5.1 Internal stress in applied coatings exhibits potential to cause a breakdown of resistance to corrosion and erosion as a result of the formation of fractures from micro-cracking and macro-cracking within the applied coating. This phenomenon can also cause blistering, peeling, reduction of fatigue strength, and loss. The resulting stress can be tensile in nature, causing the deposit to contract, or compressive in nature, causing the deposit to expand.

5.2 To maintain quality assurance by the bent strip method, it is necessary to monitor production processes for acceptable levels of internal deposit stress in applied coatings. Note that the highest value of the internal deposit stress as obtained on a stress-versus-coating-thickness curve is usually the truest value of the internal deposit stress. Most low values are false. Initial values tend to be lower than the actual value because of the effect of stock material edge burrs and the resistance of the stock material to bending. Excessive deposit thickness causes lower-than-true values since the coating overpowers and changes the initial modulus of elasticity of the test piece, which becomes more difficult to bend as the coating continues to build upon it. This phenomenon can be corrected considerably by use of a formula that compensates for modulus of elasticity differences between the deposit and the substrate materials, but it does remain a factor. See Eq 2.