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Thermal Spray Coating Specimen Preparatino

Metallographic etchant database

The metallographic specimen preparation of thermal spray coatings is affected by the specimen composition and deposition conditions. Microstructural features of interest include: porosity, flow, thickness and inclusions. Proper metallurgical preparation takes into account that the microstructure may be porous and perhaps somewhat brittle because of inadequate processing. Following proper cutting to avoid creating undue damage, the specimen is generally mounted in either a castable epoxy or acrylic.

Not required

Castable mounting acrylics or epoxies




Force/ sample



30 um DIAMAT diamond on CERMESH metal mesh cloth

DIALUBE Extender

5-10 lbs

100/100 rpm

Until plane

9 um DIAMAT diamond on SIRIUS composite disk


5-10 lbs

100/100 rpm

3 minutes

3 um DIAMAT diamond on ORION composite disk


5-10 lbs

100/100 rpm

3 minutes

1 um DIAMAT diamond on ATLANTIS polishing pad

DIALUBE Purple Extender

5-10 lbs

100/100 rpm

2 minutes

0.05 um NANOMETER Alumina on TRICOTE polishing pad   5-10 lbs

100/100 rpm

1 minute

Metallographic micrograph of NiCr plasma spray coating

Nickel Chrome Thermal Spray Coating, as polished
Mag 1000x (B.F.)

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