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OG202 & OG204 Tooke Paint Inspection Gages

U.S. Patent No. 3,340,615

Meets ASTM D4138-82

Improved Appearance Less Expensive Many Improved Features Measures Thickness of Coatings Applied to Wood, Plastic, Cement, Glass, Ceramics, Mirror Backings, Metal, Etc. Assists in Measuring Brittleness and Adhesion of Coatings and Materials.

Model OG202 Model OG204 Model OG202 & OG204 are supplied with 1X, 2X, & 10X cutting tips installed in the gage body. The 2X tip is shown extended to working position.

Direct measurement of total coating thickness, and thickness of individual coats of paint is a unique capability of the “Tooke Gage.” Thus, in addition to routine use, it often serves as a “referee” instrument to calibrate indirect or “non-destructive” thickness measuring instruments. Other uses include assessment of substrate conditions and coating adhesion, and observation of microscopic cracking, tendency for brittleness, blistering, cratering, or other microscopic film symptoms.

Principle

A special cutting tool which is integral with the gage is used to incise a small, precision V-groove through the paint film and into the substrate. This V-groove is observed vertically with an illuminated microscope bearing a measuring reticle (scale). As shown in Fig. 1, the observed horizontal projection of the film at the groove wall is related to the film thickness by the equation:

Similarly, other groove angles may be cut for convenience and precision of measurement of coating films over a wide range of thicknesses.

	A'=A= Finish Coat Thickness B'=B= Primer Coat Finish
Fig. 1.  (A) Geometry of Thickness Measurement.   (B) Grooves of 1X, 2X, and 10X Cutting Tips.
Metric Version Available, See Line Items At End Of Page

Construction

The OG202 gage body, cap, and focusing ring, are machined aluminum. The OG204 gage body is made of injection molded high-impact plastic. It contains the microscope and lamp batteries as well as the groove-cutting tungsten carbide cutting tools mounted on the narrow side. In addition to the cutting tools, two adjustable threaded guide studs also project from the body on the same side. The tripod thus formed by the three legs (guide studs and tool) provides for precise alignment of the tool with a surface to be grooved. A lanyard and keeper looped through the body secure the instrument to the inspector’s wrist. A flexible carrying case with neck strap is compartmentalized to include: the gage, a felt-tipped marker, and extra batteries and bulb. The entire unit is designed for convenience and completeness in field inspection tasks.

Measuring Procedure

Open the carrying case and remove the instrument. For field use, secure the safety lanyard to the wrist to prevent accidental dropping. Check the positioning of the cutting tips. As originally supplied, the tip positions will be from top to bottom 1X, 2X, and 10X. The numerals 1, 2, and 10 are engraved in the plastic body alongside each tip respectively. The 1X and 10X tips will be bottomed in their slot, thus protruding about 3/16" from the case. The 2X tip (center position) should be in working position, thus protruding about 5/16" from the case. In general, this is the correct configuration for making an initial measurement on a film.

Make a small mark with the brush-pen at the desired measurement location on a painted surface. Grasp the instrument with the cutting tip down as shown in Fig. 2. Place the cutter tip and guide studs in firm contact with the surface with the tip slightly above the mark and aligned to scribe across the mark. Align the forearm with the intended cutting direction to assure a straight cut. Draw the cutter tip straight across the mark, applying just sufficient pressure at the tip to cleanly penetrate through the film into the substrate. In this operation, the cutter trails midway between the two guide studs, and continuous 3-point surface contact should be maintained to assure precise vertical alignment of the groove. Excessive pressure on the guide studs should be avoided.

Fig. 2. Gage held in cutting position	Fig. 3. Viewing specimen through microscope

Turn on the microscope lamp with the slide switch on top of the case next to the eyepiece. Center the foot of the microscope on the scribed line with the mark about one-quarter inch from the foot directly under the microscope objective. Check the microscope for focus (See Fig. 3). If the image is not clear, it may be brought into sharp focus by turning the focusing screw in the body below the microscope. Check the clarity of the reticle (scale) image in the microscope. If it is fuzzy, unscrew or tighten the chrome eyepiece until it sharpens.

With focusing accomplished, view the intersection of the mark and the cut as shown in Fig. 4. Note how the mark delineates the top edge of the cut. Position the microscope as required to align the left edge of the cut with any convenient long line of the reticle and begin counting the small graduations inwardly (to the right) until the next layer or the substrate is reached. This count divided by the tip designation (2) is the film thickness. If the result should be less than 2 or more than 20 mils, the inspector may wish to utilize 10X or 1X cutting tips respectively.

This may be quickly accomplished by using the knurled-head hex key wrench to loosen the tip set screws. (The wrench is conveniently located atop the switch plate, and serves a dual function as a screw closure for the switch plate.) See Fig. 5. Allow all three tips to bottom in their slots, then pull the selected tip out to 5/16" (approximately) and retighten all tips with moderate finger pressure. Tip changes: Cutting tip designations and appropriate film thickness ranges for each are shown below.

Fig. 4. Micrograph of paint film incision.

Fig. 5 (L) Removing Tip Wrench from Switch Plate	(R) Adjusting Tip Set Screws

For convenience, always keep the tips in their designated locations:

1X—top, 2X—middle, and 10X—bottom. Note also that the narrow face of the tip which bears an angular grind should face toward the guide studs.

Calibration

Original factory calibration is accomplished by setting the guide studs in precise geometric alignment with the cutting tips. Checks are also made with precision applied film standards. For highest precision work, the user is advised to maintain painted panels of known thickness, and to check and calibrate the instrument measurements periodically.

Suggestions To Users

1. On wood or other directional material, make incisions in the grain or “machine” direction to avoid ragged cuts.
2. Soft or elastic materials can sometimes be cooled or frozen with ice or dry ice to obtain good cutting characteristics.
3. Dyes or indicator solutions such as phenolphthalein are sometimes helpful to develop appearance contrast between metals (iron-galvanizing) or paint coats.
4. Eraser “white-out” fluid may be useful as a benchmarker on dark surfaces.
5. With some coatings, improved cuts can be achieved by wetting the surface, or by speeding or slowing the cutting rate.
6. Coatings with poor adhesion will exhibit a ragged line at the substrate interface. Read
   thickness from the left incision edge in the SUBSTRATE in these cases. (Note Reference on “Coatings Adherence Measurement…” below.)

 

Special Applications

The Tooke Gage has been used to assess sandblast cleaning work, to measure plating and paint thickness on ceramics, metal, wood, and concrete, and even to measure protective backing thickness on mirrors. It is virtually the only tool for measuring paint on plastics. As indicated above, the quality of the incision in the film discloses much about characteristics of brittleness and adhesion of the material. In addition to the benefits as a dry film thickness gage, the Tooke Inspection Gage (PIG) offers the advantages of a close inspection tool. Abnormalities that would otherwise go undetected by conventional electronic or magnetic gages include pinholes, adhesion faults, deteriorated substrate conditions, and lack of overall coating integrity. Consider the Tooke Gage as an excellent adjunct to the conventional DFG and even more useful as a verification tool for the more exotic ultrasonic instruments.

Item Number	Item
DF-OG202	PAINT INSPECTION GAGE, Model OG202 - Complete with illuminated microscopes, 3 cutting tips, felt tip marker, Allen wrench, carrying case and instructions. This gage is produced in limited quantities.
DF-OG202M	Same as above with metric radical
DF-OG204	PAINT INSPECTION GAGE, Model OG204 IV - Price Complete with illuminated microscope, three cutting tips, knurled head tip wrench-switch plate closure screw, felt tip marker, extra batteries and bulb, flexible carrying case and instructions
DF-OG204M	Same as above with metric radical
DF-OG202-11	EXTRA 1X Cutting Tip
DF-OG202-12	EXTRA 2X Cutting Tip
DF-OG202-13	EXTRA 10X Cutting Tip
DF-OG202-123	1X, 2X, & 10X Cutting Tip Set.

NOTE: Metric Versions Available

References

1. “A Paint Inspection Gage” by Raymond Tooke, Jr.   OFFICIAL DIGEST, July 1963, 35, pp. 691-698.
2. “Coatings Adherence Measurement By An Angular Scribe-Stripping Technique” by W. R. Tooke, Jr. and J. Montalvo, JOURNAL OF PAINT TECHNOLOGY, January 1966, 38, pp. 18-28.
3. “Development of Specifications For Measurement of Paint Thickness On Structural Steel” by J. D. Keene and T. L. Shoemaker, JOURNAL OF PAINT TECHNOLOGY, 45, No. 585, October 1973, pp. 46-67.
4. “How Instruments Boost Coatings Application Productivity” by W. R. Tooke, Jr., PROFESSIONAL DECORATING AND COATING ACTION, October 1976, pp. 16,18.
5. “Standard Method of Measurement of Dry Film Thickness of Protective Coatings Systems by Destructive Means”, Designation: D 4138-82, 1988 ANNUAL BOOK OF ASTM STANDARDS, pp. 695-697.
6. “Method and Device for Measuring the Thickness of Films” by W. R. Tooke, Jr., U. S. Patent No. 3, 340, 615.

 

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