Define the coating layer before measuring it
The layer step establishes the coating region and boundary information used by downstream measurements. Review the layer ROI and thickness geometry on each field before accepting the result, especially where interfaces are rough, curved or partially obscured.
Review porosity masks inside the coating region
Porosity analysis is restricted to the defined coating layer so substrate and background do not automatically enter the fraction. Threshold or phase-style detection settings create a candidate pore mask that must be checked against the image before it is accepted for sample aggregation.
Quantify pore morphology from the accepted mask
Pore morphology reuses particle-analysis concepts to measure accepted pore objects. Size and shape descriptors are calculated from the reviewed pore mask, with physical dimensions available only when calibration is valid. Touching or ambiguous pore boundaries should be reviewed rather than assumed correct.
Aggregate multiple fields and compare samples
The Results step summarizes included fields at sample level and reports spread between fields. Saved Thermal Spray results can be compared across samples, but comparability rules check units and method inputs first; incompatible results are blocked or flagged instead of being forced into a misleading delta.
A short workflow
- Import cross-section fields and group the images that belong to the same coating sample.
- Calibrate each field, then define and review the coating layer and thickness geometry.
- Create and review the porosity mask, then inspect pore morphology on the accepted regions.
- Review sample-level aggregation and field-to-field spread, save the result to NotyLibrary, and compare compatible samples in the results workflow.
Output you can keep
Save the Thermal Spray study/session and the accepted analysis result in NotyLibrary. The saved result can be reopened with its analysis context and can participate in NotyResults comparisons when units and methodology are compatible.
Analysis limits to check
- One field is rarely enough to represent a heterogeneous coating; use a field set that matches your sampling plan.
- Layer boundaries, porosity masks and pore segmentation require visual review, especially in low-contrast or highly rough microstructures.
- Do not combine calibrated physical values with pixel-only measurements in the same quantitative conclusion.
- A comparable software configuration does not replace a documented experimental sampling and metallographic preparation method.
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