DJJ3213 : MATERIAL SCIENCE
LAB REPORT
EXPERIMENT NO :1
TITLE : METALLOGRAPHIC ANALYSIS
NAME : MOHD SAIFUL BIN SAFARI
: DKM 3 A/B/C/D
CLASS
:A/B/C/D
GROUP
: DIPLOMA IN MECHANICAL ENGINEERING
PROGRAMM
: 28/02/2020 (Friday)
E DATE
: EN. LEN BIN ANNUAR RIGOS
LECTURER
1
EXPERIMENT : 1
TITLE : METALLOGRAPHIC ANALYSIS
DATE / : 28/02/2020 (Friday)
DURATION
1.0 Experiment outcomes
To organize and prepare the metallographic sample for microstructures observation.
5m
2.0 Theory
Metallography consists of the study of the constitution and structure of metals and alloys. Much
can be learned through specimen examination with the naked eye, but more refined techniques
require magnification and preparation of the material's surface. Optical microscopy is sufficient
for general purpose examination; advanced examination and research laboratories often contain
electron microscopes (SEM and TEM), x-ray and electron diffractometers and possibly other
scanning devices.
Incorrect techniques in preparing a sample may result in altering the true microstructure and will
most likely lead to erroneous conclusions. It necessarily follows that the microstructure should
not be altered. Hot or cold working can occur during the specimen preparation process if the
metallurgist is not careful. Expertise at the methods employed to produce high-quality
metallographic samples requires training and practice. The basic techniques can be learned
through patient persistence in a matter of hours. Metallographic sample preparation involves
step-by-step processes which are sectioning, mounting, course & fine grinding, polishing, and
etching.
10m
3.0 Apparatus/Equipment’s
i) Mild steel;
ii) Bakelite powder;
iii) Silicon spray;
iv) Diamond polishing compound;
2
v) Nital solution (echant) and Alcohol solution;
vi) Specimen mounting press machine;
vii) Pre-grinder;
viii)Universal polisher;
ix) Ultrasonic cleaner;
x) Fume hood. 5m
4.0 Procedures
FINE GRINDING :
a) The specimen were rinsed.
b) Manual fine grinding was performed by drawing the specimens in one direction across
the surface of the water lubricated abrasive paper (Back to front is recommended). The
backward and forward motion was less desirable because there is a tendency to rock the
sample, producing a curved rather than a flat surface.
c) Began with the lowest grade abrasive paper (800 grit) and proceed to the highest (1200
grit).
d) Each fine grinding step should be performed in a direction off-angle to monitored
progress with respect to the previous step.
e) Fine grinding were been continued until the previous stage's scratches were gone. To
assure complete scratch removal, few extra stroke were used.
f) Sufficient water were applied to provide lubrication and the removal products were
flush away. Too much water will result in a hydroplaning action where the sample rides
on a film of water, thereby reducing the effectiveness of the abrasive. the valve at the
top of the roll-grinder are used to increase and decrease the quantity of water needed or
desired.
g) The specimen should be carefully rinsed after each step of fine grinding; debris from
one step must not contaminate the next step! The specimen rinsed very thoroughly
before proceeding to polishing. For the recommended method, the specimen were rinsed
by using ultrasonic cleaner.
3
POLISHING
a) Safety goggles are used when using the polisher.
b) The specimen and hands must be thorougly cleaned before polishing.
c) Polishing operation began with the 6-micron, nylon cloth polishing station.
d) The water were turn on by adjusting to less than one drop per second.
e) A small amount of Aluminium Oxide abrasive solution were applied to the polishing
cloth.
f) When polishing the specimen, it are holded by hands, the moderate amount of pressure
are applied and doesn’t not let it go. The rough Polishing Stage (6 micron) were taken
between 1 and 2 minutes each.
g) The Final Polishing station (1 micron) are proceeded when all of the marks are removed
at the 6 micron stage.
h) The specimen are holded with both hands and a small amount of pressure are applied.
The Final Polishing Stage (1-micron) are taken between 1/2 and 1 minutes.
i) Before proceeding to Etching, the specimen and hands are washed and dried thoroughly
and rinsed the specimen with distilled water. (DO NOT TOUCH THE SPECIMEN
SPACE).
ETCHING :
a) When etching, always weared acid resistant gloves
b) The specimen are placed on the table under the Fume Hood with the polished surface
up.
c) The Fume Hood were turn on.
d) Without touching the specimen surface, the surface are cleaned with alcohol and let it
dry with by using hot air gun.
e) Using the Eye-Dropper, a few drops of Etchant are applied to the specimen surface
covering the entire metalic surface of the specimen.
f) After about 20 to 30 seconds, the Etchant were rinsed into the sink with the water and
quickly rinsed the specimen with alcohol, but not touch the surface.
g) The Hot Air Gun are used to dry the sample.
h) If the specimen has many scratches and marks, returned to the fine grinding and go back
through the neccesary steps.
4
15m
5.0 Results/Data
15 mm
30 mm
Metallography Observation Record
Grind, polish, and etch the specimen given to you. Draw the microstructures you observe in
your specimens.
Grinding specimen
Magnification: M20 Magnification:M20
Specimen: Normalizing Specimen: No Heat
5
Polishing specimen
Magnification: M20 Magnification: M20
Specimen: Normalizing Specimen: No Heat
Etching specimen
Magnification: M20 Magnification: M20
Specimen: Normalizing Specimen: No Heat
6
20m
6.0 Discussion
Metallography is important to determine the structure of a material. It helps to identify spatial
distribution of the constituents, inclusions or phases in metallic alloys. Also by Metallography
can identify physical properties of a material such as strength, toughness, ductility, hardness and
etc. When it comes to choosing a material for some purpose it`s necessary to choose the right
material. Metallography can help to find correct material. Thus using metallography, cracksand
weak points in a material can be identified. To obtain a good sample of the specimen following
precautions are needed to be taken. Before analyzing the sample it’s necessary to follow above
steps carefully as listed in the introduction. Deferent materials need different grading techniques
and different lubricants. Also, when polishing, polishing agent may depend on the material.
When it’s come to etching, etching chemical solution and procedure to etching also depend on
the material. When sectioning and grinding, the heat need to be minimized to avoid alteration of
the surface properties. Usually when sectioning and grinding, water is used as a coolant. The
Microstructure is the small scale structure of a material, this can be seen on a prepared surface by
a microscope above 25× magnification. The microstructureof a material can strongly influence
physical properties such as strength, toughness, ductility, hardness, corrosion resistance,
high/low temperature behavior or wear resistance. By examining microstructure and using
microetching, following can be identified.
Macrostructural patterns resulting from solidification or working (growth patterns,
flow lines, banding, etc.)
Weld penetration depth and heat-affected zones
Physical discontinuities (porosity, cracking) due to solidification or working
Chemical and electrochemical surface modifications (decarburization, oxidation,
corrosion, contamination)
Case hardening depth (surface hardening) in steel alloys or patterns due to quenching
irregularities
Damage caused by improper grinding or machining
Thermal effects due to overheating or fatigue
7
CARBON CONTENT OF THE STEEL
Containing the compound of Carbon (C), thee amount of the dark areas, perlits per unit area can
give the Carbon content of steel. However, the microstructure of the specimen is not clear
enough to calculate this content, because the grain bounaries are not distrinct enough. The reason
of this situation is inadequate time of operation for etchant to attack and resolve details.
AVERAGE GRAIN DIAMETER
Average grain diameter of a micrstructure can be calculate with “Lineaar Intercept Method”. In
this method, the grains intercepted by a theoretical line on the specimen surface are counted.
The average grain size is indicate by teh inverse of the number of grain boundaries intersected
per unit length of the test line, corrected for the magnification of micrograph. However, because
of the unclear micrograph above, the average grain diameter cannot bo calculated .
25m
7.0 Conclusion
In conclusion, the constitutional characteristics of a metal or an aloy can be related to its
physical and mechanical properties with the aid of methods contained in metallography.
The obtained results demonstrate as the microstructural heterogeneity can influence in the
uniformity and on magnitude of the values obtained for the hardness. In the particular case
of the indentation number 3 (on the area of the figure 3), it is important to point out that
the same corresponds to a heterogeneous field that mixes coarse-grained and fine-grained
areas. Considering that the produced indentation has a diameter of approximately 1,5 mm,
was concluded that the hardness is an resultant average of the underlying heterogeneous
microestructure. Therefore, if the heterogeneous granulation of the area was more
extensive, probably the values of hardness for the indentation number 3 would be much
lower. It should be attempted for the fact, particularly critical in certified reference
materials, such as hardness standard blocks. In fact, if the situation observed in the
extracted sample to repeat symmetrically for the whole volume of the block, the
conclusion wold be that the standard in fact presents a low quality and that values
obtained in successive calibrations of the same will present different and not related
results whose magnitude and dispersion are directly influenced by the underlying
microstructure.
15m
8
8.0 References
i. Fakhrul Razi Ahmadun, Chuah Teong Guan, Mohd Halim Shah Ismail. (2005).
ii. Safety: Principal & Practices in the Laboratory, UPM Press.
iii. William F. Smith.(1990). Principle of Material Science and Engineering. Singapore:
McGraw-Hill.
iv. Callister,W.D.,Material Science and Engineering an Introduction
v. https://www.coursehero.com/file/p70dbs23/Discussion-Metallography-is-important-to-
determine-the-structure-of-a-material/
vi. https://www.scribd.com/document/255159866/Metallography-Experiment-Report
vii. https://www.slideshare.net/mobile/TitoLivioCardoso1/the-influence-of-microstructure-in-
the-homogeneity-of-hardness-standard-blocks
5m
