surface engineering measurement standards for inorganic materials

April 2005

Stanley J. Dapkunas

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Surface EngineeringMeasurementStandards forInorganic Materials

Stanley J. Dapkunas

Materials Science and Engineering Laboratory

April 2005

U.S. Department of CommerceCarlos Gutierrez, Secretary

Technology AdministrationPhillip J. Bond, Under Secretary for Technology

National Institute of Standards and TechnologyHratch G. Semerjian, Acting Director

Special Publication 960-9

NIST Recommended Practice Guide

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ii

Certain commercial entities, equipment, or materials may be identified in thisdocument in order to describe an experimental procedure or concept adequately.Such identification is not intended to imply recommendation or endorsement bythe National Institute of Standards and Technology, nor is it intended to implythat the entities, materials, or equipment are necessarily the best available for thepurpose.______________________________________

National Institute of Standards and TechnologySpecial Publication 960-9Natl. Inst. Stand. Technol.Spec. Publ. 960-9252 pages (April 2005)CODEN: NSPUE2U.S. GOVERNMENT PRINTING OFFICEWASHINGTON: 2005For sale by the Superintendent of DocumentsU.S. Government Printing OfficeInternet: bookstore.gpo.gov Phone: (202) 512-1800 Fax: (202) 512-2250Mail: Stop SSOP, Washington, DC 20402-0001

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Acknowledgements

Acknowledgements

This Recommended Practice Guide has benefited from the assistance of severalindividuals at the National Institute of Standards and Technology (NIST) and ASMInternational, and specifically members of the ASM International Surface EngineeringCommittee. Staffs of the NIST Research Library and the National Center for Standardsand Certification at NIST, in particular, were critical in providing access to standardsdescribed in this publication. Ed Mai of the NIST Administrative Services Divisiongave valuable advice on formatting and information presentation that makes thisdocument accessible. His design of Figure 1 is greatly appreciated.

In addition to members of the Editorial Committee, Bill Scott and Fran Cverna of theASM International staff provided valuable perspectives.

Photomicrographs in Figure 1 were originally published by ASM International. Theseillustrations of surface conditions clarify the organization of this Guide. Sources of thephotomicrographs are as follows:

Bare Material ASM Micrograph Center On-Line Photo CS 1376Heat Treated ASM Micrograph Center On-Line, Photo 0027Oxidized ASM Micrograph Center On-Line CS 1079Carburized ASM Micrograph Center On-Line Photo 0001Decarburized ASM Micrograph Center On-Line Photo 0030Aluminized ASM Handbook Volume 5, Surface Engineering, 1994, page 614,

Figure 3DChromized ASM Metals Handbook, 8th Edition, Atlas of Microstructures of

Industrial Alloys, 1972, page 13, Photo 83Electroplated ASM Metals Handbook, 8th Edition, Atlas of Microstructures of

Industrial Alloys, 1972, Photo 1877Galvanized/clad ASM Metals Handbook, 8th Edition, Atlas of Microstructures of

Industrial Alloys, 1972, Photo 72Physical Vapor Deposition ASM International, Journal of Thermal Spray Technology,

Vol. 6, No. 1, March 1988, page 37, Figure 5Thermal 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, withpermission, from ASTM B 659-90(2003) Standard Guide for Measuring Thickness ofMetallic and Inorganic Coatings, copyright ASTM International, 100 Barr Harbor Drive,West Conshohocken, PA 19428.

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vPreface

Preface

Surface engineering of materials is important in applications as diverse as medicalimplants and gas turbines. Historically, a coating or cladding was added to a surface, ora surface was treated, to enhance properties or performance. However, increasingly, heattreated, implanted, coated and clad surfaces are viewed as part of a materials systemwhere the substrate and surface complement each other in achieving a performance goalfor a component. The integration of the surface and substrate as an engineered systemcreates a situation where failure of the surface may, in effect, be failure of the systemand thus characterization of surfaces and measurement of surface properties areimportant to the design, maintenance, and analysis of the whole system.

The advantages of engineered surfaces have stimulated development of surface treatmentand coating processes as well as materials and, consequently, commerce. Commerce inengineered materials depends upon the ability to specify and measure composition,microstructure, dimensions and properties as well as performance in applicationsof interest.

The intent of this Guide is to give the materials community a resource for identifyingstandard methods which are used to measure surface properties and to characterizesurface engineered materials.

This Guide has been prepared with the support of the Ceramics Division of the NationalInstitute of Standards and Technology and the cooperation of the Surface EngineeringCommittee of ASM International.

Specific thanks are due the Editorial Committee which oversaw this effort. Members ofthat committee include:

Professor Christopher C. Berndt, James Cook University, School of Engineering,Queensland, Australia; previously of Stony Brook University, Department of MaterialsScience 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 photomicrographsare provided in the Acknowledgements section of this document.

ASTM International generously provided Figure 2, Applicability of Coating ThicknessMeasuring Methods. The source of Figure 2 is ASTM B 659-90 (2003) Standard Guidefor Measuring Thickness of Metallic and Inorganic Coatings.

More information on the SP 960 series can be found on the Internet athttp://www.nist.gov/practice guides. This website includes a complete list of NISTPractice Guides and ordering information.

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Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vList of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12. Organization of the Guide and Locating Standards . . . . . . . . . . . . . . . . . . . .4

2.1 Organization of the Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.2 Locating Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3. General Standards for Surface Engineering Measurement . . . . . . . . . . . . .103.1 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103.2 Laboratory Accreditation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123.3 Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4. Surface Inspection and Product Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . .254.1 General (bare and coated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254.2 Products (bare and coated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4.2.1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424.2.2 Sheet and Structural Steel . . . . . . . . . . . . . . . . . . . . . . . . . . .514.2.3 Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .574.2.4 Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

5. Surface Finish Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625.1 General (bare and coated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625.2 Methods for Specific Products and Processes . . . . . . . . . . . . . . . . . .66

6. General Product Quality Standards for Specific Coating Processes . . . . . .726.1 Anodic Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .726.2 Conversion Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .736.3 Galvanized Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756.4 Electroplated Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .766.5 Diffusion Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .806.6 Physical Vapor Deposition (PVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . .826.7 Thermal Spray Deposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .836.8 Glass and Enamel Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

7. Standards for Measurement of Surface Treatment DepthCoating Thickness and Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .887.1 Surface Treatment Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .887.2 Coating Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .977.3 Coating Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

8. Standards for Analysis of Microstructure . . . . . . . . . . . . . . . . . . . . . . . . . .1368.1 Metallography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1368.2 Porosity and Defect Measurement of Coatings . . . . . . . . . . . . . . . .141

9. Standards for Measurement of Composition and Crystal Structure . . . . . .1489.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1489.2 Crystal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

10. Standards for Residual Stress and Hardness Measurement . . . . . . . . . . .15310.1 Residual Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15310.2 Indentation Hardness Measurements . . . . . . . . . . . . . . . . . . . . . . . .15510.3 Other Hardness Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

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Table of Contents

11. Standards for Mechanical Properties and Adhesion of Coatings . . . . . . . .18111.1 Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18111.2 Adhesion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

12. Standards for Measurement of Corrosion, Wear and ThermalProperties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19112.1 Bare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19112.2 Coated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198

13. Surface Engineering Measurement Standards . . . . . . . . . . . . . . . . . . . . .21013.1 ASME (American Society of Mechanical

Engineers) Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21013.2 ASTM International (American Society for

Testing and Materials) Standards . . . . . . . . . . . . . . . . . . . . . . . . . . .21013.3 ISO (International Organization for

Standardization) Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21713.4 Military and Industry Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . .22213.5 SAE (Society of Automotive Engineers) Standards . . . . . . . . . . . . .223

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

List of FiguresFigure 1. Quick Guide to Surface Measurement Standards . . . . . . . . . . . . . . . .6Figure 2. Applicability of Coating Thickness Measuring Methods . . . . . . . . . . .97

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1Introduction

1. Introduction

This Guide is intended to aid the technical and scientific community in the evaluationof engineered surfaces by identifying standard methods for measurement of pertinentproperties and characteristics. Methods included in this Guide are for use with inorganicmaterials, 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 surfaceregions of a material to allow the surface to perform functions that are distinct fromthose functions demanded from the bulk of the material1. Surface Engineering hasalso been expanded to include consideration of the design of the surface and substrate asa system2. Engineered surfaces typically provide wear, corrosion or thermal protectionand may be created by techniques such as heat treatment to modify microstructure,implantation to modify composition, or coating and cladding where a very differentmaterial is applied to a surface. Generally, an engineered surface enhances theperformance 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 manytechnologies. For example, gas turbines rely on coatings for corrosion and thermalprotection to achieve durability and high efficiency, reciprocating engines rely on treatedand coated surfaces for wear resistance, and medical implants are coated to improvebone 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 ashardness 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 asextent of corrosive penetration or wear; and,

to predict performance through exposure in an environment which simulates theintended application, again, followed by evaluation of appropriate attributes.

Addressing these three purposes requires property measurement or characterization bymethods that not only meet the needs of the party conducting the measurement but alsoare 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 ofmeasurement. Obviously, the availability of commonly accepted measurement methodsfacilitates commerce by removing ambiguities that may arise when the same nominalproperty is determined by unique or unusual techniques.

Furthermore, some properties are so broadly useful, because they provide a commondenominator for comparing materials, that considerable effort has been invested in theirconsistent measurement. Hardness, for example, is a useful property for comparing

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2Introduction

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 thedevelopment of standard test methods, i.e., standards. Standards specify measurementdetails such as specimen design, test apparatus and calibration, test procedures, datareporting, limits of applicability, and uncertainty.

Standard measurement methods are an important component in engineering design andconstruction. For example, standard test methods may be codified, that is, made part ofa system of principles or rules. ASTM (formerly the American Society for Testing andMaterials) standards for property measurement are included in the ASME (AmericanSociety of Mechanical Engineers) Boiler and Pressure Vessel Code, which is a basisfor design and fabrication.

The widespread use of standards and the value they bring to commerce in materials andcomponents has necessitated the formation of organizations whose function is to fosterdevelopment of standard measurement methods. These standards organizations canbe civilian and voluntary, as is ASTM, or governmental, as is the JIS (Japan Instituteof Standards).

The organizations which have accepted responsibility for standards development alsomake the standards available for interested parties and update the standards, asappropriate. The standards are usually up-dated with significant contribution andreview by the technical community concerned.

In the United States, standards organizations with an interest in surface engineeringmeasurements include ASTM, SAE (Society of Automotive Engineers), ASMEInternational (American Society of Mechanical Engineers) and ANSI (AmericanNational Standards Institute). These organizations develop consensus standards throughthe efforts of volunteers, often with scientific support from NIST (the National Instituteof Standards and Technology).

The DOD (Department of Defense), NASA ( National Aeronautics and SpaceAdministration) and other government agencies conduct research on engineered surfacesand can establish test methods which amount to standards. These test methods addressthose agencies specific needs but may eventually be adopted by ASTM or otherstandards organizations.

International standards are generally developed through the cooperative efforts ofnational or regional standards organizations and reflect the methods developed for thosebodies standards. The ISO (International Organization for Standardization) is the mostnotable international organization active in the development of methods for measurementof material properties.

This Guide includes few standards for measurement of corrosion, friction, wear andabrasion. Standards in these fields that are included focus on evaluation of specificsurface conditions. The large number of corrosion and wear standards based oncorrodent or wear mechanism warrant separate compilation, as has been done in the

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3Introduction

Friction and Wear Testing Source Book of Selected References from ASTM Standardsand ASM Handbooks. That Source Book was issued jointly by ASTM Internationaland ASM International in 1997 and is available from those organizations.

Lastly, it is important to note that standards, i.e., standard test methods, are wellconsidered approaches to property measurement or material characterization and are theconsensus opinion of experienced practitioners and researchers. As such, they are ameans for those inexperienced in a specific field to quickly gain knowledge of what isregarded as a reputable measurement technique. Standard test methods do not alwaysinclude state-of-the-art techniques or address applications which are still in the researchstage and subject to rapid change.

This Guide does not provide details included in the standards identified and should notbe viewed as a substitute for those standards. Standards should be purchased from theissuing organization at the following addresses:

ASTM100 Barr Harbor DriveWest Conshocken, PA 19428-2959

ASMEThree Park AvenueNew York, NY 10016-5990

ISOCase postale 56CH-1211Geneva 20Switzerland

SAE International400 Commonwealth DriveWarrendale, PA 15096-0001

1 ASM Handbook, Volume 5, Surface Engineering, Copyright 1994 by ASMInternational, Materials Park, Ohio 44073-0002

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

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4Organization of the Guide and Locating Standards

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 users interests.

The Guide includes standards appropriate for the following surface conditions:

bare surfaces which have the same composition, phase and structure from surfaceto interior;

treated surfaces wherein the base material has been subjected to conditions whichchange surface composition, structure, phase, or properties; and,

coated surfaces wherein the base material has had specific additional materialdeposited on its surface, often significantly increasing the base materials dimensions.

Treated surfaces are those that have been subjected to processes such as carburization,decarburization, nitridation, surface implantation, surface heat treatments and abrasiveblast hardening or cleaning.

Coated surfaces are those that have been covered with material having composition andproperties significantly different from the base material. Coating processes includeelectroplating, 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 followinginformation, as appropriate:

Standards Identification including issuing organization, standard identificationnumber and standard title;

General Description including an overview of the method and the contents of thestandard;

Intended Application including the stated purpose for which the standard wasdeveloped;

Specimen Requirements including the size, condition or other characteristicsnecessary or valid use of the method;

Data Produced including the nature of the data produced (visual or instrumentgenerated numeric, for example) and further refinements or calculationsnecessary, and,

Limits of the method including inappropriate application, accuracy, precision orsafety 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,

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5Locating Standards

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 toMeasurement method to the "Appropriate Section which includes relevantstandards;

Section 13. Surface Engineering Measurement Standards, a compilation of titles ofall standards in Sections 3 through 12, organized by issuing organizations and thoseorganizations alpha-numeric identification;

Section 14. Index, a comprehensive compilation of key words associated with eachstandard;

Figure 2. Applicability of Coating Thickness Measuring Methods, which isincluded in Section 7 and provides an ASTM summary of methods for measuringthickness 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, althoughnot comprehensive, route to a relevant standard by starting with the surface conditionillustrated and proceeding through the property of interest to measurement method tothe section in which the standard(s) are located;

Property or Characteristic BasedProceeding directly to Sections 3 through 12 will enable browsing through standardswhich address general issues such as terminology or accreditation, properties orcharacteristics, material, or measurement method;

Standard BasedSection 13, the compilation of standards in Sections 3 through 12, enables the userto proceed directly to the summary of the standard of interest when the standard isknown; and,

Key WordsStandards can also be accessed by use of the alphabetized Index in Section 14. TheIndex is based on key words descriptive of the content of each standard.

Also, Figure 2, Applicability of Coating Thickness Measuring Methods, can be usedwithin Section 7 to focus on useful methods and the Index can be used to quicklyidentify standards with similar purposes or methods issued by different organizations.Sections 3 through 12 also enable comparison of standards issued by differentorganizations.

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Figure 1. Quick Guide to Surface Measurement StandardsSurface Condition Property Method Section PageBare Specifications

Geometrical Product Specifications (GPS)Acceptance standards, VisualSurface defects, fasteners

4.14.14.2

252542

Surface chemistry 9.1 148 Terminology Depth profiling (AES) Glow discharge optical Emission spectroscopy

Surfaceprofile &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

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7Locating Standards

Figure 1. Quick Guide to Surface Measurement Standards (contd)Surface Condition Property Method Section PageHeat 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 21Thickness 7.2 97

Gravimetric Split beam microscopy

Aluminized Specification 6.5 80Coating thickness 7.2 97

Microscopy

Chromized Contractor accreditation 3.2 12Coating thickness 7.2 97

Microscopy

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Figure 1. Quick Guide to Surface Measurement Standards (contd)Surface Condition Property Method Section PageElectroplated 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 198Hydrogen embrittlement

Electronic 12.2 198

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9Locating Standards

Figure 1. Quick Guide to Surface Measurement Standards (contd)Surface Condition Property Method Section PageGalvanized/Clad

Case study practices 6.3 75Coating mass measurement 7.3 125

Gravimetric X-ray fluorescence Triple spot

Composition 7.3 125

Triple spotPhysicalVaporDeposited

TiN Specification 6.6 82Contractor accreditation 3.2 12

Coating thickness 7.2 97 Microscopical Radial sectioning

ThermalSprayed

Contractor accreditation 3.2 12Specifications 6.7 83Thickness 7.2 97

Radial sectioningPhase content, hydroxyapatite 9.2 152

X-ray diffractionShear strength 11.1 181

MechanicalTensile strength 11.1 181

MechanicalFatigue strength 11.1 181

MechanicalAdhesion/cohesion strength 11.2 187

MechanicalAbrasion resistance 11.2 187

Taber Abraser

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10

General Standards for Surface Engineering

3. General Standards for Surface Engineering Measurement

3.1 Terminology

ASTM A 902Standard Terminology Relating to Metallic Coated Steel Products

General Description Data Produced

This Standard is a compilation of 47definitions of terms related to metalliccoatings used in the steel industry.The Standard also includesrecommended key words for ASTMCommittee A-5 Standards.

Not applicable/specified.

Intended Application Specimen Requirement Limits

Clarity of terminologyused in coated steelproduct descriptions.

Not specified. Not specified.

ISO 2079Surface Treatment and Metallic Coatings General Classification of Terms


This document provides general termsand definitions for several surfacetreatments and identifies relevantISO standards for those treatments.Terms and definitions are provided inEnglish, French, Russian andGerman.

Not specified.


Intended to clarifyrelevant standards.


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Terminology

ISO 2080Electroplating and Related Processes Vocabulary


This Standard provides definitions of804 terms used in electroplating andrelated processes such as metalfinishing. Definitions are in English,French, Russian and German.

Not specified.


Intended to clarifyrelevant standards.


SAE AS 4194Sheet and Strip Surface Finish Nomenclature(Aerospace Standard)


Defines nomenclature for two surfaces(2D and 2B) of sheet and twosurfaces (No. 1 and No. 2) of stripmaterial and bright annealed finish.

Not specified/applicable.


Provides explanations ofterms used to describesurface finish of iron,nickel, cobalt andtitanium base alloysused in aerospaceapplications.

Not specified/applicable. Not specified/applicable.

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12


3.2 Laboratory Accreditation

SAE AS 7101National Aerospace and Defense Contractors Accreditation Program (NADCAP)General Requirements for Materials Test Laboratory Accreditation Program (Aerospace Standard)


Establishes the minimumrequirements for materials testinglaboratories accredited by NADCAP.Test methods for metallic materialsare specified by reference to SAE,ASTM, military, ISO and ANSIdocuments. Methods referencedinclude those for: chemical,mechanical, metallography andmicrohardness, hardness, corrosion,mechanical test specimen preparation,differential thermal analysis, heattreating, X-ray diffraction and fastenertesting. Document includes definitions,and survey requirements.



Intended to giveguidance for manyaspects of a testinglaboratory requiredfor accreditation.


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Laboratory Accreditation

SAE AS 7109National Aerospace and Defense Contractors Accreditation Program Requirements for Coatings(Aerospace Standard)


This Standard establishesrequirements for suppliers of coatingservices to be accredited by theNational Aerospace and DefenseContractors Accreditation Program(NADCAP). It does not includemeasurement methods but serves asthe basic document for accompanyingAerospace Standards for specifictypes of coatings which includemeasurement or testing requirements.

Not specified.


Coating supplieraccreditation.


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SAE AS 7109-1National Aerospace and Defense Contractors Accreditation Program Requirements for Thermal Spray(Aerospace Standard)


This Standard is a supplement to SAEAS 7109 addressing: OXY/FuelPowder and Wire Spray, PlasmaThermal Spray, HVOF/D-Gun Spray,Low Pressure Plasma Spray (LPPS)and Electric Arc Wire Spray.Accreditation requirements for thefollowing applications are included:High/low Temperature Hard Coatings,Anti-fretting Coatings, Thermal BarrierCoatings, Abrasive Seal Coatings,Abradable Coatings, DimensionalBuild-up Coatings and HighTemperature LPPS Coatings. Aspectsaddressed include: TechnicalExperience, Process Planning,Manufacturing, Material Powder/WireControl, Cleaning, Masking, GritBlasting, Spray Booths, Oxy/Fuel,Plasma Thermal Spray, HVOF/D-Gun,LPPS, Electric Arc Wire, ProcessGases, De-mask/Clean, SupplementalHeat Treating, Sealing SprayedCoatings, Inspection and Compliance.Characterization and measurementare covered in the Inspectionsection.

Not specified.




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SAE AS 7109-2National Aerospace and Defense Contractors Accreditation Program Requirements for Vapor Deposit(Aerospace Standard)


This Standard supplements SAEAS 7109, specifically addressingphysical vapor deposition (PVD, ClassA) which includes sputter and electronbeam deposition and chemical vapordeposition (CVD, Class B). Thefollowing aspects of accreditation aredescribed: Technical Experience,Manufacturing, Material Control,Vapor Process Operation Sheet,Part Treatment, Cleaning, Masking,Surface Preparation, Chambers/PumpSystems, Process Gases,Supplementary Chemical Treatment,Inspection and Compliance.Characterization and measurementare included in the Inspectionsection.

Not specified.



Not specified. Standard methods forcharacterization orinspection arenot specified.

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SAE AS 7109-3National Aerospace and Defense Contractors AccreditationProgram Requirements for Cementation(Aerospace Standard)


This Standard supplements SAEAS 7109, specifically addressing packprocesses (Class A) which includesabove pack and in-pack deposition,and slurry processes (Class B).The following aspects of accreditationare included: Technical Experience,Process Planning, Manufacturing,Material Control, Cleaning, Masking,Grit Blasting, Packing/FurnaceLoading, Coating/ Thermal Treatment,De-mask/Clean, SupplementaryChemical Processing, Inspection andCompliance. Characterization andmeasurement are included in theInspection section.

Not specified.



Not specified. Standard methods forcharacterization orinspection arenot specified.

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SAE AS 7109-4National Aerospace and Defense Contractors Accreditation Program Requirements for Stripping(Aerospace Standard)


This Standard supplements SAEAS 7109, specifically addressingstripping of coated material.Stripping methods addressed include:electrolytic, mechanical (grit blast,grinding, machining) water jet, moltensalt and chemical. The followingaspects of accreditation are included:Equipment and Facilities, ProcessPlanning, Manufacturing, MaterialControl, Stripping, Water Jet, MoltenSalt, Chemical, Process ControlLaboratory Procedures (SolutionAnalysis), Post Strip Cleaning, BakeEmbrittlement Relief and Compliance.

Not applicable/specified.




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SAE AS 7109-5National Aerospace and Defense Contractors Accreditation Program Requirements for Coating Evaluation Laboratory Practices(Aerospace Standard)


This Standard supplements SAEAS 7109, specifically addressingcoating evaluation. Specific details ofevaluation methods are not describedbut appropriate references to otherdocumentation (e.g. ASTM) areincluded. The Standard covers thoseaspects of evaluation which must beaddresses to warrant accreditation,including: Personnel, Procedures,Equipment and Facilities, QualityAssurance-Lab Specific, Round RobinPrograms, Hardness Testing,Metallography and Thickness,Mechanical Testing, Heat treating ofSpecimens, Specimens (such as perASTM C 633), Replacement Testingand Retesting, Test Reports/Certificates, Tensile Testing, BendTesting and Nonstandard Compliance.

Not specified.




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SAE AS 7109-6National Aerospace and Defense Contractors AccreditationProgram Requirements for Plating of Coated Parts Laboratory Practices(Aerospace Standard)


This standard is a supplement to SAEAS 7109, specifically addressingplating of coated parts. The documentcalls out aspects of plating which mustbe addressed to meet accreditationrequirements. These aspects areincluded: Equipment and Facilities,Part Processing Control, CleaningProcedures, Masking, Lot Integrity,Housekeeping, Test and Inspection,Process Control LaboratoryProcedures (Solution Analysis) andCompliance. Test and Inspectionspecifies the use of procedures in thefollowing ASTM Standards:B 244, B 487, B 499, B 504,B 530, B 567 and B 568.

Not specified.




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SAE AS 7109-7National Aerospace and Defense Contractors AccreditationProgram Requirements for Heat Treating for Suppliers of Coatings(Aerospace Standard)


This Standard is a complement toSAE AS 7109, specifically addressingheat treating during the coatingprocess. This standard does notinclude surface related measurementor testing and is included only forcompleteness in the AS 7109 series.

Not specified.




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Sampling

3.3 Sampling

ASTM B 602Standard Test Method for Attribute Sampling of Metallic and Inorganic Coatings


This Method gives sampling plansintended for use in the inspection ofcoatings for conformance to ASTMspecifications. The plans are based oninspection by attributes. That is, thearticle is inspected and classified aseither conforming to a requirementplaced on it or not conforming. TheMethod includes a general descriptionof the approach, ordering information,formation of inspection lot,sampling,inspection and lot disposal,and drawing of samples.

Varies with specification.


Sampling inspectionpermits the estimation ofthe overall quality of agroup of product articlesthrough the inspection ofa relatively small numberof product items drawnfrom the group. Theselection of a samplingplan provides purchasersand sellers a means ofidentifying the minimumquality levels that areconsidered satisfactory.

Varies with specification. Sampling plans yieldestimates of the qualityof product, thus theresults of the inspectionare subject to error.Through the use ofsampling plans, the riskof error is knownand controlled.

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ASTM B 697Standard Guide for Selection of Sampling Plans for Inspection ofElectrodeposited Metallic and Inorganic Coatings


This Guide provides guidance in theselection of sampling plans todetermine whether submitted lots ofcoated products comply with thespecifications applicable to thecoatings. A sampling plan guides theexamination of a relatively small partof the articles in a lot. Thatexamination allows a decision as towhether the lot does or does notconform to specifications. Thesampling plans are attribute plans.Each examined article is classified asconforming or not conforming to eachcoating requirement and the numberof nonconforming articles compared toa maximum allowable number.Supplements ASTM B 602.

Number of articles with acceptableproperties.


Acceptance sampling isused when a decisionmust be made aboutwhat to do with aquantity of articles.Used where cost ofinspection is high andconsequences ofaccepting anonconforming articleare not serious; or,where 100% inspectionis boring or fatiguingand likely to result inerrors; or, wheninspection requires adestructive test.

Varies with property orcharacteristic of interest.

It is important that theinspection lot behomogeneous; i.e., thatthe articles in the lot befrom the same supplier,single finishing line,finished at thesame time, etc.

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Sampling

ASTM B 762Standard Test Method of Variables Sampling of Metallic and Inorganic Coatings


This Method gives sampling plans forinspection of coatings on products forthe purpose of deciding whether lotsof the coated articles conform tospecifications for the coatings. Acharacteristic of the coating on drawnarticles is measured and the valuesobtained are used to estimate thenumber of articles in the lot that do notconform to a numerical limit.

Number of articles in a lot that do notconform to a numerical limit.


Acceptance testing oflots of coated articles.

Varies with property orcharacteristic of interest.

A variables plan requiresthat: the characteristic ofinterest is measurable;the test method gives anumerical measure ofthe characteristic; thespecification places anumerical limit on themeasured value;variation of thecharacteristic from articleto article be normallydistributed; and, eacharticle is tested in thesame way. If one ormore of the aboveconditions are not met,an attributes plan mustbe used; e.g., ASTMB 602 or ASTM B 697.

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ISO 4519Electrodeposited Metallic Coatings and Related Finishes SamplingProcedures for Inspection by Attributes


This Standard establishes samplingplans and procedures for inspection ofelectrodeposited metallic coatingsusing attributes of those materials.The procedures described may beapplied to finished products ormaterials processing. The samplingplans are based on acceptable qualitylevels (AQLs) of 1.5 and 4.0%. Thestandard includes definitions, defectclassifications, acceptance andrejection responsibilities, sampleselection methods and plans, detailedguidance on determination ofacceptability and procedures fordrawing random samples. Thisstandard is based on ISO 2858.

Varies with property of interest.


Provides a basis forpurchase specificationsand may be applied torelated finishes. Thisstandard supportsdetermination of lotacceptability by the useof a sampling plan.

Not specified. The plans are intendedprimarily for examinationof continuing series oflots but may be used forexamination of isolatedlots. This standard is notapplicable to samplingand testing ofelectroplated mechanicalfasteners(See ISO 3269).

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General (bare and coated)

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 MetallicCoatings by Polysulfide Immersion


This Method describes a technique fordetermining gross defects and/ormechanical damage to metalliccoatings on copper or copper alloysubstrates. The Method is useful fortechniques where the coating doesnot tarnish in an alkaline polysulfidesolution. Suitable coatings includegold, nickel, tin, tin-lead, palladium ortheir alloys. The Method consists ofimmersing the test area in a solutionof alkaline sodium sulfite for 60 s at74 C and examining the test area forsigns of copper reaction productsusing a 10x microscope. The Methodgives polysulfide solution preparation,test procedure and examinationand evaluation guidelines.

Visible indications of defects.


Intended to ascertain thepresence of defects fromprocessing andmechanical damagefrom use as manifestedby exposure of copperunder plate or copperbasis metal.

Clean surfaces. Method is relativelyinsensitive to thepresence of small pores.ASTM B 809 should beused instead. Method isnot recommended forprediction of productperformance orsimulation of field failuremechanisms. Generally,corrosion products lessthan 0.05 mm (0.002 in.)in diameter are notcounted in the evaluation.Work should be performedin a fume hood.

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Surface Inspection and Product Quality

ASTM B 877Standard Test Method for Gross Defects and Mechanical Damage in MetallicCoatings by the Phosphomolybdic Acid (PMA) Method


This test standard gives equipmentand methods for using phosomolybdicacid (PMA, a solid complex ofmolybdenum trioxide and phosphoricacid) to detect gross defects andmechanical damage in gold, silver orpalladium coatings over substrates ofnickel, copper or copper alloys. Thetest consists of removing oxides in thedefect area by exposure tohydrochloric acid fumes and applyinga drop of PMA with an applicator tothe area in question. PMA contact withexposed under plate or substratecauses the molybdenum trioxideto turn blue.

Visible indications of defects.


To determine thepresence of mechanicaldamage, wear-throughand other gross defectsin the coating. Intendedfor the evaluation ofindividual samples, oneat a time, with amicroscope at 10xto 30x.

Thoroughly cleaned,particle free surfaces.A test area of less than2 mm allowsexamination bymicroscope. Test areasmay require masking toprevent PMA reactionwith exposed basemetal edges.

This is essentially apass/fail test. It may notbe suitable for someprecious metal alloycoatings that containsignificant concentrationsof non-precious metals(e.g., nickel or copper).PMA reacts with tin, leadand tin-lead solder. Testis relatively insensitive tosmall pores. Test notrecommended forprediction of productperformance. Test isdestructive and testedpieces should not beput into service.

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ISO 3274Geometrical product Specifications (GPS) Surface Texture: Profile Method Nominal Characteristics of Contact (stylus) Instruments


This Standard defines profiles and thegeneral structure of contact (stylus)instruments for measuring surfaceroughness and waviness. Instrumentproperties and basic specifications forprofile meters and profile recordersare included. It influences chain link 5for roughness, waviness and primaryprofiles in the GPS matrix model.



The primary purpose isto enable comparison ofsimilar surfaces or thecomparison of resultsfrom different measuringinstruments.


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ISO 4288Geometrical Product Specification (GPS) Surface Texture: Profile Method Rules and Procedures for the Assessment of Surface Texture


This Standard specifies the rules forcomparison of the measured valueswith the tolerance limits for surfacetexture parameters defined inISO4287, ISO 12085, ISO 13565-2 andISO 13565-3. It includes: parameterestimation, rules for comparison(areas to be inspected, 16% rule,max.-rule, uncertainty), parameterestimation, rules and procedures forinspection, and a Simplifiedprocedure for roughness inspection.

Numeric values of roughness.


Influences chain links 3and 4 of ISO standardsfor roughness andprimary profiles in theGPS matrix model.

Not specified/applicable. Not useful fordescriptions of surfacedefects.

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ISO 8502Preparation of Steel Substrates Before Application of Paints and RelatedProducts Tests for the Assessment of Surface CleanlinessPart 1: Field test for soluble iron corrosion productsPart 2: Laboratory determination of chloride on cleaned surfacesPart 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method)Part 4: Guidance on the estimation of the probability of condensation prior to paint

applicationPart 5: Measurement of chloride on steel surfaces prepared for painting (ion detection tube method)


This comprehensive standard describeseight methods for the quantitativedetermination of surface contaminantson blast cleaned steel, prior to paint orother coating application. Both fieldand laboratory measurement methodsare included.Part 1 describes a semi-quantitativemethod for analysis of ferrous ions byswabbing the test surface with watersoaked cotton and analyzing the washliquid with an indicator strip.Part 2 describes a technique fordetermination of chloride by waterwashing and subsequent titration withmercury nitrate.Part 3 describes a method for analysisof dust contamination by controlledapplication of transparent pressuresensitive tape to the test surfacefollowed by analysis of the removedtape for adherent particle size andquantity, using a hand lens andcomparator charts included inthe standard.Part 4: Guidance on the estimation ofthe probability of condensation prior topaint application based on relativehumidity and steel surface temperature.Part 5 describes a field test in whichwater-soluble chlorides are washedfrom the surface and the wash liquidanalyzed to determine the chloride ionconcentration using a detection tubecontaining silver chromate in a sandcarrier. The color change of the tubecontents with immersion in differentknown chloride ion concentrationsserves as the calibration for thefield test.

Data collected varies with method butgenerally consists of concentration ofcontaminant per unit volume which isconverted to contaminant per unitsurface area.

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ISO 8502, ContinuedPreparation of Steel Substrates Before Application of Paints and RelatedProducts Tests for the Assessment of Surface CleanlinessPart 6: Extraction of soluble contaminants for analysis The Bresle methodPart 8: Field method for the refractometric determination of moisturePart 9: Field method for the conductometric determination of water-soluble saltsPart 10: Field method for the titimetric determination of water-soluble chloridePart 12: Field method for the titimetric determination of water-soluble ferrous ions


Part 6 describes the fabrication and useof an adhesive patch applied to the testsurface into which a suitable solvent foranalysis of the contaminant in questionis injected. The solvent is repeatedlyinjected and removed with a syringe andthe solvent subsequently analyzed toascertain the contaminant level. Themethod is suitable for field use.Part 8 describes the measurement ofmoisture, generally from condensation,on a surface to which an adhesive patchdescribed in Part 6 is used to contain amixture of monoethylene glycol andwater. The mixture is repeatedly injectedand removed followed by measurementof the glycol mass fraction in arefractometer.Part 9 describes a field test for watersoluble salts using the technique ofPart 6. The change in conductivity of thetest water due to solution of salts fromthe surface is measured and used tocalculate the surface density of thesalts.Part 10 describes a field method inwhich the procedure of Part 6 is used toinject water containing sodium fluorideand hydrogen fluoride. The water actsas a solvent for chloride on the surface.The chloride concentration isdetermined by titration with mercuricnitrate. Part 12 describes the use of thetechnique in Part 6, or anotherappropriate method, to removecontaminants from the surface andacidifying the solution with phosphoricacid. The ferrous ion concentration isdetermined by titration with a dichromatesolution.

Data collected varies with method butgenerally consists of concentration ofcontaminant per unit volume which isconverted to contaminant per unitsurface area.

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ISO 8502, Continued


Intended to determinewhether a mechanicallyblast cleaned surface, ora surface betweencoating applications,meets cleanlinessspecifications required toachieve coatingperformance goals.


ISO 8785Geometrical Product Specification (GPS) Surface Imperfections Terms,Definitions and Parameters


This Standard defines terms used todescribe different types of surfaceimperfections and includes illustrativedrawings. The document provides acommon vocabulary for use in manytypes of technical publications anddrawings. Fifty-five imperfections aredescribed. Dents, warts and blistersare typical imperfections describedin English and French.

Not applicable.


Technical documentsand specifications.

Not applicable. Defined imperfectionsare not related to surfaceroughness.

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ISO 11562Geometrical Product Specifications (GPS) Surface tTexture: Profile Method Metrological Characteristics of Phase Correct Filters


This Standard specifies themetrological characteristics of phasecorrect filters for measurement ofsurface profiles, particularly how toseparate the long and short wavecontent of a surface profile. Thedocument includes definitions ofrelevant terms, characteristics ofphase correct profile filters (includingtransmission characteristics of longand short wave profile components),limits of error of phase correct filters,and criteria for selection of phasecorrect filters. The relation of thisstandard to the GPS matrix modelis provided.

Roughness profile.


Influences links 2 and 3in the chains ofstandards for primaryprofile in the GPSmatrix model.

Not specified/applicable. Not specified.

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ISO 12085Geometrical Product Specification (GPS) Surface Texture: Profile Method Motif Parameters


This Standard defines terms used inthe determination of surface texture bythe motif method and the motifmethod, including a calculationmethod for combination of motifs.Annexes provide information on therelation between motif parameters(roughness profile, waviness profileand primary profile) and function ofsurfaces as well as the relation of thestandard to the GPS matrix model.

Quantifiable roughness profilerepresentation.


Influences links 2, 3 and4 of the surface texturechain of standards onroughness and wavinessprofile in the GPSmatrix model.

Not specified/applicable. Not specified.

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ISO 13565-1 Geometrical Product Specifications (GPS) Surface Texture: Profile Method Surfaces Having Stratified Functional PropertiesPart 1: Filtering and general measurement conditions


This Standard describes a filteringmethod for description of surfaces thathave deep valleys underlying a finelyfinished plateau with a small amountof waviness. ISO 11562, bycomparison, describes a referenceline undesirably influenced by thepresence of valleys. ISO 13565-1provides a filtering approach thatsuppresses the valley influence on thereference line. This Standardaddresses surfaces common ininternal combustion cylinder liners.The filtering process to determine theroughness profile, selection of cut-offwavelength and the evaluation lengthand relation to the GPS matrixmodel are included.



This Standard influenceslinks 2 and 3 in the chainof standards forroughness profile in theGPS matrix model.


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ISO 13565-2Geometrical Product Specifications (GPS) Surface Texture: Profile Method Surfaces Having Stratified functional PropertiesPart 2: Height characterization using the linear material ratio curve


This document defines parametersbased on the linear material ratiocurve for the evaluation of the valleysuppressed roughness profile definedin ISO 13565-1. The Standardincludes determination of parameters,covering roughness profile, calculatingequivalent straight line, andcalculation of parameters forthe material ratio curve.



This Standard addresseschain link 2 forroughness profile in theGeneral GPS matrix.


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ISO 13565-3Geometrical Product Specifications(GPS) Surface Texture: Profile Method Surfaces Having Stratified Functional PropertiesPart 3: Height characterization using the material probability curve


This Standard gives a method forcalculation of parameters used tonumerically characterize twocomponents, a coarse valley textureand a fine plateau texture, through thegeneration of a material probabilitycurve, determination of its linearregions and linear regressionsthrough these regions.



The parameters areintended to aid inassessing tribologicalbehavior of, for example,lubricated slidingsurfaces and to controlmanufacturingprocesses.


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SAE J358 Nondestructive Tests (SAE Information Report)


This Information Report identifiesseveral techniques and associatedSAE documents applicable for thedetection and in some casesmeasurement of, defects which maybe surface related. A table is includedwhich provides physical principles ofthe techniques, appropriate materialsto be inspected, applications,advantages and limitations. Infrared,magnetic particle, eddy current,penetrating radiation, ultrasonic,acoustic, and leakage techniquesare briefly described.

Not specified.


Information purposes. Not specified. Not specified.

SAE J359 Infrared Testing (SAE Information Report)


This is a very brief description of theinfrared technique for nondestructivetesting. This does not containsignificant detail regarding techniqueor capabilities.

Not specified.


Information purposes. Not specified. Not specified.

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SAE J420Magnetic Particle Inspection (SAE Information Report)


This is a very brief description of theuse of magnetic particle inspection tonondestructively identify surface andnear surface defects anddiscontinuities in ferromagneticmaterials such as iron and steel.Thistechnique aids in visual inspection andmay be enhanced through the useof long wavelength ultraviolet light.

Not specified.


Not specified. Not specified. Not specified.

SAE J425Electromagnetic Testing by Eddy-Current Methods (SAE Information Report)


This Report gives very generaldescriptions on the uses of eddycurrent testing, a nondestructivetechnique, for inspection of surfacedefects, principles of operation andprocedures. The Report is notintended to give detailed guidance.ASTM Standards and otherdocuments are identified as sourcesof additional information.

Data varies with instrument designand manufacturer.


General information. Surface free of loosescale and other material.

Hot rolled material withthin, tight scale seamsas shallow as 0.25 mm(0.010 in.) are detected.Polished (ground)surfaces- seams andcracks as shallow as0.025 mm (0.001 in.)are detected.

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SAE J426 Liquid Penetrant Test Methods (SAE Information Report)


This Report provides a briefdescription of the principle of the useof liquid penetrant inspection. In thistechnique, a liquid is applied to asurface and excess fluid removed andremaining penetrant trapped insurface imperfections such as cracksor pores is detected when a developeris applied. The developer shows thepresence of remaining liquid. Shortdescriptions of types of penetrants,developers and methods of penetrantremoval are provided. Related SAEand ASTM documents are listed.

Visible indications of surfacediscontinuities.


General information. Clean parts without paintor other surface coatingswhich can maskimperfections of intereston metal or other non-porous materials.

Not specified.

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SAE J428 Ultrasonic Inspection (SAE Information Report)


This document provides briefdescriptions of the uses (includingsurface discontinuities) of ultrasonictechniques, principles of operation,types of tests with limited discussionof advantages and disadvantages.

Not specified.


Not specified. Not specified. Not specified.

SAE J1242 Acoustic Emission Test Methods (SAE Information Report)


This Report gives brief descriptions ofthe operating principle and procedurefor acoustic emission detection andmonitoring of changes such ascrack growth in a material.

Varies with instrument.


Provides information onthis nondestructivetechnique to determinewhether furtherconsiderationis warranted.


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SAE AMS 2440AInspection of Ground, Chromium Plated Steel Parts (Aerospace Material Specification)


This Specification covers therequirements, procedures, andacceptance/rejection criteria forinspecting ground chromium platedsurfaces for grinder induced damageto the chromium plate substructure.Examples of damage revealed byfluorescent dye inspectionare provided.

Visual appearance of cracks whenviewed with black light.


Not specified. Specimens should betemper etch inspectedand magnetic particleinspected prior to plating.Ground plated parts arecleaned and dried toremove any material thatwould interfere with theinspection.

Inspection shall beconducted by certifiedinspectors (STN-TC-1A,Level II). Questionableinspections shall beresolved by a Level IIIpenetrant inspector.Procedure is as specifiedin ASTM E-1417. Temperetch is per AMS 2649and magnetic particleinspection is perASTM E 1444.

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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


This Specification establishesallowable limits for various types ofsurface discontinuities that result frommanufacture of bolts, nuts screws andstuds. The specification covers metricseries with nominal diameters of 4mmand greater and minimum tensilestrengths of 800 MPa and inch serieswith nominal diameters of No. 5(0.1250 in.) and larger and withspecified minimum tensile strengths of90,000 psi and greater. TheSpecification describes types ofdiscontinuities, limits of size andlocation permitted, inspection andevaluation. Inspection is visual withmagnification to 10x allowed.

Visible evidence of surface defects.


Intended forestablishment ofpurchase specifications.


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Products (bare and coated)

ASTM F 812/F 812MStandard Specification for Surface Discontinuities of Nuts, Inch and MetricSeries


This Specification establishesallowable limits for various types ofsurface discontinuities that result frommanufacture of metric series nuts withnominal diameters 5 mm and largerand inch series nuts with nominaldiameters 0.250 inch and larger.Types of discontinuities are described,limits on discontinuity size andlocation provided, test method(ASTM F 606) for strength of nutsspecified, visual inspection andevaluation procedures described.

Visible evidence of surface defects.


Intended forestablishment ofpurchase specifications.

Not specified. The limits established formetric nuts with nominaldiameters of 5 mm to24 mm are essentiallyidentical to those inISO/DIS 6157/II. Thereare no ISO standards fornuts greater than 24 mm.

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ISO 4042 Fasteners Electroplated coatings


This is a broad Standard whichaddresses the dimensional requirementsfor coating thickness for steel andcopper alloy fasteners and givesrecommendations for hydrogenembrittlement relief for high tensilestrength or hardness and for surfacehardened fasteners. The followingissues are addressed: dimensionalrequirements before and afterelectroplating, situations which call forhydrogen embrittlement relief, corrosionprotection, coating thicknessrequirements and measurement.Ordering requirements and surfacecoating designation systems areidentified. Annexes address: hydrogenembrittlement relief; salt spray corrosionprotection performance; guidance forprocedures to accommodate thickcoatings; determination of batchaverage thickness; designation code forcoatings; and, surface areas of bolts,screws and nuts.

Measured characteristics orperformance required byspecifications.


Provides a basis fordescription of andspecification of threadedfasteners coated byelectroplating. It mayalso be applied to non-threaded parts such aswashers and pins.

Varies with propertymeasured.

Recommended coatingsmay be applied to screwsthat cut their own threads(wood screws, selftapping screws, etc.) withmaximum batch averagethickness given in thestandard ignored unlessotherwise specified.Hydrogen embrittlement isa major issue highlighted.Note is made thatcomplete elimination ofhydrogen embrittlementcannot be assured andalternative procedures tothose in the standardshould be evaluated,as appropriate.

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ISO 6157-1Fasteners Surface DiscontinuitiesPart 1: Bolts, screws and studs for general requirements


This Standard details the causes,appearance and limits for the followingsurface discontinuities: quench cracks,forging cracks, forging bursts, shearbursts, raw material seams and laps,voids, folds and tool marks. It appliesto bolts, screws and studs withnominal thread diameters 5 mm andlarger, product grades A and B andproperty classes up to and including10.9 unless otherwise specified inproduct standards or purchasingagreements.

Varies with technique.


Establishes limits forsurface discontinuities.

Product of interest mustbe sufficiently clean tobe examined visually ornon-destructively (e.g.,eddy current or magneticmethod). Secondarysamples examined bycross-sectioning if firstexamination indicatessurface discontinuities.

Limits (size ofdiscontinuity) vary withtype and size of item.

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ISO 6157-2Fasteners Surface DiscontinuitiesPart 2: Nuts


This Standard details the causes,appearance and limits of the followingsurface discontinuities: quench cracks,forging and inclusion cracks, cracks inthe locking element of all metalprevailing torque type nuts, cracks inthe washer ring of nuts with captivewashers, shear bursts, bursts, seams,folds, voids and tool marks. It appliesto nuts with nominal thread diametersfrom 5 mm through 39 mm, productgrades A and B and all propertyclasses according to ISO 898-2 andISO 898-6 unless otherwise agreed toin product standards orpurchasing agreements.




Product of interest shallbe sufficiently clean tobe examined visually at10x magnification andwith appropriatenondestructive methods.ISO 10484, Wideningtest on nuts, and ISO10485, Cone proof loadon nuts are identified asdestructive or refereetests when necessary.


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ISO 6157-3Fasteners Surface DiscontinuitiesPart 2: Bolts, screws and studs for special requirements


This Standard details the causes,appearance and limits of the followingsurface discontinuities: quench cracks,forging cracks, forging bursts forhexagonal head and circular headscrews, shear bursts for hexagonaland circular head screws, forgingcracks in socket head screws, rawmaterial seams and laps, voids, folds,tool marks, laps on the thread, anddamages. It applies to bolts, screwsand studs with nominal threaddiameters of 5 mm and larger; productgrads A and B, nominal lengths l < 10d;property class 12.9 or propertyclasses 8.8, 9.8, 10.9 when sospecified or agreed to inpurchasing agreements.




Surface coating shall beremoved beforeinspection by visual ornondestructive test.Destructive testing bysectioning at 90through the discontinuityshall be conducted whennondestructive or visualexamination indicatesdefective products.


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SAE J121 Decarburization in Hardened and Tempered Unified Thread Fasteners(SAE Recommended Practice)


This Recommended Practicedescribes measurement classificationand specification of decarburization ofhardened and tempered steel bolts,screws, studs etc. Microscopicexamination of polished and etchedcross-sections and microhardness(Knoop 500g, Vickers DPH 300g)measurements are interpreted withrespect to cross-sectiondecarburization to establish Class Cand Class D inch series threadedproducts. Definitions of degreesof decarburization are provided.

Microstructure or microhardnessindicative of carbon content changes.


Microscopic examinationis intended for inspectionpurposes, hardness isintended or referencepurposes.

Metallographicallyprepared cross-sectionsof fasteners.

Not intended to coversteel products which arecarburized to achievespecial properties.

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SAE J122 Surface Discontinuities on Nuts (SAE Recommended Practice)


This Practice defines, illustrates andspecifies allowable limits for eighttypes of discontinuities on metricseries nuts 6.3 mm to 25 mm and inch series nuts 0.250 in. to 1 in. whichare primarily intended for automotiveassemblies. Inspection proceduresand a sampling plan are included.

Varies with inspection technique,generally visual.


General informationand inspection.

Representativelot samples.

Does not includesampling requirements.

SAE J123 Surface Discontinuities on Bolts, Screws, and Studs in Fatigue Applications (SAE Recommended Practice)


This document defines, illustrates andspecifies allowable limits for surfacediscontinuities (cracks, seams, bursts,voids, laps, folds, tool marks, nicksand gouges) in bolts, screws andstuds primarily intended forautomotive applications subjected tosevere dynamic stresses (fatigue)where high strength fasteners withfatigue resistance is required.Sampling plans for visual andmicroscopic inspection are appended.

Observable discontinuities whichdetermine acceptance or rejection ofbatch.


Intended for visualinspection of batches offasteners, andmetallographicexamination for lapsand seams.

As-manufactured items. Defect limitations areprovided primarily aslocation and orientationspecific features.

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SAE J1061Surface Discontinuities on General Application Bolts, Screws, and Studs(SAE Recommended Practice)


This Practice defines, illustrates andspecifies allowable limits for surfacediscontinuities on bolts, screws andthreads in sizes through 24 mm or1 in. in diameter, lengths to 150 mm or6 in. with minimum specified tensilestrengths of 900 MPa or 120,000 psiand greater intended for use inautomotive assemblies. Briefdescriptions of inspection andsampling are included.

Varies with inspection method.


General informationand guidance.

Samples representativeof the lot(s) of interest.

Does not includesampling requirements.

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4.2.2 Sheet and Structural Steel

ASTM D 4417Standard Test Methods for Field Measurement of Surface Profile ofBlast-Cleaned Steel


This method describes measurementof the surface profile of abrasivecleaned 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 examinationwith 5x or 10x optical magnificationand comparison to prepared surfaces.

Method (b) provides a dial gagereading.

Method (c) provides a micrometerreading.


Specificationacceptance.

Flat, clean surfaces. For 37 m to 135 mpeak to heightcorrelation coefficientsof: 0.75 visual,0.99 probe,0.93 tape have beendetermined. Moreextensive descriptionsof repeatability,reproducibility andprecision are provided.

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ASTM E 430 Standard Test Methods for Measurement of Gloss of High-Gloss Surfaces byGoniophotometry


Two test methods for measuring thereflection characteristics responsiblefor the glossy appearance of highgloss surfaces are covered. Thesemethods evaluate surfacecharacteristics at specular angles of30 and 20 using commercialinstruments. Details of the apparatusand sources, other ASTM methodsand guides relevant to themeasurement, calibration standards,preparation and standardization of theapparatus, procedure, calculation ofgloss and other parameters, reporting,precision and bias are included.

Instrument readings of parameters atvarious angles and use of thesereadings to calculate relevantcharacteristics.


Measurement ofproperties forautomotive, architecturalor other applications tofacilitate differentcomponents to bespecified with matchingglossy appearance.Originally applied tobright metals, nowapplied to automotiveand other finishes.

Flat and at least 70 mm(2.75 in.) in the smallestdimension.

Not suitable for diffusefinish surfaces ormeasurement of color.

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ASTM E 1418 Standard Test Methods for Visible Penetrant Examination Using theWater-Washable Process


This Method describes the use of awater washable visible penetrant fordetection of surface discontinuitiesthat are open such as cracks, lapsand isolated pores. The Method canbe used for non-porous metallic andnonmetallic materials. A liquidpenetrant is applied to a surface,allowed to enter discontinuities,washed off with water and a developerapplied to draw remaining penetrantout. The Method includes descriptionsof reagents and penetrants, procedure,a flow sheet for the generalprocedure, personnel qualificationand requalification requirements.

Visible discontinuities.


Used for the productionexamination of largevolumes of parts orstructures where theemphasis is onproductivity.

Surface should becleaned of grease, dirtand loose debris.

Users and suppliers mayrequire the certificationof examination staff peridentified ASNT, MILSTD or ANSIrecommended practices.In some cases testpieces with real orsimulated discontinuitiesof the smallest expectedfeatures may berequired.

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SAE J810Classification of Common Surface Imperfections in Sheet Steel (SAE Information Report)


This Report provides illustrations of26 common surface imperfections insheet steel which can be seen withthe naked eye. The imperfections aredefined, photographically andschematically illustrated, andcauses identified.

Not specified.


Defect/imperfectiondescription for purposesof classification.


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SAE J911Surface Roughness and Peak Count Measurement of Cold Rolled Steel Sheet (SAE Recommended Practice)


This Practice provides guidance onthe measurement of the RoughnessAverage (Ra) and Peak Count (PC)on the surface of cold-rolled steel. Thedocument relies on ASME B 46.1 forinstrumentation specifics. Definitions,equipment, test conditions, materials,procedures and calibration areincluded. Technique is stylus based.

Data produced varies with instrument.


General informationand guidance.

Specimensrepresentative of thematerial as producedand removed from anarea at least 50 mm(2 in.) from the coil edge.Rolling direction shouldbe identified and thesample be flat androughly 150 mm (6 in.)long parallel to the rollingdirection and 100 mm(4 in.) wide.

The instrument shouldbe calibrated for averagesurface roughness with anominal Ra value in therange, typically, of0.25 m to 2.5 m(10 m to 100 in.).The standard value forthe peak count levelshould be 1.25 m(50 in.) and thestandard filter cutofflength for averageroughness and peakcount measurements oncold-rolled steel shouldbe 0.8 mm (nominally0.03 in.).

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SAE AMS 2649B Etch Inspection of High Strength Steel Parts(Aerospace Material Specification)


This Specification establishes therequirements for detection ofoverheating by grinding or machiningof high strength low alloy steel (tensilestrength of 1241 MPa (180 ksi) andhigher) and of carburized material inthe heat treated condition. Theprocedure consists of cleaning,etching and visually inspecting forcolor changes/ variations.Acceptance criteria are included.

Visual indications of overheating.


Intended for theinspection of barematerial and carburizedparts.

Guidance for cleaning,including Governmentdocuments specifyingchemicals, is provided.

SAE ARP 1923Qualification andCertification of EtchInspectors are includedby reference.

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4.2.3 Castings

ASTM A 802/A 802MStandard Practice for Steel Castings, Surface Acceptance Standards, VisualExamination


This Practice covers the acceptancecriteria for steel castings using visualexamination and comparing surfacetexture, roughness and discontinuitiesto Steel Castings Research and TradeAssociation graded referencecomparators.

Surface texture, nonmetallicinclusions, gas porosity, solidificationdiscontinuities, sand expansiondiscontinuities, metal inserts, thermallycut surfaces, mechanically preparedsurfaces, welded surfaces.


Quality control (QC),specification acceptance.

Not specified. This techniqueis qualitative.

ISO 11971Visual Examination of Surface Quality of Steel Castings


This Standard provides comparisonsof standards prepared by the Bureaude Normalisation des Industries de laFounderie (BNIF) and Steel CastingsResearch and Trade Association(SCRATA) for the visual inspection ofsurface roughness and surfacediscontinuities on steel castings.

Not applicable.


Purchase specifications. Not applicable. Qualitative descriptionsof surface roughness aredetermined.

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4.2.4 Other

ISO 14104Gears Surface Temper Etch Inspection After Grinding


This Standard describes the cleaners,etchants and procedures used todetermine and evaluate localizedoverheating on ground steel surfaces.The method is applicable to gears,shafts, splines and bearings. A surfacetemper classification system isprovided which is based on the visualappearance of the etched surface.ISO 14104 was prepared by TheAmerican Gear ManufacturersAssociation (AGMA) asANSI/AGMA 2007-B92.

Visual indication of tempering.


Qualitative indication of tempering due to surfacegrinding suitable forprocess control andpurchase specifications.

Debris free degreasedsurface.

Not applicable to nitridedor stainless steels.Approximately 0.003 mmof stock is removedby nitric acid etchingeach time the process isperformed and mayrequire masking of closetolerance areas. Usersare advised to set theirown referencestandards.

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ISO 13665Seamless and Welded Steel Tubes for Pressure Purposes Magnetic ParticleInspection of the Tube Body for the Detection of Surface Imperfections


This document specifies requirementsfor magnetic particle particleinspection of seamless and weldedsteel tubes according to four differentacceptance levels. The Standardincludes: Method of test, Evaluation ofindications, Acceptance criteriaand Reporting requirements.

Visual indication.

surface engineering measurement standards for inorganic materials

Documents

national center

technology nist

aluminized asm handbook

dchromized asm metals

nist research library

engineering laboratoryapril

technologyspecial publication

practice guide