Analytical Models for Grain Size Determination of Metallic Coatings and Machined Surface Layers Using the Four-Point Probe Method

The grain size of a metallic coating or the surface layer after the machining of metallic parts strongly impacts corrosion and wear properties along with fatigue behavior. By measuring the combined electrical resistance of this layer and the substrate using the four-point probe method, the grain size of the layer can be determined. For different grain shapes, models are derived based on an analytical approach. The parameters in the models can be determined by appropriate calibration measurements. As a result, the grain sizes can be determined quickly with a non-destructive method, which can be applied to ensure consistent coating or machining results as part of quality control routines in industrial processes.