Metallography Lab.- Prof. Dr.

Emel TABAN, 2019-2020 Spring Semester

METALLOGRAPHIC SAMPLE PREPARATION TECHNIQUES

Objectives

1. To learn and to gain experience in the preparation of metallographic specimens.

2. To examine and analyze the microstructures of metals and metallic alloys.

Proper preparation of metallographic specimens to determine microstructure and content

requires that a rigid step-by-step process be followed. In sequence, the steps include
sectioning, mounting, course grinding, fine grinding, polishing, etching and microscopic
examination. Specimens must be kept clean and preparation procedure carefully followed in
order to reveal accurate microstructures.

Background

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.

Sectioning

Operations such as shearing produce severe cold work, which can alter the microstructure of
a sample. Abrasive cutting (sectioning) offers the best solution to eliminate these undesirable
features; the resultant surface is smooth, and the sectioning task is quickly accomplished.
Low-speed cut-off wheels are utilized in cases where the heat created by standard abrasive
cutters must be avoided. Ample coolant and proper speed control are essential in all
sectioning operations.

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 Metallography Lab.- Prof. Dr. Emel TABAN, 2019-2020 Spring Semester

Abrasive Cut-Off Wheels consist of abrasive grains (such as Aluminum Oxide or Silicon
Carbide), bonded together with rubber or other materials in the form of a thin wheel. Rubber
bonded wheels are most extensively used for wet operation and resin bonds for dry cutting.

When sectioning a piece of metal, the abrasive grains on the cutoff wheel become dull,
therefore, the bond must be destroyed at the correct rate so that new grains are always at
the edge and are still held firmly by the bonding material. The rate at which the bond breaks
down is affected by several different factors, including:

1) The hardness of the bond.

2) The hardness and workability of the metal sample.

3) The size and speed of the wheel.

4) The power of the driving motor.

5) The type and amount of coolant and its method of application.

6) The amount of pressure by which the wheel is applied to the sample.

7) The amount of vibration in the machine.

Cutoff wheels are indexed from hard to soft and are referred to by "grade". As a rule of
thumb, a hard bonded wheel should be selected when sectioning soft stock, and a soft wheel
for sectioning harder material. A reasonable amount of wheel pressure must be applied so
the abrasive grains will "bite" and remove the metal in fine chips. An experienced operator
can tell whether the wheel is cutting or merely "dragging" by the feel of the control arm and
monitoring of the power consumption of the cutting equipment.

Figure 1. Abrasive cutoff wheels for sectioning.

Proper cutting procedures must be followed; abrasive cut-off wheels will crack and become
flying projectiles when used improperly.

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 Metallography Lab.- Prof. Dr. Emel TABAN, 2019-2020 Spring Semester

Mounting

Small samples are generally mounted in plastic for convenience in handling and to protect
the edges of the specimen being prepared. Compression-type molding is commonly applied
to encase specimens in 1 to 1.5 inch diameter plugs of a hard polymer. Compression
molding materials are classified as either thermosetting or thermoplastic:

1) Bakelite is a low cost, relatively hard thermosetting polymer that is commonly utilized.

2) Expensive Transoptic Thermoplastics are utilized when transparency is required.

Transoptic materials remain molten at maximum temperature and become transparent with
an increase in pressure and a decrease in temperature. By definition, thermosetting
materials require heat and pressure during the molding cycle.

During mounting, the pressure and molding temperature are generally held constant thus
time is the only variable. The metal sample is placed in the mounting cylinder which is then
encased in a pre-measured amount of powdered polymers. The mounting cylinder is then
sealed, pressurized and heated to complete the polymerization process necessary to solidly
encase the metal sample. Although inferior in quality to compression-type molding, cold
molding (room temperature) is often used with epoxy to mount samples by simply mixing the
epoxy and pouring it over a sample that is positioned face-down in a cold-mounting ring.
When the epoxy cures the specimen can be prepared. Caution must be exercised when cold
mounting due to relatively poor adhesion between the specimen edges and the epoxy plug;
gaps often form which can degrade the quality of the specimen.

Figure 2. Examples of mounted samples.

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 Metallography Lab.- Prof. Dr. Emel TABAN, 2019-2020 Spring Semester

Coarse Grinding

In view of the perfection required in an ideally prepared metallographic sample, it is essential

that each preparation stage be carefully performed. The specimen must:

1. Be free from scratches, stains and others imperfections which tend to mark the surface.

2. Retain non-metallic inclusions.

3. Reveal no evidence of chipping due to brittle intermetallic compounds and phases.

4. Be free from all traces of disturbed metal.

The purpose of the coarse grinding stage is to generate the initial flat surface necessary for
the subsequent grinding and polishing steps. As a result of sectioning and grinding, the
material may get cold worked to a considerable depth with a resultant transition zone of
deformed material between the surface and the undistorted metal. Course grinding can be
accomplished either wet or dry using 80 to 180 grit electrically powered disks or belts, but
care must be taken to avoid significant heating of the sample. The final objective is to obtain
a flat surface free from all previous tool marks and cold working due to specimen cutting.

An important factor throughout the Coarse Grinding and Fine Grinding Stages is that the
scratches be uniform in size and parallel to each other in any one grinding stage. Proper
grinding involves rotation of the sample by 90 degrees between stages while the grinding
angle must be held constant during the grinding at any one stage.

The sample MUST be washed thoroughly before proceeding from one grinding stage to the
next ! ! !

Failure to follow this basic rule will result in transferring abrasive particles between stages
and will cause time-consuming, frustrating problems in removing unwanted scratches.

Figure 3. Examples for abrasive grinding papers

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 Metallography Lab.- Prof. Dr. Emel TABAN, 2019-2020 Spring Semester

Medium and Fine Grinding

Medium and Fine Grinding of metallurgical samples are closely allied with the Coarse
Grinding which precedes them. Each stage of metallographic sample preparation must be
carefully performed; the entire process is designed to produce a scratch free surface by
employing a series of successively finer abrasives. Failure to be careful in any stage will
result in an unsatisfactory sample. The idea is to carefully move from one stage to the next
where the abrasives become finer at each successive stage. Movement from one stage to
the next should only proceed when all of the scratches from the preceding stage are
completely removed. In general, successive steps are 240, 320, 400 and 600 grit SiC and
the grinding rate should steadily decrease from one stage to the next. Proper grinding
involves the rotation of the sample between stages while the grinding angle must be held
constant during the grinding at any on stage. Recall that "The sample MUST be washed
thoroughly before proceeding from one grinding operation to the next"!

Wet grinding is generally applied in medium and fine grinding to avoid possible side affects
due to heating such as tempering, transformation, aging, incipient melting, etc. Wet grinding
also provides a flushing action for loose particles and keeps sharp edges of the grinding
medium exposed at all times.

Mechanical Polishing

Polishing involves the use of abrasives, suspended in a water solution, on a cloth-covered

electrically powered wheel. Diamond abrasives provide the best, and most expensive,
compounds utilized in polishing; standard sized aluminum oxide powders are applied for
general use purposes. Following the final 600 grit fine-grinding stage, the sample MUST be
washed and carefully dried before proceeding to the first polishing stage! At the polishing
stages, even hard dust particles in the air which settles on the polishing cloth can cause
unwanted scratching of the specimen! Careful washing of the specimen and the operator's
hands must be carried out prior to each stage of polishing! Beginning with 25-micron
suspended aluminum oxide particles (suspended in water) on a Nylon-cloth, the final fine-
grinding surface layer resulting from the previous grinding procedure should be completely
removed with a rotation rate of 150-200 rpm. The specimen is initially held at one position on
the wheel, without rotation, until most of the previous grinding marks are removed. It can be
rotated slowly, counter to the wheel rotation, until only scratches from the 25-micron
aluminum oxide are visible. During the initial polishing stage, moderate pressure can be
applied to the specimen and the entire stage should generally take 1 or 2 minutes!

After carefully washing the specimen, proceed to the 5-micron stage where a separate
polishing wheel with 5-micron particles; repeat the procedure outlined above using lighter
pressure and a gradual rotating motion across the polishing cloth. The final polishing stage
with 1-micron suspended aluminum oxide particles should be carried out on a separate
polishing wheel following "Careful washing of the specimen and operator's hands" at a
slower speed of 100 - 150 rpm using a napped cloth. After 1 or 2 minutes a properly polished
specimen should have a mirror-like surface free of scratches! During final polishing, minimal
pressure should be applied and time should be kept to a minimum since the napped material
will conform to the specimen shape under pressure.

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 Metallography Lab.- Prof. Dr. Emel TABAN, 2019-2020 Spring Semester

The wetness of the cloth used for Final Polishing has a great influence on the end result. If
the cloth is too wet the sample will show pits; if too dry, buffing and/or smearing will result. To
determine the proper wetness, the sample should be removed from the wheel and the time
required for the polishing film to dry (five to eight seconds) should be checked. A thin opaque
film indicates that sufficient abrasive is present. For precision work, extremely fine grades of
diamond abrasives may often be used for the final polishing sequence. Cerium Oxide is
especially excellent for the final polishing of aluminum and other soft metals and alloys. The
best abrasive types and sizes for various metals and alloys are listed in the literature;
references should be consulted for recommended practice. The ability to prepare a specimen
is an art and the required skill is acquired only after significant hands-on experience. Using
automated equipment, an inexperienced technician can be taught to prepare well polished
specimens in a few hours; he/she could not, however, hand polish well without further
training and experience.

Etching

Microscopic examination of a properly polished, unetched specimen will reveal only a few
structural features such as inclusions and cracks or other physical imperfections. Etching is
used to highlight, and sometimes identify, microstructural features or phases present. Even
in a carefully prepared sample, a surface layer of disturbed metal, resulting from the final
polishing stage, is always present and must be removed. Etchants are usually dilute acid or
dilute alkalis in a water, alcohol or some other solvent. Etching occurs when the acid or base
is placed on the specimen surface because of the difference in rate of attack of the various
phases present and their orientation. The etching process is usually accomplished by merely
applying the appropriate solution to the specimen surface for several seconds to several
minutes.

Nital, a Nitric Acid - Alcohol mixture, is the etchant commonly utilized with common irons and
steels. Nital is dripped onto the specimen using an eye-dropper or cotton swab. Ten seconds
to one minute is usually sufficient for proper etching depending on sample and nital
concentration. The sample is immediately washed under running water, rinsed with alcohol
and dried in an air blast. Do not touch, wipe or swab the specimen following etching; dry off
the rinsing alcohol on the specimen with the air blast and then move on to the microscopic
examination stage!

Etchants

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 Metallography Lab.- Prof. Dr. Emel TABAN, 2019-2020 Spring Semester

Microscopic Examination

Initial microscopic viewing should be done utilizing a stereomicroscope, which reveals a

three-dimensional scanning of the specimen surface. The specimen is placed on the stage of
the microscope so that its surface is perpendicular to the optical axis.

Detailed viewing is done with a Metallurgical Microscope. A metallurgical microscope has a

system of lenses (objectives and eyepiece) so that different magnifications (25X to 1000X)
can be achieved. The important characteristics of the microscope are: (1) magnification, (2)
resolution and (3) flatness of field. The resultant magnification is the product of the
magnifying power of the objective and that of the ocular.

Scanning Electron Microscopes (SEMs) are capable of magnifications up to 20,000X and

Transmission Electron Microscopes (TEMs) are utilized to view at magnifications up to
100,000X for highly detailed microstructural study.

Figure 4. An example for light optical microscopy (LOM)

Figure 5. An example for scanning electron microscopy (SEM).

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 Metallography Lab.- Prof. Dr. Emel TABAN, 2019-2020 Spring Semester

Possible questions

1. Briefly (one concise sentence each) describe the steps involved in the preparation of a
metallographic sample:

Sectioning

Mounting

Course Grinding

Fine Grinding

Polishing

Etching

2. Why must metallographic samples be washed and carefully dried before proceeding from
one grinding or polishing operation to the next?

3. What is the purpose of etching metallographic samples?

4. Why are metallographic samples sometimes mounted in plastic?

5. What is the difference between a Eutectoid steel and a Hypoeutectoid steel?