High-velocity oxyfuel (HVOF) coatings are used to protect components from corrosion and wear at higher temperatures and from wearing out after a certain period of time. Hence, to enhance the life of components, further recoating is required, but removing the older coating is a challenging task due to its high hardness. Thus, this research work studied the electrolytic dissolution process of removing WC-CoCr 86/10/4 HVOF coatings and found that at a voltage of 3 V, the coating was not removed, but at a slightly higher voltage of 6 V, the coating was removed completely. When the voltage was 12 V, the surface was damaged, and corrosion also occurred. A combination of tartaric acid (C₄H₆O₆), sodium bicarbonate (NaHCO₃), and water was used as an electrolyte. By using a combination of a voltage of 4.5 V, a current of 1.6 A, and an electrode distance of 55 mm, the coating was completely removed after 10 h, with negligible attacks on the base material. Where the corrosion of the base material is unacceptable, voltages in the range of 4 to 6 V are recommended. If parts have coatings on all surfaces, a voltage within the range of 6 to 12 V can be recommended. The coating from tab SB-002JI-5 TOOLOX-11 and hexagonal mandrel SB-00EA-1 160 TIS was also removed successfully.

Quantitative X-ray computed tomography (XCT) porosity measurement cannot always be represented adequately by a single result for the complete scan when a measured object contains pores of different size and geometry. This study investigates a task-specific approach to quantitative porosity measurement using a reference object containing six artificial internal cavities of varied size and geometry, calibrated using confocal microscopy. The objective is to determine whether and to what extent various acquisition parameter settings influence measurement accuracy differently across porosity measurement tasks represented by diverse pore geometries. An acquisition mapping varied voxel size, acceleration voltage, tube current setting and integration time. For objective comparison of pore volume measurement accuracy between acquisition settings, the weighted pore volume deviation Dweighted was adopted as the primary metric. Response spans of 41.44 percentage points for voxel size, 6.58 percentage points for current setting and 3.50 percentage points for acceleration voltage established voxel size as the dominant acquisition parameter within the tested task. The mean Dweighted response increased from 7.85% at 12.5 µm voxel size to 20.98% at 25 µm and 49.29% at 50 µm. The mean deviation with equal pore weighting, Dmean, retained the same hierarchy but produced different numerical magnitudes, demonstrating that aggregate and equally weighted pore interpretations answer different measurement questions. Regimes selected during screening as lower- and higher-deviation conditions remained clearly distinguishable under repeated measurement at 12.5 and 25 µm voxel size, as quantified by the separation-to-repeatability index (Isep = 8.24 and 4.15) but not at 50 µm voxel size (Isep = 0.78), where repeated measurements no longer reproduced the screening-based ranking. The results support a hierarchical approach to optimizing XCT acquisition parameters: establish adequate spatial sampling first, then tune secondary acquisition parameters within that sampling class and interpret global porosity metrics relative to the specific measurement task.