Thermal Spray, Hardfacing & Wear Coatings worked example

Finish Grind Allowance with as-sprayed coating thickness of 63 units: a worked example

Suppose as-sprayed coating thickness falls to 63 units. This page works the full calculation at that level so you can see exactly which result moves and by how much. Finish Grind Allowance is the extra coating you deliberately spray so grinding can bring a hardfaced or wear-coated surface down to final size and finish.

The inputs for this scenario

  • As-sprayed coating thickness: 63 units (the input this scenario stresses; the baseline uses 125)
  • Final finished coating thickness: 100 units (held at the documented default)
  • Nominal finished thickness reference: 100 units (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Finish Grind Allowance margin = available value - required value.
  • Margin works out to -37 % at these inputs, and this is the headline figure for the scenario.
  • Absolute margin works out to -37 value at these inputs.
  • Available amount works out to 63 value at these inputs.
  • Required amount works out to 100 value at these inputs.

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 248% below the baseline at -37 %.
  • It computes the grind margin as as-sprayed thickness minus finished thickness, then expresses that margin as a percent of a nominal reference thickness. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Margin: -37 % (headline result)
  • Absolute margin: -37 value
  • Available amount: 63 value
  • Required amount: 100 value

Run it with your numbers

  • To rerun this with your own numbers, open the live Finish Grind Allowance calculator, set as-sprayed coating thickness to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.