Hi PlasmaGuy
to the Surface Engineering Forum.
Probably not the best person to answer this, but here goes. Assuming everything else is perfect, to remove surface texture I guess about 0.1 mm (0.004”) on coating thickness. This will depend though on your substrate preparation and spraying process. Everything else may not be perfect
so if we consider errors introduced during pre-coating machining, grit blasting, coating thickness variation, process induced distortion, measurement error, datum point errors etc., you could be looking at something like 0.5 mm (0.020”) on coating thickness.
I don't think every situation/job will be the same. Obviously, a safe point where we get no rejects for not cleaning up, but not too much safety that we are wasting expensive materials and time. I think you need initially to estimate all the compounding errors and add a little safety factor and then fine tune from practical experience.
Hopefully, someone with more practical production experience could comment