The surface finish characteristics of thermally applied coatings are an important component in establishing the resultant wear and friction values of the tribological systems. An ongoing issue, in terms of specifying and measuring the surface finish of the thermally applied coatings, is the inability to separate the inherent surface finish from the effect of porosity. The paper provides data developed utilizing a recently developed three dimensional surface finish measuring system for quantifying finish of thermally applied cylinder bore coatings. The advanced Three Dimensional Surface Finish System quantifies: • Surface finish values over the total area of use with a 95% confidence value with and without including the effect of porosity • Size distribution and percent area occupied by the surface porosity • Torn and folded material developed as a result of the honing or grinding process in applications such as engine cylinder bores • Hone angles in cylinder bore or grinding lead angles on seal surfaces.

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