Designation: C664 10

Standard Test Methods for

Thickness of Diffusion Coating1
This standard is issued under the fixed designation C664; 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.

INTRODUCTION

Diffusion coating is a thermally activated means of protecting certain iron, nickel, and cobalt based
alloys against severe operating conditions. It creates a chemically bonded, tenacious coating that acts
as a diffusion barrier against oxygen and other elements into the substrate to provide superior
oxidation, corrosion and erosion resistance up to 2100F (1150C). It is commonly used for gas
turbine components, power generation components, and diesel engines. This test procedure provides
a mean of determining the thickness of a diffusion coating.

1. Scope ment. It is necessary to know that certain phases are growing at

1.1 These test methods cover two procedures for measuring the expense of others and to know the previous history of a
the thickness of diffusion coatings. coating to understand the significance of coating thickness
1.2 Test Method A is the determination of the dimensional- data.
change thickness, defined as the difference in the thickness of 1.6 Values in SI units are to be regarded as the standard.
the part before and after coating. (The terms micrometer Inch-pound units are provided for information only.
thickness and part growth are considered synonymous with 1.7 This standard does not purport to address all of the
dimensional change thickness.) safety concerns, if any, associated with its use. It is the
1.3 Test Method B is the determination of total coating responsibility of the user of this standard to establish appro-
thickness, defined as the distance between the observably priate safety and health practices and determine the applica-
unaffected substrate and the exterior surface of the coating. bility of regulatory limitations prior to use.
This includes the total of all included phases, zones and layers. 2. Referenced Documents
(The term case depth is considered to be synonymous with total
coating thickness.) The total coating thickness is determined by 2.1 ASTM Standards:2
cross-sectioning the coating, preparing a metallurgical mount D374 Test Methods for Thickness of Solid Electrical Insu-
and microscopically measuring the coating thickness. lation
1.4 The total coating thickness as determined microscopi- E3 Guide for Preparation of Metallographic Specimens
cally from a cross-section will usually be greater than, or equal 3. Significance and Use
to, the dimensional change thickness determined by part
growth. When the coating is produced primarily by reaction 3.1 A diffusion coating is one produced by causing an
with the substrate, the substrate-coating interface recedes as the element or elements to react with or diffuse into, or both, the
substrate is consumed in the reaction. In such cases the surface of a metallic substrate, thus chemically altering the
difference between the total coating thickness and the dimen- substrate adjacent to the surface. To appreciate the significance
sional change thickness is the thickness of the substrate of coating thickness measurements one must understand the
consumed. contributions to a particular coating of solid-solution zones in
1.5 Diffusion coatings are usually formed at elevated tem- the substrate and reaction products such as intermetallic
peratures for service at elevated temperatures. This means that compounds.
diffusion coatings are dynamic systems which are continually 4. Test Method A
undergoing changes while in an elevated-temperature environ-
4.1 ApparatusThe instrument shall be a machinists type
micrometer without a locking device. If calibrated in inches, it
1
These test methods are under the jurisdiction of ASTM Committee B08 on
Metallic and Inorganic Coatings and are the direct responsibility of Subcommittee
2
B08.12 on Materials for Porcelain Enamel and Ceramic-Metal Systems. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved April 1, 2010. Published May 2010. Originally contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
approved in 1970. Last previous edition approved in 2005 as C664 87(2005). DOI: Standards volume information, refer to the standards Document Summary page on
10.1520/C0664-10. the ASTM website.

Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

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 C664 10
shall be constructed with a vernier reading to 0.0001 in. (0.1 demark the boundaries of the coating as well as properly
mil). If calibrated in metric units, it shall be capable of reading differentiate included zones, if it is desirable to measure their
to 0.01 mm. It shall have a ratchet or similar mechanism, such thickness as well.
as a friction thimble, for controlling measuring pressure and 5.2.5 Measure the total coating thickness microscopically
shall have anvil and spindle surfaces 6.00 6 0.03 mm (0.250 6 with the aid of a calibrated-filar eyepiece, or by direct
0.001 in.) in diameter. It shall meet all other requirements and measurement of a projected image on ground glass. Magnify
calibration procedure for Method A of Test Method D374. the coating a minimum of 2503 diameters, although 5003 is
4.2 Procedure: preferable. When measuring from ground glass, measure the
4.2.1 Clean the area selected for coating-thickness measure- image of the coating to the closest 1.27 mm (0.05 in.). The
ment of dust or other powdery materials prior to coating. exterior bounds of the coating is the average of the peaks and
Record the precise area to be measured, so that the same area valleys. Visually average over a minimum length of 10 mils
can be remeasured after coating. (0.254 mm (0.010 in.)). Determine the interior bounds of the
4.2.2 Take a minimum of two readings, using the machin- coating as the depth to which the substrate has been visually
ists micrometer, in each area selected. Use the same procedure altered by the coating. (One must appreciate that this depth is
for using the micrometer as that stipulated in Test Methods highly dependent upon the etchant employed, and mutual
D374. agreement of concerned parties should be sought.) As was the
4.2.3 After the part has been coated and the surface has been case of the exterior bounds, visually average over a 10 mil
cleaned of superficial powder or dirt, repeat the measurement (0.254 mm (0.010 in.)) length. Measure the specific zones or
procedure. It is necessary to ensure that the same location is phases by a mutual agreement between the purchaser and the
remeasured. vendor. Measure the total coating thickness at a minimum of 10
4.2.4 The thickness of the part after coating minus the locations around the entire metallographic specimen with the
thickness of the part prior to coating divided by two, is the measurement points separated by at least 20 mils (0.508 mm
dimensional change thickness per coated surface. (0.020 in.)). Average the individual total coating-thickness
measurements.
5. Test Method B
5.1 Apparatus: 6. Report
5.1.1 Standard metallurgical specimen-preparation equip-
6.1 The report shall include the following:
ment.
6.1.1 Thickness as mils per surface. Maximum, minimum,
5.1.2 Metallographic or optical microscope.
and average of the individual measurements made on a specific
5.1.3 The equipment used shall be consistent as to type and
part or specimen.
quality as specified in Practice E3.
6.1.2 Type of coating thickness determined and the method
5.2 Procedure:
employed,
5.2.1 Section with a fine grained cut-off wheel the area of
the coated part in which the total coating thickness is to be 6.1.3 Specific area where the thickness was measured,
measured. Control the clamping of the part, lubricant cooling 6.1.4 Type and condition of the coating such as as depos-
fluid, and control the cutting rate to produce a square cut edge ited or after a specified term of service,
without chipping the coating. Exercise care to ensure that the 6.1.5 If Test Method B is employed, the etching procedure.
cut is perpendicular to the surface of the coating. A photomicrograph showing the bounds of a typical area of the
5.2.2 After cleaning with an organic solvent, plate the coating is suggested, and
section (electrolytically or electroless) with nickel, chromium, 6.1.6 If Test Method B is employed, the thickness of any
or other metallic plating which approximates the hardness of phases or layers as agreed upon between the purchaser and the
the coated substrate. As an alternative to plating, wrap the seller in mils per surface.
specimen in a metallic foil. The foil applied must give
sufficient support to prevent chipping, and be in sufficient 7. Precision and Bias
proximity to the specimen to prevent gaps and rounding of the 7.1 Test Method A (dimensional change thickness)60.2
edges during polishing. mil (0.005 mm (0.0002 in.)). This test method assumes that
5.2.3 Use the standard techniques detailed in Practice E3 for both sides of surfaces of the coated piece have an equal coating
mounting and polishing of the metallurgical specimen. thickness, if both surfaces are coated. The validity of this
5.2.4 The etching procedure, if required, shall be in general assumption will vary with different coatings and processes of
accordance with Practice E3. The specific etchant and etch application.
time, if employed, will be by mutual agreement between the 7.2 Test Method B (total coating thickness)60.1 mil
customer and vendor. The etching procedure will clearly (0.0001 in., 0.0025 mm).

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