Do powder losses change this part rate?

Only if they cause a part to fail inspection or require rework. Measure powder retention separately with deposition efficiency.

Should a part with three defects count three times?

No. Count that part once; defect counts and affected-part counts answer different questions.

Does successful rework remove the original defect?

Not from this first-pass measure. Track final accepted yield separately from the original need for rework.

Who sets the maximum reject rate?

Your quality plan or improvement target sets it. The default is illustrative and is not an industry acceptance rule.

Thermal Spray, Hardfacing & Wear Coatings calculator

Coating Reject Rate Calculator

Compare the share of coated parts requiring rejection or rework with your maximum. Use unique affected parts and the total count from the same quality record.

What this calculator does

Compare the share of coated parts requiring rejection or rework with your maximum.

Formula used

Reject rate = 100 × Affected parts ÷ Coated parts
Unaffected parts = Coated parts − Affected parts
Rate above limit = Reject rate − Maximum allowed rate

Inputs explained

Rejected or Reworked Parts: Unique coated parts rejected or sent for rework.
Total Coated Parts: All unique parts in the same completed coating batch.
Maximum Reject Rate: Your allowed share requiring rejection or rework.

How to use the result

Best suited to coating lot reviews, First-Pass acceptance tracking.
This fraction does not identify the defect cause or replace acceptance criteria.

Current U.S. benchmarks

Industrial electricity averages 9.77 cents per kWh across the U.S. (EIA, Jul 2026), up 4.7% from a year earlier. Energy-intensive steps carry this directly into unit cost.
The producer price index for industrial chemicals stands at 336.006 (BLS, Aug 2026), up 13.3% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The U.S. has 14,543 chemical manufacturing establishments employing about 911,245 workers (Census County Business Patterns, 2023).

Common questions

Do powder losses change this part rate? Only if they cause a part to fail inspection or require rework. Measure powder retention separately with deposition efficiency.
Should a part with three defects count three times? No. Count that part once; defect counts and affected-part counts answer different questions.
Does successful rework remove the original defect? Not from this first-pass measure. Track final accepted yield separately from the original need for rework.
Who sets the maximum reject rate? Your quality plan or improvement target sets it. The default is illustrative and is not an industry acceptance rule.

Last reviewed 2026-10-12.