Coating Failure Analysis Calculator

Evaluate coating system integrity from adhesion tests, thickness measurements, and service conditions to predict failure risk and identify failure modes.

Inputs

Pull-off adhesion (PSI)

Cross-cut rating (0-5)

Specified DFT (mils)

Measured DFT max (mils)

Measured DFT min (mils)

Years in service

Environment (1-5)

Tab to move between fields

Results

Failure risk score (0-100)

Remaining life (years)

Adhesion margin (%)25

DFT ratio (%)117

Thickness variation (%)42.9

Service life used (%)30

Cross Cut Name4B (Good)

Cross Cut PassYes

Risk LabelMODERATE

How to Use This Calculator

Enter Pull-off adhesion (PSI), Cross-cut rating (0-5), and Specified DFT (mils).
Set Measured DFT max (mils), Measured DFT min (mils), and Years in service.
Adjust Environment (1-5) as needed.
Review Failure risk score (0-100) and Remaining life (years).
Use Adhesion margin (%) and DFT ratio (%) to inform your decision.

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