MSc degree in corrosion science and engineering and a PhD in metallurgy. He was awarded the Johnson Matthey Silver Medal in 1978 for a research paper, based on his MSc Thesis, on potential sources of corrosion in transistor packages. He is a Fellow of the Institute of Materials, Institute of Corrosion and Institute of Metal Finishing.

Dr Ray has held posts with Fulmer Research Institute, ITT Semiconductors, British Steel, City of London Polytechnic and University College, London, before joining the Quality Assurance Directorate, Ministry of Defence. He is a member of the British Standards Institution’s (BSI) Technical Committees on Electrodeposited and Related Finishes (STC 33), Corrosion Tests (STC 37) and Methods of Test for Metallic and Related Coatings (STC 39); American Society for Testing and Materials’ (ASTM) Technical Committees on Metallic and Inorganic Coatings, Hydrogen Embrittlement and Corrosion; and the Industrial and Technical Committee of the Institute of Metal Finishing. Since 1983, he has represented the UK as a specialist expert as well as a leader of the UK delegation at the International Standards Organisation's (ISO Technical Committee 107) sub-committees on Methods of Inspection and Co-ordination of Test Methods (SC2), Electrodeposited Coatings and Related Finishes (SC3) and Corrosion Tests for Metallic and Related Coatings (SC7). He is also a specialist representative of the UK to the Working Group (WG 3) of ISO/TC 107/SC3 dealing with hydrogen embrittlement.

Dr Ray has published a number of papers on the properties of materials, thickness testing of metallic and inorganic coatings, hydrogen embrittlement, and on the crack initiation characteristics in steel under corrosion fatigue conditions in Metallurgia, Transactions of the Institute of Metal Finishing, British Corrosion Journal, Corrosion Science, Journal of Material Science, ASTM Standardization News and BSI News. He is also the author of a number of standards dealing with surface preparation, electrodeposition, physical vapour deposition, chemical replacement coatings and hydrogen embrittlement. He has lectured extensively on these subjects in addition to standardisation and quality assurance.

Table of Contents

PART ONE

CHAPTER ONE

Measurement of Coating Thickness by Microscopical Examination of Cross-sections

1.1 Introduction

1.2 Method

1.2.1 Preparation of Cross-sections

1.2.1.1 Taper Sectioning

1.2.1.2 Etchants

1.2.1.3 Measurement

1.3 Advantages

1.4 Disadvantages

1.5 Measurement Uncertainty

1.6 Applications

1.7 Related Method

1.7.1 Measurement of Coating Thickness by Scanning Electron Microscope

1.7.1.1 Introduction

1.7.1.2 Instruments

1.7.1.3 Method

1.7.1.3.1 Preparation of Cross-sections

1.7.1.3.2 Measurement

1.7.1.4 Calculation of Magnification and Thickness

1.7.1.5 Measurement Uncertainty

1.7.1.6 Applications

 

CHAPTER TWO

Measurement of Coating Thickness by the Coulometric Method

2.1 Foreword

2.2 Introduction

2.3 Apparatus

2.3.1 The Electrolytic Cell

2.3.2 Electrical Requirements

2.4 Calibration Standards

2.5 Electrolytes

2.6 Method of Operation

2.7 Calculation of Results

2.8 Accuracy

2.9 Applications

2.A Appendix

 

CHAPTER THREE

Measurement of Coating Thickness by the Jet Test Method

3.1 Introduction

3.2 Apparatus

3.3 Method

3.3.1 Surface Preparation

3.3.2 Testing

3.4 Calculation

3.5 Accuracy

3.6 Applications

3.7 Related Methods

3.7.1 Dropping Test Method

3.7.2 Spot Test Method

 

CHAPTER FOUR

Measurement of Coating Thickness by the Strip and Weigh Method

4.1 Introduction

4.2 Method

4.3 Stripping Solutions

4.4 Thickness Calculation

4.5 Accuracy

4.6 Application

4.7 Related Methods

4.7.1 Analytical Method

4.7.2 Measurement of Hydrogen Evolved from Stripping the Deposit

4.7.3 Calorimetric Method

4.7.4 Clarke’s Gassing Test for Cadmium

4.7.5 Workshop Test for Zinc Deposits on Steel

 

PART TWO

CHAPTER FIVE

Measurement of Coating Thickness by Magnetic Methods

5.1 Introduction

5.2 Electromagnetic Methods

5.2.1 Types of Instruments

5.2.1.1 Types of Probes

5.2.2 Principle of Operation

5.2.3 Instrumentation and Calibration

5.2.3.1 Analogue Instruments

5.2.3.2 Digital Instruments

5.2.4 Operation

5.2.5 Instrument Precision and Measurement Accuracy

5.3 Magnetic Methods

5.3.1 Types of Instruments

5.3.1.1 Direct Mechanical Pull-off

5.3.1.2 Controlled Pull-off

5.3.1.3 Magnetic Flux Measurement

5.3.2 Calibration and Operation

5.3.3 Instrument Precision and Measurement Accuracy

5.4 Limitations

5.5 Applications

 

CHAPTER SIX

Measurement of Coating Thickness by the Beta Backscatter Method

6.1 Introduction

6.2 Principle

6.3 Instrumentation

6.4 Calibration of Instruments

6.5 Measuring Procedure

6.6 Limitations

6.6.1 Atomic Numbers of Coating and Substrate Material

6.6.2 Substrate

6.6.3 Coating

6.6.4 Aperture

6.6.5 Counting Statistics

6.6.6 Wear of Calibration Standard

6.7 Measurement Uncertainty

6.7.1 Calibration Error (Uncertainty)

6.7.2 Relative Instrument Error

6.7.3 Total Error

6.8 Applications

6.9 Safety

6.A Appendix

6.A.1 Activity and Decay

6.A.2 Backscatter

6.A.3 Normalised Backscatter

6.A.4 Dead Time and Resolving Time

6.A.5 Saturation Thickness

 

CHAPTER SEVEN

Measurement of Coating Thickness by the X-ray Spectrometric Method

7.1 Introduction

7.2 Principle

7.2.1 General

7.2.1.1 Generation of Exciting Radiation

7.2.2 Dispersion

7.2.3 Thickness Measurement

7.3 Apparatus

7.4 Principle of Operation

7.4.1 Radiation Generator

7.4.2 Collimator

7.4.3 Detector

7.4.4 Evaluating Unit

7.4.5 Calibration of Instrument

7.5 Procedure

7.6 Measurement Uncertainty

7.7 Limitations

7.7.1 Coating

7.7.2 Substrate

7.7.3 Counting Statistics and Measuring Area

7.7.4 Specimen Curvature

7.7.5 Stability of the Instruments

7.7.6 Radiation Path

7.8 Applications

7.A Appendix

7.A.1 X-ray Fluorescence (XRF)

7.A.2 Count Rate

7.A.3 Intensity of Fluorescent Radiation

7.A.4 Intermediate Coatings

7.A.5 Normalised Intensity (In)

7.A.6 Saturation Thickness

 

CHAPTER EIGHT

Measurement of Coating Thickness by the Profilometric Method

8.1 Introduction

8.2 Principle

8.3 Instrumentation

8.4 Calibration

8.5 Measuring Procedure

8.5.1 Preparation of the Specimen

8.5.2 Measurement of Thickness

8.6 Limitations

8.6.1 Stability

8.6.2 Cleanliness

8.6.3 Vibrations

8.6.4 Profile Record

8.6.5 Surface Characteristics

8.6.6 Calibration

8.7 Uncertainty

 

CHAPTER NINE

Measurement of Coating Thickness by Optical Methods

9.1 Introduction

9.2 Split-beam Method

9.2.1 Principle

9.2.2 Instrumentation

9.2.3 Calibration

9.2.4 Procedure

9.2.5 Accuracy and Precision

9.2.6 Applications

9.3 Interference Method

9.3.1 Principle

9.3.2 Double-beam Interference Microscopy

9.3.2.1 Instrumentation

9.3.2.2 Procedure

9.3.2.2.1 Non-destructive Technique

9.3.2.2.2 Destructive Technique

9.3.2.3 Accuracy

9.3.2.4 Application

9.3.3 Multiple-beam Interference Microscopy

9.3.3.1 Instrumentation

9.3.3.2 Calibration

9.3.3.3 Procedure

9.3.3.4 Accuracy

9.3.3.5 Application

 

CHAPTER TEN

Measurement of Coating Thickness by the Eddy Current Method

10.1 Introduction

10.2 Principle

10.3 Calibration

10.4 Procedure

10.5 Limitations

10.6 Accuracy and Precision

10.7 Applications

 

CHAPTER ELEVEN

Measurement of Thickness of Anodised Coatings on Aluminium by the Breakdown Voltage Method

11.1 Introduction

11.2 Principle

11.3 Method of Operation

11.4 Calibration

11.5 Accuracy

11.6 Applications

 

CHAPTER TWELVE

Measurement of Coating Thickness by Micro-resistance Model

12.1 Introduction

12.2 Principle

12.3 Procedure

12.4 Accuracy

 

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 Page last revised 11.02.05

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