Density, hardness and bulk conductivity are useful indicators of lot shifts, but they do not locate defects inside a tip. Equal pore volume can affect heat and force paths differently when concentrated below the working face or dispersed throughout the body. Silver-rich regions and tungsten aggregates can also disappear within an acceptable average composition. Use convenient production measurements to complement section examination during qualification.

Sections should include functionally significant positions such as the contact center, edge and attachment region. One attractive micrograph cannot establish uniformity throughout a tip, and cutting direction or magnification changes the apparent connectivity. Silver smearing or particle pullout during preparation can resemble genuine pores. Standardize preparation and confirm questionable features using another section or analytical method.

Tungsten connections support the structure, but excessive contiguous networks can provide preferred crack paths; more connectivity is not always better. Define uniformity as control of harmful segregation and defects rather than perfect identity at every point. Acceptance should specify defect size and distribution together with examined area and location. Measurable criteria prevent differences in photographic appearance from being mistaken for quality differences.