Thermal Spray, Hardfacing & Wear Coatings worked example

Finish Grind Allowance with as-sprayed coating thickness of 310 units: a worked example

What does the result look like when as-sprayed coating thickness reaches 310 units? The full calculation is worked below with real intermediate numbers. Use it when finish grind allowance in thermal spray, hardfacing and wear coatings needs a clean margin number for a thermal spray, hardfacing and wear coatings go / no-go review.

The inputs for this scenario

  • As-sprayed coating thickness: 310 units (raised for this scenario; the documented default is 125)
  • Final finished coating thickness: 100 units (unchanged)
  • Nominal finished thickness reference: 100 units (unchanged)

Working through the calculation

  • Applying the documented formula (Finish Grind Allowance margin = available value - required value) to the inputs above produces each figure below.
  • At this operating point the engine returns 210 % for margin, the number this scenario is built around.
  • At this operating point the engine returns 210 value for absolute margin.
  • At this operating point the engine returns 310 value for available amount.
  • At this operating point the engine returns 100 value for required amount.

How this compares with the baseline

  • Against the tool's baseline example, where as-sprayed coating thickness sits at 125 units and the headline result is 25 %, this scenario comes in 740% above the baseline at 210 %.
  • A figure at this level is achievable when as-sprayed coating thickness is genuinely sustained, not just peaked for a shift. It is a one-dimensional stock check — it does not account for grind wheel wear, coating hardness, or run-out that may demand more allowance on out-of-round or warped parts.

Results at a glance

  • Margin: 210 % (headline result)
  • Absolute margin: 210 value
  • Available amount: 310 value
  • Required amount: 100 value

Run it with your numbers

  • Every input above is editable in the live Finish Grind Allowance calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.