Microstructural evaluation is a common approach for determining the quality of thermal spray coatings. The need for careful consideration of the mounting material is realized due to the inconsistent quantitative measurements attained, in this article, using automated image analysis to evaluate optical microscopic images. Various epoxy and embedding techniques are used. The layers selected for these investigations included both porous and dense, ductile EAS Cu-base layers, plasma-sprayed, porous nickel-aluminum, YSZ, tungsten carbide and dense HVOF-sprayed aluminum oxide-titanium dioxide, chromium carbide, and tungsten carbide layers. The results suggest a significant influence on the measured values and suggest that the embedding method must be carefully selected. Paper includes a German-language abstract.

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