Designation: E768 − 99 (Reapproved 2010)

Standard Guide for

Preparing and Evaluating Specimens for Automatic
Inclusion Assessment of Steel1
This standard is issued under the fixed designation E768; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.

1. Scope 2.2 ASTM Adjuncts:5

1.1 This guide2 covers two preparation methods for steel ADJE0768 Differential Interference Contrast Magnification
metallographic specimens that will be analyzed for nonmetallic 100X and 500X (6 micrographs)
inclusions with automatic image analysis (AIA) equipment. 3. Terminology
The two methods of preparation are offered as accepted
methods used to retain nonmetallic inclusions in steel. This 3.1 Definitions:
guide does not limit the user to these methods. 3.1.1 For definitions used in this practice, refer to Termi-
nology E7.
1.2 A procedure to test the suitability of the prepared 3.1.2 differential interference contrast microscopy—a com-
specimen for AIA inclusion work, using differential interfer- prehensive definition appears in Guide E883, paragraph 11.8.
ence contrast (DIC), is presented.
3.2 Definitions of Terms Specific to This Standard:
1.3 The values stated in SI units are to be regarded as 3.2.1 rigid grinding disk—a non-fabric support surface,
standard. No other units of measurement are included in this such as a composite of metal/ceramic or metal/polymer,
standard. charged with an abrasive (usually 6 to 15-µm diamond
particles), and used as the fine grinding operation in a metal-
2. Referenced Documents lographic preparation procedure.
2.1 ASTM Standards:3
E3 Guide for Preparation of Metallographic Specimens 4. Significance and Use
E7 Terminology Relating to Metallography 4.1 Inclusion ratings done either manually using Test Meth-
E45 Test Methods for Determining the Inclusion Content of ods E45 or automatically using Practice E1122 or E1245 are
Steel influenced by the quality of specimen preparation. This guide
E883 Guide for Reflected–Light Photomicrography provides examples of proven specimen preparation methods
E1122 Practice for Obtaining JK Inclusion Ratings Using that retain inclusions in polished steel specimens.
Automatic Image Analysis (Withdrawn 2006)4
4.2 This guide provides a procedure to determine if the
E1245 Practice for Determining the Inclusion or Second-
prepared specimens are of suitable quality for subsequent
Phase Constituent Content of Metals by Automatic Image
rating of inclusions. None of these methods should be con-
Analysis
strued as defining or establishing specific procedures or limits
of acceptability for any steel grade.
1
This guide is under the jurisdiction of ASTM Committee E04 on Metallography 5. Preparation Methods
and is the direct responsibility of Subcommittee E04.01 on Specimen Preparation.
Current edition approved Nov. 1, 2010. Published January 2011. Originally 5.1 Background:
approved in 1999. Last previous edition approved in 2005 as E768–99(2005). DOI: 5.1.1 The inclusions in the plane of polish must be fully
10.1520/E0768-99R10.
2
Supporting data have been filed at ASTM International Headquarters and may
preserved and clearly visible. Preparation should not produce
be obtained by requesting Research Report RR:E04-1002. excessive relief around the perimeter of the inclusions that
3
For referenced ASTM standards, visit the ASTM website, www.astm.org, or would exaggerate the size and number of inclusions on the
contact ASTM Customer Service at [email protected]. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
5
the ASTM website. A colored plate, consisting of six micrographs that illustrate the use of DIC in
4
The last approved version of this historical standard is referenced on determining a properly prepared sample (at 100x and 500x), is available from
www.astm.org. ASTM Headquarters. Order Adjuct: ADJE0768.

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 E768 − 99 (2010)
plane of polish. In many cases, the preparation of specimens TABLE 1 Comparison of ANSI (CAMI) versus FEPA versus
for inclusion rating is more readily performed after the Median Diameter of Grit Size in Micrometers
specimens have been hardened by a suitable heat treatment ANSIA (CAMI)B FEPAC Approximate Median
Diameter
procedure (austenize, quench to fully martensitic structure, (µm)
temper at a relatively low temperature). 60 P60 250
5.1.2 Cleanliness is an important consideration in all stages 80 P80 180
of specimen preparation. 100 P100 150
120 P120 125
5.1.2.1 Heat-treated specimens should be wire brushed or 150 P150 90
shot blasted or have the surface ground to remove adherent 180 P180 75
220 P220 63
scale. 240 P240 58.5
5.1.2.2 After completing the grinding steps and before P280 52.2
performing the polishing steps, the specimens and specimen 280 P320 46.2
320 P360 40.5
holders must be cleaned to prevent contamination of the next P400 35.0
preparation step. Cleaning the specimens and specimen holders 360 P500 30.2
between each grinding step can eliminate contamination of 400 P600 25.8
P800 21.8
coarse abrasives to the following finer preparation step. 500 P1000 18.3
5.1.2.3 After the preparation is complete, swab the surface 600 P1200 15.3
800 P2400 8.4
carefully with cotton and a water/soap solution containing a 1200 P4000D 3.0
corrosion inhibitor such as a machine coolant or ethyl alcohol A
ANSI - American National Standards Institute
solution to remove any films or other debris that would B
CAMI - Coated Abrasives Manufacturers Institute
interfere with the inclusion rating. C
FEPA - Federation of European Abrasive Producers
D
Not a FEPA designation
5.1.2.4 It is advisable to perform the inclusion analysis as
soon as possible after preparation to minimize staining or other
problems that can affect the analysis.
5.1.3 The two methods that follow have been found to be
reliable procedures for retaining inclusions in steel and achiev- 5.2.2.1 Low pressures are recommended to ensure the
ing the desired results when evaluated by DIC. There are other retention of an assortment of inclusion types found in a variety
methods that will result in a quality specimen as revealed by of steel grades. The relatively low pressures suggested in this
DIC. Each laboratory should develop preparation procedures procedure will not necessarily result in a satisfactory polish for
for their materials so that the prepared surfaces meet the etching and the further evaluation of the specimen’s general
requirements presented in 6 of this guide. microstructure. The pressures used in the following rigid disk
5.1.4 As described in Prractice E3, the specimens may be procedure are more likely to result in a surface more satisfac-
sectioned and mounted to ease handling during preparation. It tory for revealing general microstructures.
is advisable to use a mounting medium that is hard enough to 5.2.3 Grind the specimens on ANSI 80 grit (P80 FEPA)
preserve edges and maintain flatness. silicon carbide paper to ensure all sectioning artifacts and
5.1.5 Abrasive grit size designations in this guide are deformation damage have been removed and the entire speci-
expressed in the American National Standards Institute (ANSI) men surface is co-planar to the grinding surface.
or Coated Abrasives Manufacturers Institute (CAMI) system
NOTE 2—If the sectioning method resulted in a smooth face and little
units with the corresponding Federation of European Abrasive deformation damage, and if after securing the specimens in a fixture for
Procedure (FEPA) numbers in parentheses. Table 1 provides a polishing, the entire surface of interest is co-planar to the grinding surface,
correlation between these two systems and the approximate then finer grit papers, such as ANSI 180 to 240 (P180 to P240 FEPA) can
median particle diameter for a given grit size in micrometres. be used for the initial grinding step.
5.1.6 Most preparation systems apply pressure on the speci- 5.2.3.1 An adequate flow of water should remove all loos-
mens being processed. The best pressure to be used for each ened abrasive and grinding debris from the paper during the
preparation step should be determined experimentally. Conver- grinding procedure. The flow of water should ensure the
sions between applied force and pressure are discussed in the specimen is kept cool during grinding.
Appendix X1. 5.2.4 Continue grinding through the sequence of silicon
carbide papers listed in Table 2. It may be necessary to clean
NOTE 1—Care must be taken to protect the polished specimen surface
from scratches or contaminants when using a specimen leveling device.
the samples between every grinding step to prevent contami-
nation of the next preparation step.
5.2 Silicon Carbide Procedure: 5.2.5 After completing the entire grinding operation, clean
5.2.1 A summary of the silicon carbide procedure can be the specimens thoroughly, using ethyl alcohol and cotton, then
found in Table 2. rinse and dry. Ultrasonic cleaning can be used.
5.2.2 When using a semi-automatic polishing equipment, 5.2.5.1 The use of a soap and water solution in an ultrasonic
grinding and polishing should be performed using approxi- cleaner can attack non-metallic inclusions in some carbon and
mately 18 kPa pressure per specimen. (For a specimen holder low alloy steels, leading to an exaggeration in the inclusion’s
containing six 32-mm mounts, a force of approximately 87 N apparent size. Adding an inhibitor (such as that used as a
must be applied (see X1.4.2). machining coolant) may reduce this size exaggeration.

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 E768 − 99 (2010)
TABLE 2 Preparation Method I Silicon Carbide Abrasive Paper Grinding
Surface Coolent/ Abrasive Size/Type Time ForceC Surface Relative Rotation
Lubricant ANSIA [FEPA]B (seconds) newtons [lbs] Speed
RPM
Planar Grinding
Paper Water 80 [P80] grit SIC 60 14 [2] 300 ComplementaryD
Fine Grinding
Paper Water 120 [P120] grit SIC 14 [2] 300 Complementary
Paper Water 240 [P240] grit SIC 60 14 [2] 300 Complementary
Paper Water 320 [P500] grit SIC 60 14 [2] 300 Complimentary
Paper Water 400 [P600] grit SIC 60 14 [2] 300 Complementary
Paper Water 600 [P1200] grit SIC 60 14 [2] 300 Complimentary
Paper Water 800[P2400] grit SIC 60 14 [2] 300 Complementary
Rough Polishing
NAP free cloth Extending fluid 3 µm diamond 50 14 [2] 150 Complementary
Final Polishing
Low nap cloth Extending fluid 1 µm diamond 50 14 [2] 150 Complementary
Optional Polishing (manual)
Low nap cloth Extending fluid 1 µm diamond 50 relatively high NA NAE
A
American National Standards Institute (ANSI) designation of grit size.
B
Federation of European Producers of Abrasives (FEPA) designation of grit size.
C
Force per 3-mm (1.25-in.) diameter specimen.
D
Complementary rotation, surface and specimens spin in same direction.
E
Since this optional step is completed manually, these two categories are not applicable.

5.2.6 Polish the specimens using 3-µm diamond abrasive on 5.3.1 A summary of the rigid grinding disk procedure can be
a low nap cloth, such as woven wool, for 50 s. Clean and dry found in Table 3.
the specimens as described in 5.2.5. 5.3.2 Semi-automatic grinding equipment is required, with
5.2.7 Polish the specimens using a 1-µm diamond abrasive specimens contained in a circular fixture for the entire proce-
on a high nap cloth for 50 s. Clean and dry the specimens as dure. For 5.3.2-5.3.5, a pressure of 42 kPa should be applied
described in 5.2.5. per specimen. (For a specimen holder containing six 32-mm
5.2.8 A final manual polishing step may be added, using circular mounts, a force of approximately 203 N must be
0.25-µm diamond abrasive on a low nap cloth for 10 to 20 s,
applied (see X1.4.3).
using relatively high pressure. Clean and dry the specimens as
described in 5.2.5. 5.3.3 Grind for at least 15 s after achieving a co-planar
5.2.8.1 Ultrasonic cleaning is not recommended after the condition, using a 150-grit alumina grinding stone at 1450 rpm
final manual or automatic polishing step. Ultrasonic cleaning or 80-grit (P80 FEPA) alumina/zirconia grinding paper at 300
can cause cavitation damage, ultimately distorting the inclu- rpm.
sion sizes. 5.3.3.1 An adequate flow of water should remove all loos-
NOTE 3—Depending on the material, it may be advisable to avoid water ened abrasive and grinding debris from the paper during the
after polishing. grinding procedure. The flow of water should ensure the
5.3 Rigid Grinding Disk Procedure: specimen is kept cool during grinding.

TABLE 3 Preparation Method II - Rigid Grinding Disk Procedure

Surface Coolant/ Abrasive Size/Type ANSIA Time - seconds ForceC Surface Speed Relative Rotation
Lubricant [FEPA]B newtons [lbs] RPM
Planar Grinding
Alumina/zirconia paper Water 80 [P80] grit >15 34 [8] 300 ComplementaryD
Or
Alumina grinding stone Water 150 [P150] grit >15 34 [8] 1450 Complementary
Fine Grinding
Rigid grinding disk Alcohol/glycol 9 µm diamond 180 34 [8] 150 Complementary
Rough Polishing
Napless or stiff napped cloth Alcohol/glycol 3 µm diamond 240 34 [8] 150 Complementary
Final Polishing
Soft short napped cloth Alcohol/glycol 1 µm diamond 120 34 [8] 150 Complementary
Optional Polishing
Porous Synthetic Cloth Water Alkaline Colloidal Silica or 90 100 [23] 150 Complementary
Acidic Colloidal AluminaE
A
American National Standards Institute (ANSI) designation of grit size.
B
Federation of European Producers of Abrasives (FEPA) designation of grit size.
C
Force per 32-mm (1.25-in.) diameter specimen.
D
Complementary rotation surface, and specimens spin in same direction.
E
Water is substituted for the colloidal oxide during the last 20 s.

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 E768 − 99 (2010)
5.3.3.2 It may be necessary to clean the samples between condition, using a first order gypsum (1l) plate, is the most
every grinding step to prevent contamination of the next useful mode of DIC illumination (plane areas magenta; inclu-
preparation step. sions dark).
5.3.4 Finish grind using 9-µm diamond on a rigid grinding 6.2 Observation at 100x will reveal whether residual
disk for 3 m at 150 rpm, using an alcohol/glycol lubricant. scratches are present and whether background relief is evident.
Clean the specimens and fixture thoroughly (ultrasonic clean- 6.3 At 500x in the DIC sensitive tint condition, all of the
ing is helpful) with alcohol and cotton, then dry with forced air. edges of inclusion particles should be sharp and recognizable
5.3.4.1 The use of a soap and water solution in an ultrasonic as sharp edges. Narrow bright lines indicating narrow ditches
cleaner can attack non-metallic inclusions in some carbon and at some inclusion edges may, however, still be seen. A test may
low alloy steels, leading to an exaggeration in the inclusion’s be made to determine whether these ditches will be detected by
apparent size. Adding an inhibitor (such as that used as a the image analysis system.
machining coolant) may reduce this size exaggeration. 6.3.1 The polarizer is slowly rotated away from the full DIC
5.3.5 Rough polish using 3-µm diamond on a napless cloth position and the inclusion edges watched for apparent motion.
(silk or non-woven chemotextile) or a low nap cloth (woven There could be a critical trough configuration beyond which
wool) for 4 min at 150 rpm using alcohol/glycol lubricant. the bright troughs turn black at some point in the transition to
Clean as in 5.3.4. bright field illumination, and the inclusions appear to become
5.3.6 Final polish using 1-µm diamond on a high nap cloth larger. This condition indicates insufficient preparation. (The
for 2 min at 150 rpm, using alcohol/glycol lubricant. Clean as use of a filar eyepiece may be helpful at this point to determine
in 5.3.4. whether the inclusion through has widened)
5.3.6.1 Ultrasonic cleaning is not recommended after the 6.3.2 Narrow troughs can be accepted as harmless if they
final polishing step. Ultrasonic cleaning can cause cavitation vanish into the background when the polarizer is opened a
damage, ultimately distorting the inclusion sizes. small part of its range.
5.3.7 An optional oxide-polishing step, using a porous 6.4 Some fine scratches from final polishing will usually be
synthetic cloth with either alkaline colloidal silica or acidic seen under DIC at 500x. These normally also vanish on
colloidal alumina, may be used if necessary to eliminate fine opening the polarizer and, therefore, should not affect quanti-
scratches. The conditions are 90 s at 150 rpm, 100 N, with tative measurement at lower magnification.
water substituted for the colloidal oxide during the last 20 s. NOTE 4—While highly instructive, the DIC examination remains
Clean as in 5.3.4. subjective with respect to the question of whether a reproducible and
accurate surface preparation has been obtained. Tests by actual measure-
6. DIC Evaluation Method5 ment are necessary to determine that errors in specimen preparation were
not contributory to outlier observations.
6.1 A microscope equipped with DIC illumination at mag-
nifications of about 100x and 500x should be used while 7. Keywords
developing the preparation procedure to verify the true surface 7.1 automatic image analysis; differential interference con-
topography of properly prepared specimens. The sensitive tint trast; inclusions; specimen preparation; steel

APPENDIX

(Nonmandatory Information)

X1. APPLIED LOAD CONVERSIONS

X1.1 Automatic preparation machines commonly display and display the applied load accordingly.
applied force in either pound-force (lbf) or newtons (N). The
ability to convert from one unit to another may be necessary X1.3 Caution should be taken when using automated ma-
when trying to interpret a documented procedure. chines that display pressure in pound-force per square inch
(psi). Typically, the machine is displaying the air pressure
X1.1.1 To convert from pound-force to newton, multiply the within the loading cylinder and not the true pressure applied to
pound-force value by 4.5. either the specimen holder or each individual specimen.
X1.1.2 To convert from newton to pound-force, multiply the
X1.4 When converting from a force to a pressure, the
newton value by 0.225.
surface area of the specimen must be determined. The value of
X1.2 When multiple specimens are held in a holder, the force is then divided by the contact area to determine the
applied force must be divided by the number of specimens in required pressure.
the holder to determine the load per specimen. Some auto- X1.4.1 Example 1—What is the force in pound-force if 87 N
mated machines apply the load individually to each specimen is applied?

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 E768 − 99 (2010)
~ 87 N ! 3 ~ 0.225! 5 19.6 lbf (X1.1) X1.4.3 Example 3—What is the applied load, in newtons,
X1.4.2 Example 2—What is the applied load, in newtons, required to apply a pressure of kPa to an individual specimen
required to apply a pressure of 18 kPa to an individual in a holder containing six 32-mm mounts?
specimen in a holder containing six 32-mm circular mounts? Pressure = (Force)/(Area), therefore . . . Force = (Pressure)
Pressure = (Force)/(Area), therefore . . . Force = (Pressure) × (Area)
× (Area) Area = P r2 = P (16)2 = 804.25 mm2
Area = P r2 = P (16)2 = 804.25 mm2 Total Area = (6 mounts) × (804.25 mm2 = 4825.5 mm2
Total Area = (6 mounts) × (804.25 mm2) = 4825.5 mm2
18 kPa = 18 000 Pa = 18 000 N/m2 = 0.018 N/mm2 42 kPa = 42 000 Pa = 42 000 N/m2 = 0.042 N/mm2
Therefore, Therefore,
Force = (0.018 N/mm2) × 4825.5 mm2) = 86.9 N Force = (0.042 N/mm2) × 4825.5 mm2) = 203 N

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