Coating thickness measurement

Coating thickness measurement

Coating thickness measurement covers all relevant methods and test equipment for film-thickness-compliant quality control of coatings. It uses magnetic induction in accordance with ISO 2178 for non-magnetic coatings on steel/Fe as well as the eddy current method in accordance with ISO 2360 for non-conductive coatings on non-ferrous metals such as aluminium or copper. Combination instruments (F/N) automatically detect the substrate, while wedge cut and metallographic methods in accordance with ISO 2808/ASTM D4138 analyse multi-layer systems in detail. Evaluation of the results is carried out in accordance with ISO 19840. The scope of supply includes probes, calibration foils, reference standards and digital data and reporting functions.

Applications & benefits

The systems are suitable for coaters working with liquid paint and powder coating, as well as for electroplating, anodizing, steel construction, automotive, mechanical engineering and maintenance. With suitable probes and calibration sets, very thin electroplated coatings, thick powder coatings and rough or blasted surfaces can be tested reliably. This ensures specification-compliant coating thicknesses, minimises rework and generates audit-proof evidence.

Measuring tasks & kit configuration

Magnetic induction (ISO 2178): Measurement of non-magnetic coatings such as paint, powder or electroplating on ferromagnetic substrates (steel/Fe). This method provides fast, non-destructive results with high repeatability and is ideal for production control.

Eddy current method (ISO 2360): Testing of non-conductive coatings on non-ferrous metals such as aluminium or copper. The method enables precise measurements even for very thin coatings and sensitive surfaces.

FN combination instruments: Automatic substrate detection and switching between Fe and NFe measurement without user intervention. Ideal for mixed components or variable coating systems.

Wedge cut / metallography (ISO 2808 / ASTM D4138): Analysis and reference testing for multi-layer systems or to verify coating build-ups. This method complements non-destructive techniques with microscopic precision.

Calibration: Use of calibration foils and traceable standards to adapt to geometry and roughness. Regular calibration cycles ensure comparability and standard conformity of results.

Documentation: Automatic statistics and limit checking, label / QR code creation and PDF/CSV export of measured values. A structured user and serial number management guarantees traceability and auditability.

Product areas & integration

The portfolio includes handheld gauges with interchangeable probes, micro-probes for small areas, edges or tubes, as well as functions for roughness and geometry compensation. In addition, there are app and cloud solutions and interfaces to quality management software. Together with the user we define the scope of testing, the standards reference (ISO 2178, 2360, 19840, 2808) and the measuring point plan and integrate the systems seamlessly into QM workflows, photo and report archiving and audit processes.

Benefits at a glance

• Wide coverage – Fe/NFe, thin to thick, including rough substrates
• Standards-compliant – ISO 2178/2360/19840 & ISO 2808, traceable calibration
• Digital documentation – statistics, limit checking, labels/QR, PDF/CSV & traceability
• Less rework – reliable limit evaluation & approvals

Top manufacturers – coating thickness measurement

• Elcometer – coating thickness gauges, probes, wedge cut & reporting.
• DeFelsko – PosiTector/PosiTest for Fe/NFe, statistics & app/cloud documentation.
• Neurtek – complete sets for gloss, colour, adhesion & coating thickness.
• Helmut Fischer – precision instruments for induction/eddy current & lab standards.
• ElektroPhysik – QNix instruments & special probes for demanding geometries.
• BYK-Gardner – accessories & visual assessment in the coating process.
• TQC Sheen – wedge cut accessories, reference materials & test equipment.
• Mahr – precision metrology & gauges for QA/labs.
• Rubert – reference standards/surface comparators for inspection tasks.
• 3M – labels/sample accessories & PPE for inspections.
• KSJ – portable inspection & gloss instruments.
• Testo – ambient/climate monitoring for stable measuring conditions.
• PCE Instruments – environmental/measuring technology & data loggers.
• Extech – electrical/field measuring instruments.
• Rotronic – humidity/temperature & data loggers.
• OMEGA – sensors, probes & data acquisition.
• Phoenix Instrument – laboratory/test equipment.
• Grant – temperature/data loggers & stability control for test environments.
• SIS Verlag – standards/guidelines & training materials.
• SATA – test and accessory components for coating.
• beschicht. – QM templates, QR/label sets & customer-specific sets.

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