AWS C2 16 2017 Guide For Thermal

AWS C2.16/C2.
16M:2017
An American National Standard
Guide for Thermal

Spray Operator
Qualification
Programs
AWS C2.16/C2.16M:2017
An American National Standard
Approved by the
American National Standards Institute
March 10, 2017
Guide for Thermal Spray

Operator Qualification Programs
4th Edition
Supersedes AWS C2.16/C2.16M:2002
Prepared by the
American Welding Society (AWS) C2 Committee on Thermal Spraying
Under the Direction of the

AWS Technical Activities Committee
Approved by the
AWS Board of Directors
Abstract
This guide contains recommendations for establishing a thermal spray operator qualification program. Information
related to training, knowledge and skill testing, and coating system inspection methods is provided. Example thermal
spray operator qualification tests (TSOQT) parameters and forms are provided, to address common engineering and cor-
rosion control applications using arc, flame, atmospheric plasma, and high velocity oxygen fuel (HVOF) spray processes.
AWS C2.16/C2.16M:2017
ISBN: 978-0-87171-911-9
© 2017 by American Welding Society
All rights reserved
Printed in the United States of America
Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any
form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright
owner.
Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, or
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ate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400;
Internet: <www.copyright.com>.
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AWS C2.16/C2.16M:2017
Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American
Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the
American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or
made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmen-
tal bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards
must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws
and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes
the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS
standard must be by agreement between the contracting parties.
AWS American National Standards are developed through a consensus standards development process that brings
together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the proc-
ess and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or
verify the accuracy of any information or the soundness of any judgments contained in its standards.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether
special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, or reliance
on this standard. AWS also makes no guarantee or warranty as to the accuracy or completeness of any information pub-
lished herein.
In issuing and making this standard available, AWS is neither undertaking to render professional or other services for or
on behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someone
else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the
advice of a competent professional in determining the exercise of reasonable care in any given circumstances. It is
assumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.
This standard may be superseded by new editions. This standard may also be corrected through publication of amend-
ments or errata, or supplemented by publication of addenda. Information on the latest editions of AWS standards includ-
ing amendments, errata, and addenda is posted on the AWS web page (www.aws.org). Users should ensure that they have
the latest edition, amendments, errata, and addenda.
Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept
any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of
any patent or product trade name resulting from the use of this standard.
AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.
Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,
in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society,
Attention: Managing Director, Standards Development, 8669 NW 36 St, # 130, Miami, FL 33166 (see Annex D). With
regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These
opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such
opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak
on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addi-
tion, oral opinions are informal and should not be used as a substitute for an official interpretation.
This standard is subject to revision at any time by the AWS C2 Committee on Thermal Spraying. It must be reviewed
every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions,
or deletions) and any pertinent data that may be of use in improving this standard are requested and should be addressed
to AWS Headquarters. Such comments will receive careful consideration by the AWS C2 Committee on Thermal Spraying
and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to
attend all meetings of the AWS C2 Committee on Thermal Spraying to express their comments verbally. Procedures for
appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical
Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 8669 NW 36 St, # 130,
Miami, FL 33166.
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AWS C2.16/C2.16M:2017
Personnel
AWS C2 Committee on Thermal Spraying
K. L. Sender, Chair Oerlikon Metco (US), Incorporated
W. J. Arata Jr., Vice Chair Matheson Gas
J. M. Rosario, Secretary American Welding Society
D. M. Beneteau Centerline Ltd.
C. C. Berndt Swinburne University of Technology
M. M. Blasingame Superior Shot Peening, Incorporated
T. J. Connelly Green Belting Industries Ltd.
A. Duminie HC Starck North American Trading LLC
M. Froning The Boeing Company
D. T. Haegele Select Arc
D. Hayden Hayden Corporation
J. O. Hayden Hayden Corporation
I. R. Lasa Florida Department of Transportation
D. A. Lee Kennametal Stellite
W. M. Medford INSPEC, Incorporated
J. J. Medrano Oerlikon Metco (US), Incorporated
D. R. Moody Plasma Powders and Systems
B. Mosier Polymet Corporation
J. Ryan Oerlikon Metco (US), Incorporated
K. Sampath Chart Industries
C. Sauer NAVAIR In-Service Support Center
A. P. Yanski Praxair TAFA
Advisors to the AWS C2 Committee on Thermal Spraying

R. Ahmed RasGas Co Ltd.
B. T. Costello NAVSEA
L. F. Grimenstein Nation Coating Systems Incorporated
A. J. Grubowski DDL OMNI
D. Guillen Idaho National Laboratory
J. A. Kapur Bay State Surface Technologies
A. Roy Quality Calibration & Consulting
C. Tudor International MetalFusion Corporation
T. H. Via Via Technologies
M. Weinstein Wall Colmonoy Corporation
AWS C2F Subcommittee on Thermal Spray Operator Qualification Programs

D. R. Moody, Chair Plasma Powders and Systems
J. M. Rosario, Secretary American Welding Society
M. M. Blasingame Superior Shot Peening, Incorporated
J. O. Hayden Hayden Corporation
D. A. Lee Kennametal Stellite
W. M. Medford INSPEC, Incorporated
K. L. Sender Oerlikon Metco (US), Incorporated
A. P. Yanski Praxair TAFA
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AWS C2.16/C2.16M:2017
Advisors to the AWS C2F Subcommittee on Thermal Spray Operator Qualification Programs
L. F. Grimenstein Nation Coating Systems Incorporated
A. J. Grubowski DDL OMNI
J. A. Kapur Bay State Surface Technologies
J. R. Reid Reid Consulting
S. Rice KTA-Tator, Incorporated
A. Roy Quality Calibration & Consulting
R. Sayman Air Force Material Command
T. Snyder Progressive Surface
S. Szapra Naval Surface Warfare Center
D. Wixson TMS Metalizing Systems Ltd.
R. J. Wong Naval Surface Warfare Center
D. W. Wright Accuwright Industries, Incorporated
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AWS C2.16/C2.16M:2017
Foreword
This foreword is not part of this standard but is included for information purposes only.
The purpose of this document is to provide a guide for companies, agencies, and institutions, to create a program for
qualifying thermal spray operators. Such qualification programs are frequently employer or site specific, to address a
unique set of thermal spray processes, procedures, equipment, coating systems, and customer or contract requirements.
The objective is to share common and best practices related to the structure, execution, and maintenance of qualification
programs.
Previous editions of the document are as follows:
ANSI/AWS C2.16-78, Guide for Thermal Spray Operator and Equipment Qualification
ANSI/AWS C2.16-92, Guide for Thermal Spray Operator Qualification
AWS C2.16/C2.16M:2002, Guide for Thermal Spray Operator Qualification
This edition has been extensively revised and reformatted to clarify the intent and readability. Because of this, the vertical
line in the margin or underlined text in clauses, tables, or figures common to AWS standard revisions has not been applied
to indicate editorial or all technical changes from the previous edition.
Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, AWS
C2 Committee on Thermal Spraying, American Welding Society, 8669 NW 36 St, # 130, Miami, FL 33166.
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Table of Contents
Page No.
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
List of Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1. General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Exclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Terms and Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Qualification Program Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1 Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.4 Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Qualification Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Functions of the Qualified Operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Candidate Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5.3 Qualification Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.4 Period of Validity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5 Revocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.6 Reinstatement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.7 Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.8 Requalification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.9 Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. Training Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Process Theory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2 Hands-On Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3 Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.4 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Knowledge Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.1 General Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.2 Process Determination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.3 Equipment Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.4 Process Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8. Skill Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.2 Workpiece Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.3 Equipment Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.4 Process Execution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
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8.5 Process Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8.6 Process Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Nonmandatory Annexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Annex A (Normative)—Thermal Spray Process Qualification Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Annex B (Informative)—Example Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Annex C (Informative)—Bibliography. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Annex D (Informative)—Requesting an Official Interpretation on an AWS Standard. . . . . . . . . . . . . . . . . . . . . . . . . 29
List of AWS Documents on Thermal Spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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List of Tables
Table Page No.
1 Example Thermal Spray Operator Qualification Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Designated Example Coating Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 Recommended Test Piece (TP) Quantities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A.1 Example Thermal Spray Process Acceptance Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A.2 Tensile-Bond Qualification Requirements for Thermal Spray Operators. . . . . . . . . . . . . . . . . . . . . . . . . . 17
List of Figures
Figure Page No.
1 Example of a Test Rig for the Preparation of HVOF Coating Specimens. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A.1 Test Piece for Atmospheric Plasma Spraying of Metals and Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
A.2 Test Piece for Flame-Sprayed Self-Fluxing Alloy Coating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A.3 Test Piece for Flame- and Arc-Sprayed Aluminum and Zinc Alloy Coating. . . . . . . . . . . . . . . . . . . . . . . . 14
A.4 Example of an Almen Gage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A.5 Example of an Almen Gage with Specimen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A.6 Thermal Spray Coating Bend Test: Pass/Fail Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
List of Forms
Form Page No.
B.1 Thermal Spray Process and Spray Parameters for Plasma Spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
B.2 Thermal Spray Process and Spray Parameters for Arc Spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B.3 Thermal Spray Process and Spray Parameters for Flame Spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
B.4 Thermal Spray Process and Spray Parameters for HVOF Spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
B.5 Example Thermal Spray Operator Qualification Certificate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Guide for Thermal Spray

Operator Qualification Programs
1. General Requirements
1.1 Scope. This guide contains recommendations for establishing, conducting, and maintaining a thermal spray operator
qualification program. Such programs generally include training, knowledge and skill testing, and documentation
requirements. The skill tests described in this guide relate to flame spraying, arc spraying, atmospheric plasma spraying,
and high velocity oxygen fuel (HVOF) spraying.
While this guide does not preclude the possibility to establish a qualification program for operators of automatic thermal
spray equipment, the examples in this guide assume the objective is to qualify operators who develop process parameters,
apply the thermal spray process, and evaluate the effectiveness of the coating process.
This document is not to be used as a stand-alone document for operator qualification or certification. An operator would
not be “qualified in accordance with AWS C2.16/C2.16M” as this document does not address relevant acceptance stand-
ards. However, a qualification program can state that it follows the guidelines of AWS C2.16/C2.16M.
Although this guide is not written with mandatory requirements, mandatory language, such as the use of “shall,” will be
found in those portions of the document where failure to follow the instructions or procedures could produce inferior,
misleading, or unsafe results.
1.2 Exclusion. AWS C2.16/C2.16M does not preclude an employer or contractor from continuing to qualify thermal
spray operators in accordance with any established qualification program or the requirements of standards such as:
(1) AWS C2.19, Specification for the Application of Thermal Spray Coatings to Machine Elements for OEM and Repair.
(2) MIL-STD-1687, Thermal Spray Processes for Naval Ship Machinery Applications.
(3) Various original equipment manufacturers’ (OEM) or after-market repair, thermal spray process, and spray
specifications.
(4) ISO 14918, Thermal spraying—Approval testing of thermal sprayers.
1.3 Units of Measurement. This guide makes use of both U.S. Customary Units and the International System of Units
[SI]. The latter are shown within brackets [ ] or in appropriate columns in tables and figures. The measurements may not
be exact equivalents; therefore each system must be used independently.
1.4 Safety. Safety and health issues and concerns are beyond the scope of this standard and therefore are not fully
addressed herein. Safety and health information is available from the following sources:
American Welding Society:
(1) ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes
(2) AWS Safety and Health Fact Sheets
(3) Other safety and health information on the AWS website
Material or Equipment Manufacturers:
(1) Safety Data Sheets supplied by materials manufacturers
(2) Operating Manuals supplied by equipment manufacturers
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Other:
(1) NFPA 5IB, Standard for Fire Prevention During Welding, Cutting, and Other Hot Work
Applicable Regulatory Agencies
Work performed in accordance with this standard may involve the use of materials that have been deemed hazardous, and
may involve operations or equipment that may cause injury or death. This standard does not purport to address all safety
and health risks that may be encountered. The user of this standard should establish an appropriate safety program to
address such risks as well as to meet applicable regulatory requirements. ANSI Z49.1 should be considered when devel-
oping the safety program.
1.5 When qualifying a thermal spray operator candidate using a program that has been developed in accordance with this
standard, the qualifier shall ensure that all equipments used for pre-coat processing, coating, and post-coat processing as
well as testing and measurement equipment and instruments are properly maintained according to the manufacturers’
recommendations and properly calibrated.
2. Normative References
The following standards contain provisions which, through reference in this text, constitute provisions of this AWS stand-
ard. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. However,
parties to agreements based on this AWS standard are encouraged to investigate the possibility of applying the most
recent editions of the documents shown below. For undated references, the latest edition of the standard referred to
applies.
(1) AWS A3.0M/A3.0, Standard Welding Terms and Definitions, Including Terms for Adhesive Bonding, Brazing,
Soldering, Thermal Cutting, and Thermal Spraying.
3. Terms and Definitions

AWS A3.0M/A3.0, Standard Welding Terms and Definitions, provides the basis for terms and definitions used herein.
However, the following terms and definitions are included below to accommodate usage specific to this document.
Almen strip. A strip of SAE 1070 steel manufactured in accordance with the requirements of SAE J442, and used to
quantify the surface stress generated on the part by the coating.
arc spraying. A thermal spray process using an arc between two consumable electrodes of surfacing materials as a heat
source and a compressed gas to atomize and propel the surfacing material to the substrate.
atmospheric plasma spray. Plasma spray carried out under atmospheric conditions.
automatic thermal spraying. Thermal spraying with equipment that requires only occasional or no observation of
the thermal spraying, and no manual adjustment of the equipment controls.
candidate. A person who is pursuing recognition of their qualification.
employer. The term is used collectively to mean contractor, fabricator, or manufacturer.
essential variables. Variables critical to the thermal spray process.
flame spraying. The thermal spray process in which an oxygen fuel gas flame is the source of heat for (partially) melting
the surfacing material. Compressed gas may or may not be used for atomizing and propelling the surfacing material to
the substrate.
high velocity oxygen fuel (HVOF). A thermal spraying process using a high velocity, oxygen fuel mixture to heat and
propel a powdered surfacing material to a substrate.
manual thermal spraying. Thermal spraying with a thermal spray gun manipulated by hand.
plasma spraying. The thermal spray process in which a non-transferred arc is used to create a plasma for (partially)
melting and propelling the surfacing material to the substrate.
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process instruction. A document detailing the equipment and procedures required to perform an industrial operation that
also addresses safety, operator qualifications, materials, equipment, procedure, method, quality control, and records.
qualification. Demonstrated training, skill, knowledge, and experience required for personnel to perform the duties of a
specific job or function, typically demonstrated by passing a performance test.
qualified thermal spray operator. A thermal spray equipment operator who has demonstrated training, skill, knowl-
edge, and experience to perform a specified range of duties.
qualification specification. The document specifying the requirements for qualification of the thermal spray operator.
qualifier. The employer, organization, or individual specified in the referencing document as responsible for conducting
and supervising qualification testing.
referencing document. The product standard or contract document that invokes the requirement for thermal spray oper-
ator qualification.
semi-automatic thermal spraying. Thermal spraying with equipment that requires manual adjustment of the equipment
controls in response to visual observation of the thermal spraying.
specific acceptance criteria. A document providing in detail the criteria by which a thermal sprayer can be tested to be
approved for a particular technique or application area.
specification. Document stating requirements.
test. A series of operations that includes knowledge and skill for applying a thermal spray coating on a thermal spray test
piece and subsequent non-destructive, or destructive testing, or both, and reporting the results.
test piece. The thermal spray workpiece used for the TSOQT.
test specimen. A portion cut from the test piece in order to perform a specified analytical test.
test supervisor. The individual who administers, supervises, or evaluates candidate testing on behalf of a qualifier.
thermal spray operator. An individual who, through education and training, performs an occupational role of operating
thermal spray equipment.
thermal spray operator qualification test (TSOQT). The test of knowledge and skill used to confirm the operator is
qualified to conduct the thermal spray process in accordance with specified performance expectations.
thermal spray technician. See thermal spray operator.
thermal spray test facility (TSTF). The entity qualified to assess whether thermal spray operators have the knowledge
and skill required by the TSOQT, issue test reports, and ensure TSOQT records are maintained.
training. An organized program developed to impart the knowledge and skills necessary for qualification.
written practice. A document to specify methods, requirements, examination, records, program official, etc., for a com-
pany’s thermal spray operator qualification program.
4. Qualification Program Definition

The ultimate objective of the thermal spray operator qualification program is to demonstrate an operator has the training,
knowledge, skill, and experience to consistently perform the duties assigned to the operator regarding thermal spraying.
4.1 Objectives. The objectives of the qualification program may be given in a standard, code, or contract. Alternatively,
an employer or other group may be motivated to establish an operator qualification program tailored to a specific set of
objectives determined by factors such as the:
– requirements of a number of referencing documents (e.g., product standards or codes and contract documents)
applicable to the work;
– specific thermal spray equipment and processes employed;
– expectations of thermal spray operator capability, performance, and responsibility;
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– range and innovation of coating systems executed; and

– availability of relevant external qualification programs.
4.2 Specification. Once the objectives and requirements have been determined, it is necessary to fully describe the
qualification program elements in a specification that clearly defines:
– the scope of qualification or qualification levels;
– those responsible for defining, administering, and maintaining the qualification specification;
– candidate requirements;
– knowledge and skill qualification tests;
– recognition and maintenance of qualification status;
– means for ensuring the qualification program goals have been realized; and
– documented recognition and maintenance of qualification status. An example qualification certificate is provided
in Annex B.
The specification may be a compilation of customer expectations and requirements, or an entirely custom-tailored
program. While the concepts of this guide are applicable to an adaption of existing qualification specification documents,
the assumption is that many employers are interested in establishing a qualification program that meshes well with their
specific workplace or coating system expertise. The generic examples and recommendations of this guide may be com-
bined with process and performance requirements to develop the detailed specification for a thermal spray operator
qualification program.
When the employer has more than one qualification specification, it would be necessary to identify the thermal spray
operator qualification. The elements of the designation may incorporate components such as:
– Process description. The examples provided in Table 1 utilize the following abbreviations: AS = arc spray;
FS = flame spray; APS = atmospheric plasma spray; HVOF = high velocity oxygen fuel spray.
– Application description. Any means for designating the specific substrate and coating system being
qualified. The examples in Table 1 incorporate a sequentially assigned number for this purpose. Thermal spray operator
employers may impose and subdivide their classification requirements to group their qualification classes by substrate
material, feedstock composition, etc.
– Method of application. The method of application may be included in the designation if appropriate to specifically
denote the scope of qualification. For example the control of process parameters, the spray gun, and workpiece manipula-
tion or handling may be manual, semi-automatic, automatic, mechanized, adaptive, or robotic. An operator who is quali-
fied for either manual or mechanized thermal spraying is likely qualified to monitor automatic equipment in any
classification for which the operator is qualified.
The descriptions of the thermal spray operator qualification test designations used throughout this guide are given in
Table 1.
4.3 Implementation. Implementation of the qualification specification will require the designation of responsible
personnel and appropriate facilities.
4.3.1 Test Supervisor. Qualification testing should be performed under the direction of a person designated as a test
supervisor by the management of the qualifier. The test supervisor(s) would typically be charged with:
(1) Supervising and evaluating the results of knowledge testing.
(2) Enforcement of TSTF safety rules, operating procedures, and housekeeping policies. This includes the responsi-
bility and authority to terminate skill testing immediately if the candidate does not exhibit sufficient knowledge and skill
to perform the test(s) safely and satisfactorily.
(3) Determining when a candidate may retest.
(4) Determining successful completion of the skill tests.
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Table 1
Example Thermal Spray Operator Qualification Designations
TSOQ Designation Process Description
APS-1 Atmospheric Plasma Spraying of Metals and Alloy Powders for Engineering Purposes
APS-2 Atmospheric Plasma Spraying Ceramics for Engineering Purposes
APS-3 Atmospheric Plasma Spraying of Metal Based Carbides for Engineering Purposes
AS-1 Arc Spraying Zinc, Aluminum, and Their Alloys and Composites for Corrosion Protection of Steel
AS-2 Arc Spraying of Metal Alloys for Engineering Purposes
FS-1 Flame Spraying of Wires for Corrosion Protection of Steel or for Engineering Purposes
FS-2 Flame Spraying of Metal and Alloy Wires and Ceramic Rods for Engineering Purposes
FS-3 Flame Spraying of Metal and Alloy Powders for Engineering Purposes
FS-4 Flame Spraying Self-Fluxing Alloys for Engineering Purposes
A&FS-1 Arc and Flame Spraying Zinc Anodes on Reinforced Concrete
HVOF-1 HVOF Coating Application of Carbide Composites (Cermets), Polymers, and Metals and Metallic Alloys
4.3.2 Thermal Spray Test Facility (TSTF). The test facility may be dedicated for qualification testing, a customer
job site, a production cell, or any other location deemed appropriate or required by the specification. As skill testing
involves the application and evaluation of coating systems, the TSTF may involve more than one physical location and a
range of equipment. The ability to control and monitor the applicable facilities is important for ensuring the validity of
qualification.
Figure 1 illustrates a test rig used for preparing HVOF coating specimens for procedure or performance qualification.
Equipment such as this may be configured to hold pull test plugs and test strips for tensile tests, bend tests, and/or metal-
lographic specimens. The illustrated test rig allows for control of gun distance and traverse rate. Along with indication of
the speed of traverse, in revolutions per minute, the calculation of the coating application rate is possible.
4.3.3 Outside Agency. At the option of the employer, an outside agency may be engaged to provide assistance in training
and qualification services. In such instances, the employer is responsible to assure that training and qualification are in
accordance with the thermal spray operator qualification program specification. Methods of assuring compliance may
include verification of the outside service’s third party accreditation, verification of customer approval status of the outside
service, or the conduct of a periodic audit of the outside service. The employer should maintain a written record of audit(s).
Source: J. Stricker
Figure 1—Example of a Test Rig for the Preparation of HVOF Coating Specimens
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4.4 Verification. While it is obvious there should be means to verify qualification performance and status, the employer
should also ensure the process includes mechanisms to ensure the Thermal Spray Qualification Program realizes the
defined program objectives. In addition to regular comparison with specification, code, or contract requirements, feedback
may involve measures such as:
– process quality feedback;
– production efficiency; and,
– operation and/or maintenance cost.
5. Qualification Requirements
5.1 Functions of the Qualified Operator. In establishing a program, the employer should state in a written practice, the
specific functions to be carried out by the thermal spray operator. The following are examples of duties that may be
incorporated into the written practice.
– Identify and apply the appropriate apparatus and method to prepare workpiece for coating application
– Prepare equipment for coating
– Develop, document, and qualify thermal spray procedures
– Perform qualified thermal spray procedures
– Evaluate quality of thermal spray coatings
The employer methods for accomplishing and evaluating each duty should be defined.
5.2 Candidate Requirements. The specification may detail minimum physical, education, and experience requirements
for qualification.
5.2.1 Physical Requirements. The minimum physical requirements to safely perform the activities would be specified
by the employer. In addition to physical strength and mobility requirements, there may be requirements related to
workplace situations (e.g., heights, confined spaces) and exposure (e.g., temperature, chemical, electromagnetic energy).
As near vision acuity is generally considered essential to the performance of thermal spraying and the examination of
thermal spray coating systems, candidate evaluation may be required. One measure involves the ability to read Jaeger
Number 2 letters or smaller at a minimum distance of 12 inches with at least one eye—with or without correction. It may
be a requirement for the thermal spray operator to take a color perception test for specific applications where this is con-
sidered appropriate or essential.
5.2.2 Education and Experience Requirements. The specification may detail minimum educational and experience
requirements. Some qualification specifications may require a minimum number of instruction, training, or spraying
hours, production pieces, or projects to establish the candidate has been exposed to and resolved process variation.
Proficiency in employing one thermal spray process may be a prerequisite for qualification in another thermal spray
process.
5.3 Qualification Process. The principal elements of the qualification process are knowledge and skill testing. Training
may also be incorporated or required.
5.3.1 Training. Review, instruction, or training may be incorporated into the qualification process to share and
confirm knowledge, expectations, and requirements. Training is useful to provide the candidate with confidence and
relieve stress from the qualification procedure. It may also provide the test supervisor an opportunity to confirm the
candidate is sufficiently prepared to be effective in knowledge and skill tests. Clause 6 addresses training in more detail.
5.3.2 Knowledge Testing. The knowledge requirements defined in the qualification specification are evaluated to ensure
the candidate understands the interaction of essential process variables. Knowledge testing is described in detail in Clause 7.
5.3.3 Skill Testing. The qualification specification must identify the required operator skills related to workpiece
preparation, coating application, and quality evaluation. Table 2 identifies coating systems corresponding to the example
thermal spray operator qualification designations of Table 1. The qualification specification would include a description
of a coating system(s) such as these to be performed by the candidate.
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Table 2
Designated Example Coating Systems
TSOQ Per Pass Coating
Designation Suggested Coating System Masking Thickness Thickness
APS-1 Self-bonding stainless steel Heat reflecting tapea
alloy powder such as
— —
NiCrAlMoFe (73+, 9, 7,
5.5, 5%)
APS-2 A 0.003–0.005 in [75–125 μm] Heat reflecting tapea
thick nickel/aluminum
(95/5) powder bond coat, with — 0.008±0.002 in [200±50 µm]
an alumina titania ceramic
(87/13) powder topcoat
APS-3 Tungsten-carbide cobalt-alloy Heat reflecting tapea
— 0.008±0.002 in [200±50 µm]
powder (WC-Co, 83, 17%)
AS-1 Any suitable for application Cloth duct tape and/
and equipment or sheet metal 0.002–0.004 in [50–100 µm] 0.008±0.002 in [200±50 µm]
masks
AS-2 W-FeCrNi-1 stainless steel Heat reflecting tape
— —
(30416L) wire
FS-1 For corrosion protection Thermal spray
coating: W-A1-1100 or W-Zn-1 masking tape or
wire sheet metal mask(s) 0.002–0.004 in [50–100 µm] 0.008±0.002 in [200±50 µm]
For engineering purpose
coating: W-FeCrNi-1 wire
FS-2 W-FeCrNi-1 stainless steel Heat reflecting tape
— 0.008±0.002 in [200±50 µm]
(304 alloy) wire.
FS-3 CuAlFe (89+, 9.5, 1.0%) Thermal spray
aluminum bronze powder masking tape or — 0.008±0.002 in [200±50 µm]
sheet metal mask(s)
FS-4 Nickel based self-fluxing alloy Heat reflecting tape
— 0.020±0.002 in [500±50 µm]
powder, RHC 40–50 or paint stopoff
A&FS-1 Zn (99.9) wire Cloth duct tape and/
— 0.015–0.020 in [375–500 µm]
or sheet metal masks
HVOF-1 Tungsten-carbide cobalt-alloy Tapes, molding
(WC-Co, 83, 17%) powder compounds, and/or
— 0.008±0.002 in [200±50 µm]
applied 0.008±0.002 in sheet metal masks
[200±50 µm] thick
a
Usually a silicone coated tape that can stand up to grit blasting and plasma spray temperatures.
5.3.5 Retest. In the event the candidate fails to meet the requirements of the qualification skill test, the qualification
specification may permit the test supervisor to authorize and schedule a retest. There may be a minimum interval defined
for additional training or skill development before a retest is permitted. The test supervisor may have the authority to
grant an immediate retest if a thermal spray or inspection equipment fault contributed to the failure.
5.4 Period of Validity. The validity of the thermal spray operator’s qualification begins on the date all required tests are
satisfactorily completed and continues indefinitely as long as:
(1) The qualified operator has worked satisfactorily in a thermal spray station in shop or field facility within a
six-month period.
(2) The qualified operator maintains the qualification by performing all the work to the criteria in the TSOQT for
which the qualified operator is qualified including at least 8 hours of thermal spraying in the qualification categories in a
six-month period.
(3) The employer does not revoke the qualification.
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Thermal spray operator with an expired or canceled qualification status should not be permitted to perform thermal spray
operations in categories covered by the qualification specification.
5.5 Revocation. The conditions under which the qualification of the thermal spray operator may be revoked should be
defined. Example conditions include:
(1) There is a specific reason to question the ability of a thermal spray operator to meet the requirements for
qualification.
(2) It has been more than six-months since the thermal spray operator has performed at least 8 hours of specified
thermal spraying.
(3) The evidence of the thermal spray operator’s qualification certificate is not recorded and maintained by the indi-
vidual’s employer.
5.6 Reinstatement. The individual whose qualification has been revoked may be retested for the qualification sought.
Reinstatement of qualification will typically require the individual to demonstrate ability and skills to the same or the
current qualification test. The final authority for retest frequency, training requirements, and overall evaluation of the
individual’s qualification in accord with this document, and granting of qualification or reinstatement of qualification
rests with the employer.
5.7 Renewal. Renewal of qualification may require satisfactory preparation of test specimen(s) sufficiently in advance
of the expiration of the qualification interval to provide adequate time for the test supervisor to review and confirm the
records and update the qualification records. When a thermal spray operator’s qualification has expired, requalification
is typically required.
5.8 Requalification. A thermal spray operator who has not carried out production spraying for six months must follow
the initial applicant qualification procedure to regain a qualified status. In this case, training requirements associated with
the qualification program may be waived.
5.9 Responsibility. The employer is responsible for notifying the qualified operator and the test supervisor of the
qualification renewal interval. Scheduling of requalification shall be the responsibility of the test supervisor.
6. Training Requirements
As noted in 5.3.1, instruction or training may be incorporated into the qualification process to share and confirm knowl-
edge, expectations, and requirements. Training may involve: process theory study or instruction; hands-on practice
related to spraying, inspection, or testing; and troubleshooting case studies or exercises. The qualification specification
may establish requirements for training duration or evidence of satisfactory accomplishment.
6.1 Process Theory. Process theory instruction may be available through a variety of channels including the relevant
published resources listed in Annex C, Bibliography. Generic or application-specific training may address:
(1) The process or processes.
(2) Coating systems and bonding mechanisms.
(3) Substrate and feedstock materials.
(4) Equipment calibration, operation, and maintenance.
(5) Workpiece preparation, handling, and preservation.
(6) Establishing, maintaining, and adjusting essential spraying variables.
(7) Relationship to essential variables as they impact coating quality requirements.
(8) Health and safety.
6.2 Hands-on Training. Hands-on training may be provided using virtual methods, training rigs, or production tools to
ensure the candidate receives necessary knowledge and experience such as:
(1) Operation of equipment.
(2) Coating system requirements.
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(3) The correct adjustment of parameters.

(4) Workmanship.
(5) Equipment and process safety.
6.3 Inspection and Testing. There is value to provide training related to inspection and testing, even if the qualification
scope does not include the performance of quality verification procedures. An understanding of the quality requirements
and expectations will give the operator an understanding of the essential process variables, process expectations, and
process quality indicators. Training may address aspects of quality such as:
(1) The specifications, standards, or contract requirements applicable to the inspections being performed.
(2) Visual inspection for coverage, uniform structure, cracks, voids, spalling, chipping, flaking, or other indications
of poor adhesion.
(3) Dimensional verification including uniformity and thickness.
(4) Essential variable relationship to the relevant nondestructive examination and destructive tests.
6.4 Troubleshooting. Training for troubleshooting may involve case studies, simulations, or the resolution of actual
issues occurring during training or production. The expectations of operator troubleshooting knowledge and capability
will vary widely but are likely to involve:
(1) Identification of coating issues.
(2) Adjustment of equipment and process parameters to achieve desired coatings.
7. Knowledge Testing
Tests of a candidate’s job knowledge may be given by any of the following methods or combination of these methods:
(1) Written tests
(2) Oral examination following a set of written questions
(3) Computer testing
The examination format may include an open-book test on industry standards or contracts applicable to the employer, and
a closed-book test on thermal spray fundamentals (including safety) and practical applications.
The test performance should be structured and the criteria for acceptance should be clear. For example, a minimum
passing score (e.g., 70%) may be required to achieve qualification.
Verification that the candidate met the minimum requirements of the qualification standard should be a permanent part of
the employee’s records.
A qualified thermal spray operator has knowledge of the thermal spray process from beginning to end; an operator is able
to perform the job safely and confidently. The Job Knowledge Test should be prepared and administered by the thermal
spray test supervisor.
The knowledge portion of the thermal spray operator qualification test (TSOQT) may address the subjects listed
in 7.1 to 7.4.
7.1 General Knowledge
7.1.1 Process Basics
(1) Thermal spray technology principles and terminology.
(2) Equipment setup, operation, and maintenance including: gas and electrical energy supply devices, primary com-
ponents, and cooling systems.
(3) Identification and interpretation of equipment and feedstock manufacturer’s product information.
7.1.2 Essential variables should be defined by the user. See Annex B for examples.
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7.1.3 Health and Safety

(1) Safe handling of the thermal spray feedstock.
(2) Equipment operation including: proper handling of all electrical, gas, and air supplies and connections; start-up
and shut-down; issues such as leak detection and flashback devices.
(3) Personal protective equipment (PPE).
(4) Management of dust, noise, fire, and ultraviolet radiation emissions.
7.2 Process Determination
7.2.1 Feedstock selection and handling
(1) The influence of feedstock handling and storage on coating quality.
7.2.2 Workpiece preparation
(1) Recognize and measure the suitability, or non-suitability, of a surface to accept the proposed thermal spray coating
system.
(2) Understand the interactions of cleaning, degreasing, pressure-pot and mechanical surface roughening methods,
preheating, and storage.
(3) Demonstrate an awareness of the effects of blast media cleanliness, angular profile, and the degree of cleanliness
and angular profile depth required for different types of thermal spray coatings.
(4) Demonstrate an understanding of proper grit media selection.
(5) Demonstrate an understanding of masking procedures for both surface preparation and thermal spraying.
7.3 Equipment Operation
(1) General knowledge of the equipment.
(2) Operating procedures per the equipment manufacturer instruction or the employer’s refinement thereto.
(3) Equipment operation troubleshooting.
(4) Suitability of operating environment conditions such as temperature, humidity, and dew point.
(5) Operational safety concerns such as noise, dust, heat, radiation, electrical and fuel handling care.
7.4 Process Qualification. Basics should include:
(1) Thermal spray coating structure;
(2) Visual inspection, knowledge about metallographic results and the consequence of improper spray parameters;
and
(3) Procedures for adhesion testing, bend testing, and cut testing.
8. Skill Testing
Skill tests are employed to determine if the candidate is qualified to apply sound coating systems under conditions that will
be encountered in production. The examinations may incorporate checkpoints, requiring the test supervisor to give author-
ization to proceed, as the candidate demonstrates sufficient proficiency to proceed through the examination process.
The skill portion of the thermal spray operator qualification test (TSOQT) may include the elements described in 8.1 to 8.6.
8.1 General
(1) Test supervisor would typically confirm the identity of the candidate and initiate the test record.
(2) The candidate should demonstrate knowledge and proper use of applicable personal protective equipment and
safe handling and use of the equipment.
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(3) The candidate should review the TSOQT requirements to understand the nature and scope of the skill test.
(4) The candidate should initiate a thermal spray data sheet or other required documentation.
8.2 Workpiece Preparation. The candidate should demonstrate:
(1) The ability to verify the material and dimensions of the test piece(s) including features such as holes, fasteners,
edges, angles, etc.
(2) Handling and fixturing of the test piece in accordance with the TSOQT; manual or mechanized as appropriate.
(3) The ability to recognize the suitability, or non-suitability, of a surface to accept the proposed thermal spray coating
system. This may be accomplished by:
(a) Examination of specimen coupons displaying surface conditions such as:
(i) Surface blasted with ball shot to provide clean surface but without angular profile.
(ii) Surface blasted for too short a time, leaving excessive contamination or too shallow a profile depth, or
both. NOTE: Near white metal calls for a maximum of 5% visible rust contamination, without oil, grease,
dirt, and loose material or grease.
(iii) Surface overly blasted exhibiting peening back and polishing indicating a reduced profile insufficient for
thermal spraying.
(iv) Surface contaminated with oil, grease, dirt, and loose material or dust.
(v) Surface blasted correctly, giving a clean near-white or white metal surface with an angular profile appro-
priate to the coating type. The surface as prepared should be free of dust arising from other spraying
operations, broken down blast media, etc.
(b) Inspection and acceptance of the surface preparation condition of the test piece when prepared by others, by
measuring the surface cleanliness and angular profile depth in accordance with the TSOQT.
(c) Preparation of the surface of the test piece and measurement of the surface cleanliness and angular profile
depth in accordance with the TSOQT.
(4) Mask selection and application for both surface preparation and spraying.
(5) Verification of feedstock material type and lot number(s).
8.3 Equipment Preparation. The candidate should demonstrate:
(1) The ability to setup and operate the equipment in accordance with the manufacturer’s instruction, including any
additional requirements by the employer or TSTF.
(2) Verification of equipment qualification.
(3) Machine adjustments. Before starting the qualification test, the candidate should adjust the machine settings to
meet those stated in the TSOQT.
(4) The ability to recognize when equipment is not functioning properly and to know what corrective action is needed.
8.4 Process Execution. The qualification specification should describe the number and type of test pieces, coupons, or
specimens required during the skill test. Table 3 provides recommended number and type of test pieces corresponding to
the example thermal spray operator qualification designations of Table 1. The test piece designations are illustrated and
described in A2. The quantities given are generally the minimum number required to accomplish the common methods
of coating evaluation described in A4.
The candidate should then be able to:
(1) Measure and validate that the test pieces meet the substrate surface temperature and air temperature, dew point,
and humidity requirements. The substrate temperature would generally need to be 5°F [3°C] above the dew point, and the
humidity must be less than 85%. Must verify air is free from contaminates.
(2) Setup and operate the thermal spray equipment in accordance with Table 1 of this TSOQT.
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Table 3
Recommended Test Piece (TP)a Quantities
TSOQ
Designation TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9
APS-1 1 — 5 — 6 — — — —
APS-2 1 — 5 — — — — — —
APS-3 1 — 5 — 6 — — — —
AS-1 — — — — 5 — 1 1 —
AS-2 1 — 5 — 6 — — — —
FS-1
1 — — — 5 — 1 1 —
corrosion
FS-1
1 — 5 5 5 — 1 — —
engineering
FS-2 1 — 5 — 6 — — — —
FS-3 1 — 5 — 12 — — — —
FS-4 — 1 — — — — — — —
A&FS-1 — — — — — — — — 1
HVOF-1 1 — 5 — 6 1 — — —
Refer to Annex A for the description of the test pieces corresponding to the designations in this table. Actual quantity required would be established
a
in the qualification standard or contract requirements.
(3) Preheat as required.

(4) Spray test specimens.
(5) Conduct the required in-process and quality control measurements.
(6) Apply post-spraying sealer.
(7) Finish in accordance with the process instruction.
(8) Apply post-finishing sealer as specified by the process instruction.
8.5 Process Documentation. The candidate should demonstrate:
(1) The ability to prepare the thermal spray process and spray parameters data sheet. Test supervisor verification of
process parameters may be required prior to conducting the thermal spraying test.
(2) Recording of necessary job control information on the Test Facility’s Job Control Record.
8.6 Process Qualification. The test supervisor would validate the thermal spray operator skill qualification by
confirmation that the test coupons achieve the defined acceptance criteria.
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AWS C2.16/C2.16M:2017
Annex A (Normative)
Thermal Spray Process Qualification Tests
This annex is part of this standard and includes mandatory elements for use with this standard.
A1. General
This annex provides a description of common qualification test pieces and specimens employed to perform various coat-
ing system qualification tests. When a standard qualification test is specified, the standard should be consulted to verify
the test specimen dimensions, quantities, and acceptance criteria.
A2. Test Piece and Specimen Designations

The test piece and specimen description below correspond to the designations employed in Table 3.
A2.1 TP1. Round bar (low carbon steel) 2 in diameter × 10 in long [50 mm × 250 mm] undercut for a length of 6 in
[150 mm] centrally per Figure A1. The undercut may be 0.02 in [0.5 mm] deep (shown) for metals and metallic alloys or
0.01 in [0.25 mm] for cermet composites.
A2.2 TP2. Round bar (low carbon steel) 3 in diameter × 10 in long [75 mm × 250 mm]. The two ends of the bar should
be reduced to 2 in [50 mm] diameter to 3 in [75 mm] from each end as shown in Figure A2.
A2.3 TP3. Tensile specimen per ASTM C 633. These specimens are 1 in diameter × 1.5 in long [25.4 mm × 38.1 mm]
with a thread provided to engage the tension apparatus.
A2.4 TP4. Tensile specimen per ASTM D 4541.
Figure A.1—Test Piece for Atmospheric Plasma Spraying of Metals and Alloys
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AWS C2.16/C2.16M:2017
Figure A.2—Test Piece for Flame-Sprayed Self-Fluxing Alloy Coating
Figure A.3—Test Piece for Flame- and Arc-Sprayed Aluminum and Zinc Alloy Coating
A2.5 TP5. Flat coupon: 2 in × 4 in to 8 in × 0.050 in [50 mm × 100 mm to 200 mm × 1.25 mm] for bend test per
AWS C2.23.
A2.6 TP6. Almen test strip.
A2.7 TP7. 90° angle bar stock: 6 in wide × 20 in long × 0.25 in thick [150 mm × 500 mm × 6.5 mm]; see Figure A3.
A2.8 TP8. Companion coupons (flat plates approximately 4.0 in × 6.0 in × 0.385 in [100 mm × 150 mm × 10 mm]) or
as specified by the purchaser.
A2.9 TP9. Application specific field testing. For example, qualification to AWS C2.20/C2.20M, Specification
for Thermal Spraying Zinc Anodes on Steel Reinforced Concrete, is commonly performed in the field on actual structures.
A3. Specimen Preparation

Table 2 provides examples of coating pass and final thicknesses used in conjunction with the test pieces and specimens
of A2. The coating location should be defined in the specification (e.g., TP7 should be coated on both inside surfaces).
A4. Specimen Evaluation

There are many methods employed to evaluate coatings during and after thermal spraying. The selection of method(s)
and the acceptance criteria should be described in the qualification specification. This clause provides a description of the
method and some typical acceptance criteria.
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A4.1 Visual Inspection. The coating surface should be visually inspected for lumps, debris, blisters, and bonding on the
edges of the sample. Surface should be relatively smooth and uniform in appearance, without runs, drips, sags, or cracks.
The backside of the test strip should not be discolored but may have a very light brown color. Dark blue coloration is
typically a cause for rejection.
A4.2 Surface Profile Measurement. The profile depth is measured according to a standard such as ASTM D 7127,
Standard Test Method for Measurement of Surface Roughness of Abrasive Blast Cleaned Metal Surfaces Using a Portable
Stylus Instrument or ASTM D 4417, Test Method for Field Measurement of Surface Profile of Blast Cleaned Steel,
Method C (replica tape, x-coarse, or Method B (profile depth gauge). An anchor-tooth depth of 0.002–0.004 in [50–100
µm] is generally desired.
A4.3 Coating Thickness Measurement. Per pass and total thickness require verification by measurement. SSPC-PA 2
is a standard which provides direction on measurement of dry film thickness. Determination of coating thickness may
involve measurement of specimen diameter or thickness, and may require multiple measurements at random or specific
locations.
A4.4 Flatness Measurement. Flatness may be measured by contact or non-contact profilometer, or by using a dedicated
apparatus such as the Almen Gage shown in Figures A4 and A5. Standards such as SAE J442, Test Strip, Holder, and
Gage for Shot Peening, AMS 2430, Shot Peening, Automatic, or AMS2432 Shot Peening Computer Monitored, may
provide specific flatness requirements. In the case of the Almen strip to determine if the coating is in compression, it is
important to measure the strip after blasting and before coating, as well as after the coating process has taken place, to
identify and document strip deflection. While discoloration of the backside of the Almen strip is normal, dark blue
coloration may indicate excessive heating and cause rejection of the test strip.
A4.5 Conductivity Testing. Verification of electrical isolation of the coating or of specific coating conductivity may be
required. An example is impressed current corrosion protection systems where a thermal sprayed zinc coating must not
contact any metal rebar as it could create a short circuit. Verification of isolation may involve a low voltage audible
continuity tester, a high potential (i.e., hi pot) test instrument, or an Ohm meter threshold (minimum or maximum) value.
An Ohm meter would commonly be specified for electrical resistance value determination. Care should be taken to
ensure the process of measurement does not damage the coating.
A4.6 Surface Contamination. Identification of surface contaminants is application or coating system specific. A
chloride test kit is an example of a means for identification of a specific issue.
Source: J. Stricker Source: J. Stricker
Figure A.4—Example of Figure A.5—Example of

an almen Gage an Almen gage with
Specimen
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AWS C2.16/C2.16M:2017
A4.7 Hardness Testing. Mass hardness measurement of the sprayed surface would be determined using a prescribed
method such as ASTM E18-07, Standard Test Methods for Rockwell Hardness and Rockwell Superficial Hardness of
Metallic Materials or ASTM E92, Standard Test Method for Vickers Hardness of Metallic Materials and Knoop Hardness
of Metallic Materials. Hardness values, which may be appropriate for the TSOQTs are included in Table A1. The
acceptance criteria may be given by or related to the feedstock manufacturers’ product data sheet. The standard may
require that multiple measurements be taken at random or specific locations.
A4.8 Cut Test. In this test, coating adhesion is evaluated by applying a single knife or chisel (e.g., 1.5 in [40 mm] long)
cut through the coating to the substrate. The coating adhesion may be sufficient for the application if there is no lifting of
the coating along the cut line when using a knife blade to vigorously try to pry the coating from the substrate.
A4.9 Machining. There may be a requirement to machine the thermal spray coating using an appropriate process such
as single-point turning or grinding. The objective would be to verify the thermal spray coating will clean-up smoothly
without particle pullout or other voids, over the entire surface. Visual inspection of the finished surface would be used to
identify cracks, porosity, or detachment of the coating.
A4.10 Tensile Testing. Evaluation of coating adhesion may involve the application of standard tests such as ASTM C
633, Standard Test Method for Adhesion or Cohesive Strength of Flame-Sprayed Coatings, ASTM D 7234, Standard Test
Method for Pull-Off Adhesion Strength of Coatings on Concrete Using Portable Pull-Off Adhesion Testers or ASTM D
4541, Test Method for Pull-Off Strength of Coating Using Portable Adhesion Testers. Example acceptance criteria are
presented in Tables A1 and A2.
Table A.1
Example Thermal Spray Process Acceptance Criteria
Allowable
Tensilea Discontinuities Hardness
Averageb Minimumc Porosityd Oxidesd Minimum Average
TSOQT No. Spray Method psi [MPa] psi [MPa] (%) (%) DPH 300 15N HRB HRC
APS-1 Atmospheric 4000 [27.6] 3500 [24.1] ≤6 ≤20 80
Plasma Spray
APS-2 Atmospheric 3500 [24.1] 2500 [17.2] ≤4 — 850 63
Plasma Spray
APS-3 Atmospheric 6000 [41.4] 4500 [31.0] — — ≥50
Plasma Spray
AS-1e Arc Spray 1500e[10.3] 1000e[6.70] — —
AS-1e Arc Spray 750e[5.20] 500e)[3.40] — —
AS-2 Arc Spray 4000 [27.6] 3000 [20.7] ≤6 ≤20 95
A&FS-1 Arc and 150 [1.03]
e
100 [0.689]
e
— —
Flame Spray
FS-1e Flame Spray 1500e[10.3] 1000e[6.70] ≤6 ≤20
FS-1e Flame Spray 750e[5.17] 500e[4.38] ≤6 ≤20
FS-2 Flame Spray 3000 [20.7] 2000 [13.8] ≤4 — 90
FS-3 Flame Spray 4500 [31.0] 3500 [24.1] ≤6 ≤20 55
FS-4 Flame Spray — — — — 38–42
HVOF-1 HVOF Spray >10,000 [69.0] 9000 [62.1] 1 — 1000 91
(adhesive failure)
a
Tensile bond per ASTM C 633 except for AS-1, FS-1, and A&FS-1, in which case per ASTM D 4541 using a portable self-aligning tester.
b
Average tensile of five specimens.
c
Minimum tensile of the five specimens.
d
Per metallographic examination. Establish the minimum acceptable porosity and oxide values from the feed stock manufacturer’s technical informa-
tion for the spray method used. Values for porosity and oxide values per MIL-STD-1687 Table 1 and/or AWS C2.19/C2.19M:2013 Table 3.
e
Using an adhesion tester as per ASTM D 4541 using self-aligning adhesion tester.
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AWS C2.16/C2.16M:2017
Table A.2
Tensile-Bond Qualification Requirements for Thermal
Spray Operators
(per ASTM D 4541 using a portable self-aligning
tensile bond instrument)
Spray Material Average Tensile of 5, psi [MPa] Minimum Tensile, psi [MPa]
Aluminum ≥1500 [10.3] ≥1000 [6.7]
Zinc ≥750 [5.2] ≥500 [3.5]
85/15 ≥1050 [7.2] ≥700 [4.8]
90/10 MMC ≥1500 [10.3] ≥1000 [6.7]
Figure A.6—Thermal Spray Coating Bend Test: Pass/Fail Examples
A4.11 Bend Test. The bend test subjects the test coupon or specimen to a bend to stress the coating system. Figure A6
illustrates an apparatus used to wrap the coupon (i.e., a 180° bend) around a 0.5 in [12.7 mm] mandrel. Coating acceptance
may require no cracking or only minor cracking visually observed on the bend radius; and require that minor cracks
cannot be picked off with a knife blade.
A4.12 Adhesion Flame Test. This test involves the application of localized heating to identify “hot spots,” which may
be evidence of delimitation. The procedure usually involves the application of a slightly reducing flame perpendicular to
the coated surface using an oxyacetylene torch with either a National #10 or #12 tip (or equivalent). The flame is held
about 1/2 in [12 mm] from the coated surface and moved at a moderate rate of speed (approximately 1 in [25 mm] per
second) without allowing the flame to dwell in one area. An improperly bonded area will develop a “hot spot” as evidenced
by the area having a red glow. The temperature of the part should not exceed 350°F [180°C] when the test is performed
properly.
A4.13 Tapping Test. This extension of the adhesion flame test involves lightly tapping raised or coated areas that do not
glow to ensure adhesion is sufficient to resist delamination.
A4.14 Liquid Penetrant. Migration of liquid penetrant into coating surface discontinuities will produce indications,
which can be evaluated against standard, customer, or penetrant supplier acceptance criteria.
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AWS C2.16/C2.16M:2017
A4.15 Metallography. This test generally involves preparation of a section view of the substrate and coating to examine
the coating and coating interface microstructure. Evaluation may involve comparison against specimens or counting or
measurement of discontinuities. The test may be applied to identify the presence of imbedded abrasive, globular particles,
unreacted particles, oxides, cracks, porosity, or voids. It may also be used to look for interruption of the bond line and
verify the uniformity of coating constituents.
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AWS C2.16/C2.16M:2017
Annex B (Informative)
Example Forms
This annex is not part of this standard but is included for informational purposes only.
B.1 Thermal Spray Process and Spray Parameters for Plasma Spraying
B.2 Thermal Spray Process and Spray Parameters for Arc Spraying
B.3 Thermal Spray Process and Spray Parameters for Flame Spraying
B.4 Thermal Spray Process and Spray Parameters for HVOF Spraying
B.5 Example Thermal Spray Operator Qualification Certificate
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AWS C2.16/C2.16M:2017
B.1 Thermal Spray Process and Spray Parameters for Plasma Spraying
Substrate material
Powder type and identification no.
Lot no.
Masking material(s)
Area(s) to be masked
Surface preparation
Grit type and size
Anchor-tooth profile depth, 0.001 in [mm]
Pressure-pot blasting pressure, psi [kPa]
Blasting nozzle type
Blasting nozzle to work distance, in [mm]
Blasting nozzle to work angle, degrees
Blasting rate, ft2/hr [m2/hr]
Spray gun type and model Powder feed unit type and model
Type and model Flow control valve setting, clicks
Anode Key mechanical-feed parameters
Cathode Meter wheel type
Injector Meter wheel rpm
Primary gas type
Primary gas pressure, psi [kPa]
Primary gas flow rate, ft3/hr [L/min] Key fluidized-bed parameters
Secondary gas type Carrier gas
Secondary gas pressure, psi [kPa] Carrier gas pressure, psi [kPa]
Secondary gas flow rate, ft3/hr [L/min] Carrier gas flow rate, ft3/hr [L/min]
Cooling water flow, gpm [L/min]
Spray parameters Bond Coat Finish Coat
Spray rate, lb/hr [kg/hr]
Gun to substrate distance, in [mm]
Gun to substrate angle, degrees
Preheat temperature, °F [°C]
Maximum substrate temperature, °F [°C]
Gun traverse rate, in/min [mm/min]
Surface speed of workpiece, ft/min [m/min]
Coating thickness/pass, 0.001 in [mm]
Bond sample coating thickness, 0.001 in [mm]
Bend QC specimen coating thickness, 0.001 in [mm]
Final coating thickness (value and ±), 0.001 in [mm]
Cooling method
Sealer type
Finishing methods and parameters
Other/Remarks
Abbreviations: ft2/hr = square foot per hour; m2/hr = square meter per hour; ft3/hr = cubic foot per hour; L/min = liter
per minute.
Thermal sprayer (print name)_______________________________________________ Date___________

Reviewed and accepted by test supervisor____________________________________ Date___________
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AWS C2.16/C2.16M:2017
B.2 Thermal Spray Process and Spray Parameters for Arc Spraying
Substrate material: concrete test block
Feedstock
Wire type and ID no.
Wire diameter, in [mm]
Surface preparation
Grit type and size
Spray equipment
Type and model
Gun nozzle type and size
Air cap type
Power supply
Arc control unit
Spray parameters
Amperage, A
Voltage, V
Atomizing gas
Atomizing gas pressure, psi [kPa]
Starting area preheat temperature, °F [°C]
Minimum coating thickness/pass, 0.001 in [mm]
Maximum coating thickness/pass, 0.001 in [mm]
Final coating thickness
Minimum, 0.001 in [mm]
Maximum, 0.001 in [mm]
Other/Remarks
Abbreviations: ft2/hr = square foot per hour; m2/hr = square meter per hour.
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AWS C2.16/C2.16M:2017
B.3 Thermal Spray Process and Spray Parameters for Flame Spraying
Substrate material
Powder type and identification no.
Lot no.
Masking material(s)
Surface preparation
Grit type and size
Spray gun type and model Powder feed unit type and model
Type and model Flow control valve setting, clicks
Spray nozzle type and size Key mechanical-feed parameters
Air cap type Meter wheel type
Metering valve Meter wheel rpm
Vibrator
Fuel gas type
Fuel gas pressure, psi [kPa] Key fluidized-bed parameters
Oxygen pressure, psi [kPa] Carrier gas
3
Fuel gas flow rate, ft /hr [L/min] Carrier gas pressure, psi [kPa]
Oxygen flow rate, ft3/hr [L/min] Carrier gas flow rate, ft3/hr [L/min]
Spray parameters
Spray rate, lb/hr [kg/hr]
Preheat temperature, °F [°C]
Surface speed of workpiece, ft/min [m/min]
Coating thickness/pass, 0.001 in [mm]
Bond sample coating thickness, 0.001 in [mm]
Bend QC specimen coating thickness, 0.001 in [mm]
Final coating thickness (value and ±), 0.001 in [mm]
Sealer type
Finishing methods and parameters
Other/Remarks
Abbreviations: ft2/hr = square foot per hour; m2/hr = square meter per hour; ft3/hr = cubic foot per hour; L/min = liter
per minute.
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AWS C2.16/C2.16M:2017
B.4 Thermal Spray Process and Spray Parameters for HVOF Spraying
Substrate material and part description
Powder type and Lot no. Specification (where applicable)

identification no.
Masking material(s)
Surface preparation
Finish Blasting nozzle type
Grit type and size Blasting nozzle work distance, in [mm]
Anchor-tooth profile depth, 0.001 in [mm] Blasting nozzle work angle, degrees
Pressure-pot blasting pressure, psi [kPa] Blasting rate, ft2/hr [m2/hr]
HVOF type, model, and settings Barrel type and length used
Type and model Spray distance, in [mm]
Fuel Fuel type Powder feeder model and settings

Supply pressure, psi [kPa] Type and model
Flow rate, gal/min [L/min]
Back pressure, psi [kPa] Carrier gas type
Oxygen Supply pressure, psi [kPa] Supply pressure, psi [kPa]
Flow rate, ft3/hr [L/min] Flow rate, ft3/hr [L/min]
Back pressure, psi [kPa] Back pressure, psi [kPa]
Combustion pressure where applicable, psi [kPa] Feed rate settings
Water Flow rate, gal/min [L/min]
Pressure, psi [kPa] Spray rate, lb/hr [gal/min]
Inlet temperature °F [°C]
Outlet temperature °F [°C]
Coating Thickness/pass, 0.001 in [mm]
thickness Final, 0.001 in [mm]
Other/Remarks
Abbreviations: ft2/hr = square foot per hour; m2/hr = square meter per hour; gal/min = gallon per minute; L/min = liter
per minute; ft3/hr = cubic foot per hour.
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AWS C2.16/C2.16M:2017
B.5 Example Thermal Spray Operator Qualification Certificate

Thermal Spray Operator Qualification Certificate
Qualifying Organization
Thermal Spray Operator
Name
Identification
Qualification Description
Thermal Spray Process
Qualification Designation
Application Method
Substrate
Coating System
Testing Results
Date Performed Accepted
Knowledge
Skill
Examiner Name
Examiner Signature
Date of Issue
Renewal
Revoke
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AWS C2.16/C2.16M:2017
Annex C (Informative)
Bibliography
Equipment manufacturer’s instructions (technical manual and bulletins) including spray parameters for selected
feedstock.
Abrasive blasting media and feedstock Safety Data Sheets
AWS Welding Handbook, 9th Edition, Volume 3, Part 2, Chapter 11, Thermal Spraying and Cold Spraying1
AWS TSM, Thermal Spraying, Practice, Theory, and Applications
AWS C2.19, Specification for the Application of Thermal Spray Coatings to Machine Elements for OEM and Repair
AWS C2.20/C2.20M, Specification for Thermal Spraying Zinc Anodes on Steel Reinforced Concrete
AWS C2.21M/C2.21, Specification for Thermal Spray Equipment Performance Verification
AWS C2.23, Specification for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their
Alloys and Composites for the Corrosion Protection of Steel. Also available as SSPC CS 23.00 and NACE No. 12
AWS C2.25/2.25M, Specification for Solid and Composite Wires and Ceramic Rods for Thermal Spraying
AMS2430, Shot Peening, Automatic2
AMS2432, Shot Peening, Computer Monitored
ASM Handbook, Volume 5A: Thermal Spray Technology3
ASME Boiler and Pressure Vessel Code, Section IX4
ASTM B 833, Specification for Zinc and Zinc Alloy Wire for Thermal Spraying (Metallizing)5
ASTM C 633, Standard Test Method for Adhesion or Cohesive Strength of Flame-Sprayed Coatings
ASTM D 4258, Standard Practice for Surface Cleaning Concrete for Coating
ASTM D 4285, Standard Test Method for Indicating Oil or Water in Compressed Air
ASTM D 4417, Test Method for Field Measurement of Surface Profile of Blast Cleaned Steel
ASTM D 4541, Test Method for Pull-Off Strength of Coating Using Portable Adhesion Testers
ASTM D 5295, Standard Practice for Abrading Concrete
1
American Welding Society, 8669 NW 36 Street, # 130, Miami, Florida 33166-6672.
2
AMS standards are published by SAE International, 400 Commonwealth Drive, Warrendale, PA 15096.
3
ASM World Headquarters, 9639 Kinsman Road, Materials Park, OH 44073-0002.
4
ASME, Two Park Avenue, New York, NY 10016-5990.
5
ASTM International standards are published by the American Society of Testing and Materials, 100 Barr Harbor Drive, West
Conshohocken, PA 19428-2959.
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AWS C2.16/C2.16M:2017
ASTM D 7127, Standard Test Method for Measurement of Surface Roughness of Abrasive Blast Cleaned Metal Surfaces
Using a Portable Stylus Instrument
ASTM D 7234, Standard Test Method for Pull-Off Adhesion Strength of Coatings on Concrete Using Portable Pull-Off
Adhesion Testers
ASTM E18, Standard Test Methods for Rockwell Hardness of Metallic Materials
ASTM E337, Standard Test Method for Measuring Humidity with a Psychrometer (the Measurement of Wet- and Dry-
Bulb Temperatures)
ASTM E92, Standard Test Method for Vickers Hardness of Metallic Materials and Knoop Hardness of Metallic Materials
SSPC PA 2, Procedure for Determining Conformance to Dry Coating Thickness Requirements6
SSPC-PA 17, Procedure for Determining Conformance to Steel Profile/Surface Roughness/Peak Count Requirements
SSPC SP 5, White Metal Blast Cleaning. See also NACE No. 1.
SSPC SP 10, Near White Metal Blast. See also NACE No. 2.
SSPC Guide to Vis 1, Visual Standard for Abrasive Blast Cleaned Steel
SSPC-Guide to Vis 1-89, Visual Standard for Abrasive Blast Cleaned Steel
SSPC Guide 15, Field Methods for Retrieval and Analysis of Soluble Salts on Steel and other Nonporous Substrates
SSPC CS 23.00, Specification for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their
Alloys and Composites for the Corrosion Protection of Steel. Also available as AWS C2.23 and NACE No. 12.
NACE No. 1, White Metal Blast Cleaning. See also SSPC SP 5.7
NACE No. 2, Near White Metal Blast. See also SSPC SP 10
NACE No. 12, Specification for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their
Alloys and Composites for the Corrosion Protection of Steel. Also available as SSPC CS 23.00 and AWS C2.23.
MIL-STD-1687, Thermal Spray Processes for Naval Ship Machinery Applications8
ISO 14923, Thermal spraying—Characterization and testing of thermally sprayed coatings9
ISO 2063, Thermal spraying—Metallic and other inorganic coatings—Zinc, aluminium and their alloys
ISO 12679, Thermal spraying—Recommendations for thermal spraying
ISO 14920, Thermal spraying—Spraying and fusing of self-fluxing alloys
ISO 14919, Thermal spraying—Wires, rods and cords for flame and arc spraying—Classification—Technical supply
conditions
ISO 12690, Metallic and other inorganic coatings—Thermal spray coordination—Tasks and responsibilities
ISO 14188, Metallic and other inorganic coatings—Test methods for measuring thermal cycle resistance and thermal
shock resistance for thermal barrier coatings
ISO 14231, Thermal spraying—Acceptance inspection of thermal spraying equipment
ISO 14232, Thermal spraying—Powders—Composition and technical supply conditions
ISO 14916, Thermal spraying—Determination of tensile adhesive strength
ISO 14917, Thermal spraying—Terminology, classification
6
The Society for Protective Coatings (SSPC), 40 24th Street, 6th Floor, Pittsburgh, PA 15222.
7
NACE International, 15835 Park Ten Place, Houston, Texas 77084.
8
DLA Document Services, Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.
9
International Organization for Standardization (ISO), Chemin de Blandonnet 8, CP 401, 1214 Vernier, Geneva.
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AWS C2.16/C2.16M:2017
ISO 14918, Thermal spraying—Approval testing of thermal sprayers

ISO 14922-1, Thermal spraying—Quality requirements of thermally sprayed structures—Part 1: Guidance for selection
and use
ISO 14922-2, Thermal spraying—Quality requirements of thermally sprayed structures—Part 2: Comprehensive quality
requirements
ISO 14922-3, Thermal spraying—Quality requirements of thermally sprayed structures—Part 3: Standard quality
requirements
ISO 14922-4, Thermal spraying—Quality requirements of thermally sprayed structures—Part 4: Elementary quality
requirements
ISO 17834, Thermal spraying—Coatings for protection against corrosion and oxidation at elevated temperatures
ISO 17836, Thermal spraying—Determination of the deposition efficiency for thermal spraying
ISO 14924, Thermal spraying—Post-treatment and finishing of thermally sprayed coatings
ISO 14921, Thermal spraying—Procedures for the application of thermally sprayed coatings for engineering components
ISO 12670, Thermal spraying—Components with thermally sprayed coatings—Technical supply conditions
ISO 12671, Thermal spraying—Thermally sprayed coatings—Symbolic representation on drawings
ISO 27307, Thermal spraying—Evaluation of adhesion/cohesion of thermal sprayed ceramic coatings by transverse
scratch testing
SAE J442, Test Strip, Holder, and Gage for Shot Peening10
10 SAE International, 400 Commonwealth Drive, Warrendale, PA 15096.
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AWS C2.16/C2.16M:2017
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AWS C2.16/C2.16M:2017
Annex D (Informative)
Requesting an Official Interpretation on
an AWS Standard
D1. Introduction
The following procedures are here to assist standard users in submitting successful requests for official interpretations to
AWS standards. Requests from the general public submitted to AWS staff or committee members that do not follow these
rules may be returned to the sender unanswered. AWS reserves the right to decline answering specific requests; if AWS
declines a request, AWS will provide the reason to the individual why the request was declined.
D2. Limitations
The activities of AWS technical committees regarding interpretations are limited strictly to the interpretation of provi-
sions of standards prepared by the committees. Neither AWS staff nor the committees are in a position to offer interpre-
tive or consulting services on (1) specific engineering problems, (2) requirements of standards applied to fabrications
outside the scope of the document, or (3) points not specifically covered by the standard. In such cases, the inquirer
should seek assistance from a competent engineer experienced in the particular field of interest.
D3. General Procedure for all Requests

D3.1 Submission. All requests shall be sent to the Managing Director of AWS Standards Development. For efficient
handling, it is preferred that all requests should be submitted electronically through technical@aws.org. Alternatively,
requests may be mailed to:
Managing Director
Standards Development
American Welding Society
8669 NW 36 St, # 130
Miami, FL 33166
D3.2 Contact Information. All inquiries shall contain the name, address, email, phone number, and employer of the
inquirer.
D3.3 Scope. Each inquiry shall address one single provision of the standard unless the issue in question involves two or
more interrelated provisions. The provision(s) shall be identified in the scope of the request along with the edition of the
standard (e.g., D1.1:2006) that contains the provision(s) the inquirer is addressing.
D3.4 Question(s). All requests shall be stated in the form of a question that can be answered “yes” or “no.” The request
shall be concise, yet complete enough to enable the committee to understand the point of the issue in question. When the
point is not clearly defined, the request will be returned for clarification. Sketches should be used whenever appropriate,
and all paragraphs, figures, and tables (or annexes) that bear on the issue in question shall be cited.
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AWS C2.16/C2.16M:2017
D3.5 Proposed Answer(s). The inquirer shall provide proposed answer(s) to their own question(s).
D3.6 Background. Additional information on the topic may be provided but is not necessary. The question(s) and
proposed answer(s) above shall stand on their own without the need for additional background information.
D4. AWS Policy on Interpretations

The American Welding Society (AWS) Board of Directors has adopted a policy whereby all official interpretations of
AWS standards are handled in a formal manner. Under this policy, all official interpretations are approved by the techni-
cal committee that is responsible for the standard. Communication concerning an official interpretation is directed through
the AWS staff member who works with that technical committee. The policy requires that all requests for an official
interpretation be submitted in writing. Such requests will be handled as expeditiously as possible, but due to the proce-
dures that must be followed, some requests for an official interpretation may take considerable time to complete.
D5. AWS Response to Requests

Upon approval by the committee, the interpretation is an official interpretation of the Society, and AWS shall transmit the
response to the inquirer, publish it in the Welding Journal, and post it on the AWS website.
D6. Telephone Inquiries

Telephone inquiries to AWS Headquarters concerning AWS standards should be limited to questions of a general nature
or to matters directly related to the use of the standard. The AWS Board Policy Manual requires that all AWS staff mem-
bers respond to a telephone request for an official interpretation of any AWS standard with the information that such an
interpretation can be obtained only through a written request. Headquarters staff cannot provide consulting services.
However, the staff can refer a caller to any of those consultants whose names are on file at AWS Headquarters.
30
AWS C2.16/C2.16M:2017
List of AWS Documents on Thermal Spraying

Designation Title
C2.16/C2.16M Guide for Thermal Spray Operator Qualification Programs
C2.18 Guide for the Protection of Steel with Thermal Sprayed Coatings of Aluminum and Zinc and
Their Alloys and Composites
C2.19/C2.19M Specification for the Application of Thermal Spray Coatings to Machine Elements for OEM
and Repair
C2.20/C2.20M Specification for Thermal Spraying Zinc Anodes on Steel Reinforced Concrete
C2.21M/C2.21 Specification for Thermal Spray Equipment Performance Verification
C2.23M/C2.23 Specification for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc,
and Their Alloys and Composites for the Corrosion Protection of Steel
C2.25/C2.25M Specification for Thermal Spray Feedstock-Wire and Rod
31
AWS C2.16/C2.16M:2017
32

AWS C2 16 2017 Guide For Thermal

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AWS C2.16/C2.

Guide for Thermal

Guide for Thermal Spray

Supersedes AWS C2.16/C2.16M:2002

Under the Direction of the

Statement on the Use of American Welding Society Standards

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Advisors to the AWS C2 Committee on Thermal Spraying

AWS C2F Subcommittee on Thermal Spray Operator Qualification Programs

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8.5 Process Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Guide for Thermal Spray

3. Terms and Definitions

4. Qualification Program Definition

– range and innovation of coating systems executed; and

(3) The correct adjustment of parameters.

7.1.3 Health and Safety

in the qualification standard or contract requirements.

(3) Preheat as required.

A2. Test Piece and Specimen Designations

Figure A.2—Test Piece for Flame-Sprayed Self-Fluxing Alloy Coating

A3. Specimen Preparation

A4. Specimen Evaluation

Source: J. Stricker Source: J. Stricker

Figure A.4—Example of Figure A.5—Example of

Figure A.6—Thermal Spray Coating Bend Test: Pass/Fail Examples

Thermal sprayer (print name)_______________________________________________ Date___________

Powder type and Lot no. Specification (where applicable)

Fuel Fuel type Powder feeder model and settings

B.5 Example Thermal Spray Operator Qualification Certificate

ISO 14918, Thermal spraying—Approval testing of thermal sprayers

10 SAE International, 400 Commonwealth Drive, Warrendale, PA 15096.

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D3. General Procedure for all Requests

D4. AWS Policy on Interpretations

D5. AWS Response to Requests

D6. Telephone Inquiries

List of AWS Documents on Thermal Spraying

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Thermal sprayer (print name)_____________________________________ Date_

10 SAE International, 400 Commonwealth Drive, Warrendale, PA 15096.