The characterization of a thermal barrier coating (TBC) using routine metallographic methods has had investigators uncertain as to the authenticity of the microstructure concerning porosity, cracking and other features. Mounting is a very important step in the process. A greater understanding of relationships between high and low viscosity mounting epoxies exposed to vacuum impregnation, pressure impregnation procedures (PIP), and the combined methods is the goal of this paper. This study will attempt to show how variations in sample mounting procedures will affect the final results in conjunction with varied metallographic procedures.