Thickness Gauges

Thickness gauges, digital or LCD, are precision tools used to measure the thickness measurements of parts, materials, or coatings in a wide range of applications. While some gauges employ a mechanical jaw that is closed and reset to zero, then opened to fit around the material or part to provide a thickness readout. Others utilise advanced techniques like ultrasonic waves or electromagnetic principles to measure thickness without physical contact. The choice of gauge depends on the material being measured, the required accuracy, and the accessibility of the measurement location.

Types of Thickness Gauges

Essential tools for various industries, different types of thickness gauges are available to cater to specific needs and applications:

Coating Thickness Gauges

These devices specialise in measuring the thickness of coatings applied to various substrates, such as paint on metal, plastic coatings on electronics, or plating on metallic parts. They utilise methods like magnetic induction, eddy current, or ultrasonic technology, depending on the coating and substrate.

Ultrasonic Thickness Gauge

Employing sound waves, these gauges measure thickness from one side, making them ideal for limited access applications where access to both sides of the material is limited. They are widely used to measure the thickness of pipes, tanks, and structures, including materials like steel, aluminium, plastics, and composites. These gauges offer high accuracy, and ease of use, and often include features like data logging and digital displays.

Mechanical Thickness Gauges (Callipers/Micrometres)

Traditional instruments that use a mechanical jaw or spindle to physically measure thickness. They are simple to use and provide direct readings but require access to both sides of the material. They are often used for general-purpose measurements and calibration checks.

Mini Thickness Gauge

These compact and portable devices are designed for measuring thin materials like paper, film, and foil. They find applications in industries such as packaging, printing, and electronics manufacturing where space is limited, and portability is essential.

Thickness Meter

This broad category encompasses various gauges that utilise mechanical contact or ultrasonic methods to measure material thickness. Examples include thickness meters for steel, which often use magnetic induction, and thickness gauge meters for plastic films, which may employ capacitive or optical methods.

Electromagnetic Thickness Gauges

These gauges use electromagnetic principles to measure the thickness of non-conductive materials, such as plastics, composites, and coatings. They are often used in the automotive, aerospace, and construction industries.

Factors to Consider When Choosing a Thickness Gauge

Selecting the right thickness gauge involves evaluating several key factors to ensure accurate and reliable measurements for your specific needs. These factors include:

• Accuracy: Choose a gauge with an accuracy level that aligns with the precision required for your application to prevent errors in manufacturing, potential safety hazards, wasted resources, and failed inspections.
• Resolution: Resolution represents the smallest detectable difference in thickness that the gauge can discern. A higher resolution allows for more precise measurements of subtle variations in thickness.
• Measurement Range: The measurement range indicates the minimum and maximum thickness the gauge can measure. Ensure the gauge's range encompasses the thicknesses you typically work with.
• Type of Material: Different materials require different types of gauges. Consider compatibility with ferrous metals, non-ferrous metals, or other materials.
• Measurement Method: Choose from various methods like mechanical contact, magnetic induction, eddy current, or ultrasonic, depending on the application and material properties.
• Ease of Use: Look for gauges with clear displays, intuitive controls, and ergonomic designs for user-friendly operation.
• Calibration and Certification: Ensure easy calibration and the availability of calibration certificates for traceability and compliance with industry standards.
• Durability and Build Quality: Choose robust gauges with features like water resistance or shock resistance, especially for use in harsh environments.
• Portability: Consider compact and lightweight gauges for convenient use in fieldwork or on-site measurements.
• Data Logging and Connectivity: Evaluate features like backlighting, data logging, and connectivity options for enhanced data analysis and reporting.

Important Features of Thickness Gauges

Thickness gauges come with various features that enhance their functionality and usability across different applications:

• Non-destructive Testing (NDT): Many gauges utilise NDT methods like ultrasonic waves or eddy currents to measure thickness without damaging the material, preserving its integrity.
• High Level of Accuracy: Thickness gauges offer a high level of accuracy, ensuring precise measurements for quality control, compliance with standards, and proper functioning of components.
• Digital, LCD Display: Most modern gauges feature digital LCD displays for clear and easy-to-read measurements, eliminating the need for manual interpretation and reducing errors.
• Single Sided Access (Ultrasonic Gauges): Ultrasonic gauges can measure thickness from one side, ideal for situations where access to both sides is limited.
• Simple and Quick to Use: Gauges are designed for user-friendly operation with intuitive controls and interfaces, enabling efficient and quick measurements.
• A-Scan Display (Ultrasonic Gauges): Some advanced ultrasonic gauges offer an A-scan display, which shows the waveform of the ultrasonic signal, allowing for more detailed analysis and identification of potential defects within the material.
• Automatic Material Compensation: Some gauges offer automatic material compensation, which adjusts the measurement based on the material being tested, improving accuracy and reducing the need for manual calibration.
• Statistics Mode: Certain models provide statistical analysis capabilities, such as calculating the average, minimum, maximum, and standard deviation of a series of measurements.
• Alarm Function: Some gauges feature an alarm function that alerts the user when the measured thickness exceeds or falls below a predefined threshold.

Industrial Application of Thickness Gauges

Thickness gauges are vital tools in various industries for diverse applications:

• Mechanical Engineering: Used to measure the thickness of components, parts, and assemblies to ensure they meet design specifications and tolerances.
• Metal Fabrication: Crucial for quality control in metal fabrication by accurately measuring the thickness of sheet metal, plates, and components during manufacturing.
• Vehicle Restoration: Assess the thickness of paint and body filler on vehicles to determine the extent of previous repairs and ensure proper restoration.
• Aerospace Industry: Ensure the structural integrity and safety of aircraft by accurately measuring the thickness of various components.
• Shipbuilding: Essential for measuring the thickness of hull plates and structural components to ensure strength and seaworthiness.
• Construction Industry: Verify the thickness of concrete structures, pipes, and building materials for compliance with building codes and safety regulations.
• Corrosion Monitoring: Assess the thickness of structures susceptible to corrosion to identify areas requiring maintenance or repair, preventing potential failures.
• Oil and Gas Industry: Crucial for measuring the thickness of pipelines, tanks, and equipment to ensure integrity and prevent leaks or spills.
• Electronics Manufacturing: Measuring the thickness of printed circuit boards, components, and materials to ensure proper functioning and performance in electronic devices.
• Food Industry: Helps to ensure food safety and preservation by accurately measuring the thickness of packaging materials.
• Textile Industry: Measure the thickness of fabrics, yarns, and textile materials for quality control and compliance with industry standards.
• Coating and Paint Industry: Wet film thickness gauges ensure even application and optimal performance of coating of paint while still in liquid form, allowing for adjustments before drying to achieve the desired effect.
• Railway Industry: Measure the thickness of rails, wheels, and components to ensure the safety and reliability of railway infrastructure and rolling stock.

Shop Thickness Gauges at RS Malaysia

Here at RS Malaysia, we support engineers with quality products and technical information, allowing you to find the right thickness gauge for your application. Our range of thickness gauges is of the highest quality and sourced from leading brands such as; Extech, Mitutoyo, and RS PRO.

Beyond thickness gauges, we offer a wide selection of tools, including moisture meters and data loggers, available for purchase online at competitive prices. Experience fast, nationwide doorstep delivery when you shop with RS Malaysia. For more information, visit our Delivery Page.