Table of Contents

1. Introduction
2. Documentation
3. Section & Cutting
4. Mounting
5. Planner Grinding
6. Rough Polishing
7. Final Polishing
8. Etching
9. Microscopic Analysis
10. Metallographic Analysis
11. References

Introduction

Metallography is the study of a materials microstructure. Analysis of a materials

microstructure aids in determining if the material has been processed correctly and is
therefore a critical step for determining product reliability and for determining why a material
failed. The basic steps for proper metallographic specimen preparation include: sectioning
and cutting, mounting, planar grinding, rough polishing, final polishing, etching, microscopic
analysis, and hardness testing.
The microstructure - inclusions, grains, or matrix - has a significant effect on the
macroscopic properties of alloys, e.g., tensile strength ,elongation, and both thermal and
electrical conductivity. The understanding of the relationship between composition,
microstructure, and macroscopic properties plays a key role in the development and
manufacture of alloys, where metallography is often exploited.

Documentation
Metallographic analysis is a valuable tool. By properly documenting the initial provides a
powerful quality control as well as an invaluable investigative tool.

Section and Cutting

We use following steps for sectioning and cutting of a small specimen from work piece : First we define the intended sectional plane and marks it on work piece.
Than we put the work piece in oppressive sort and fix it securely, selects the cutting
parameters and starts first oppressive cutting.
Intensive water cooling and Appropriate cutting parameters to keep the material as
cool as possible.
Then specimen is placed in Ultra sonic cleaner bar for a few seconds. Alcohol and
ultra sonic waves help to remove loose particles from the surface.
After that we use hot air, now the specimen is dry and clean for mount.
Proper sectioning is required to minimize damage, which may alter the
microstructure and produce false metallographic characterization.
Proper cutting requires the correct selection of abrasive type, bonding, and size; as
well as proper cutting speed, load and coolant.

Mounting
The mounting operation accomplishes three important functions: 1. It protects the specimen edge and maintains the integrity of a material surface
features.
2. Fills voids in porous materials.
3. Improves handling of irregular shaped samples.

Mounting Process
To mount the specimen small plastic molds are suitable, then we put clear specimen
carefully places it in the mold.
The intended plane of the examination must be at the bottom.
Than we pour a mixture of cold settling compound hardner and cold settling
compound binder into the mold.
After 25-30 min. we remove the resin from mold but the specimen surface is still
uneven and slightly sticky.

Planer Grinding
Planer grinding is required to planarize the specimen and to reduce the damage
created by sectioning.
The planar grinding step is accomplished by decreasing the abrasive grit/ particle size
sequentially to obtain surface finishes that are ready for polishing.
We use more coarse paper for planer grinding.
We use silicon carbide waterproof paper of P 60 grade for planer grinding.

Care must be taken to avoid being too abrasive in this step, and actually creating
greater specimen damage than produced during cutting.

Rough Polishing
The purpose of the rough polishing step is to remove the damage produced during
cutting and planar grinding.
We use four different silicon carbide waterproof papers for rough polishing:

First we use P 220 grade paper for polishing.

Then we use P 320 grade paper for polishing.

After that we use P 400 grade paper for polishing.

Finally, we use P 600 grade paper for rough polishing of metal specimen

Proper rough polishing will maintain specimen flatness and retain all inclusions or
secondary phases.
Make sure to press the specimen calmly and evenly on the paper.

After the rough polishing the specimen surface is almost mirror like, no more
scratches can be seen from naked eyes.

Final Polishing
The purpose of final polishing is to remove only surface damage.
It should not be used to remove any damage remaining from cutting and planar
grinding. If the damage from these steps is not complete, the rough polishing step
should be repeated or continued.
High napped polishing pads are the most common final polishing cloths for metals
and polymers. Its high nap provides it a very soft and gentle polishing action.
We use colloidal alumina as polishing abrasive.
The polishing times should nominally be less than 30 seconds.
Put less pressure on the specimen during final polishing.
At the end of the final polishing special care has to be taken to clean the specimen.

Etching
The purpose of etching is to optically enhance microstructural features such as grain
size and phase features.
Etching selectively alters these microstructural features based on composition, stress,
or crystal structure.
The most common technique for etching is selective chemical etching.
Chemical etching selectively attacks specific microstructural features. It generally
consists of a mixture of acids or bases with oxidizing or reducing agents.
We use NITAL solution (a mixture 2% of Nitric acid + 98% of Ethyl alcohol) for
etching of steel specimen.
We dip the specimen in NITAL solution for 1-3 minutes.
Now the specimen is ready for microscopic analysis.

Microscopic Analysis
First we put the steel specimen onto the microscope, be careful that always put
prepare surface faces downward.

 Using the built in digital camera the polished specimen surface can be observed on the
monitor screen.
If one wants to see crystals, grains and grain boundaries than the micro section has to
be etched.

Metallographic Analysis

Metallurgical analysis (metallography) of the microstructural provides the Material

Scientist or Metallurgist information varying from phase structure, grain size,
solidification structure, casting voids, etc.
We see the micro structure of steel specimen and compare it with the standard results
required for steel casting.
The standard microstructure of cast steel is as cast steel containing pearlite and ferrite
with widmanstalten pattern of ferrite.

References

http://www.metallographic.com/Basics.htm
www.leica-microsystems.com
Metallography: Principles and Practice, G.F. Vander Voort, ASM International,
Materials Park, OH, 1999
Video on metallography Metallography Part II - Microscopic Techniques, Karlsruhe
University of Applied Sciences.