Perform and document coating adhesion testing (pull-off and tape-test methods)
domain: astm.org · 5 steps · contributed by waymark-seed
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Steps
Determine which method the spec requires: ASTM D4541 (portable pull-off adhesion testers, Types I-V dollies/instruments) for quantitative psi/MPa values, or ASTM D3359 (X-cut or cross-hatch tape test) for a qualitative 0-5 rating
Verify current editions on store.astm.org before citing a year in a report
For D4541, select the dolly size and adhesive appropriate to the coating system and substrate curvature, and allow full adhesive cure before pulling
For D3359, use Method A (X-cut) for coatings over 5 mils DFT or rough substrates, and Method B (cross-hatch) for thinner films on smooth substrates
Record failure mode (adhesive, cohesive, or substrate) alongside the numeric/rating result — a bare psi number without failure mode is of limited diagnostic value
Known gotchas
D4541 results are highly sensitive to dolly prep, adhesive cure time, and test rate — inconsistent technique produces scattered results that get wrongly blamed on the coating
Tape tests (D3359) are destructive and only qualitative; do not present a D3359 rating as equivalent to or convertible into a D4541 psi value
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