Metallography

Dr. Asep Ridwan Setiawan

Andrie Harmaji, S.T., M.T.
Metallography
 Introduction
 Metallography is basically the study of the structures and
shapes of metals and alloys, using metallurgical
microscopes and magnifications, so that the physical and
mechanical properties of an alloy can be related to its
observed microstructure.

 It provides information about the specimen under

investigation, including the size and shape of the grains
(crystallites), the presence of micro defects (such as
segregation, hair cracks, and nonmetallic inclusions), and
the nature and distribution of secondary phases.
 Introduction

 Microstructure:
is the geometric
arrangement of grains and
the different phases present
in a material.
 Grain Boundaries:
is the interface between two
grains in a polycrystalline
material where the crystal is
disordered due to rapid change in
crystallographic directions.
 Applications
Study and characterization of materials.
Ensure that the associations between properties and
structure are properly understood.
Predict properties of materials.
Design alloys with new properties.
Check if the material has been correctly heat treated.
Preparation of Specimens for
Metallographic Examination
 Metallography
Cutting
Grinding – emery paper (240, 300, 400, 600)
Polishing (0.5, 0.1, 0.05μ)
Etching –Nitol/ Kellers Solution
Microscopy
Cutting (Sectioning)
 Grinding
 Grinding is a subset of cutting, as grinding is a true metal cutting
process.
 Abrasive :The use of Premium SiC abrasive paper is the most
efficient and practical technique for grinding metallic
metallographic specimens. Although many qualities of silicon
carbide are readily available, only the premium grade SiC powder
provides the most consistent results and highest grinding rates.

 Each grain of abrasive functions as a microscopic single-point

cutting edge and shears a tiny chip that is analogous to what
would conventionally be called a "cut" chip (turning, milling,
drilling, tapping, etc.)
 Grinding Soft non-ferrous metals
Soft non-ferrous metals - Initial grinding is recommended with 320
grit SiC
 abrasive paper followed by 320 400, 600 and , 800 grit SiC paper. because
These materials are relatively soft they do not easily break down the SiC
paper.

 The initial grinding with 320 grit is generally sufficient for minimizing
initial deformation and yet maintaining adequate removal rates.

 For extremely soft materials such as tin, lead and zinc it is also
recommended that the abrasive paper be lightly coated with a paraffin wax.
The wax reduces
 the tendency of the SiC abrasive to embed into the soft specimen.
Grinding Ferrous metals
 Ferrous metals - are relatively easy to grind with the depth of
deformation being a major consideration.

120 grit SiC abrasives provide a good initial start with subsequent use
of 240 or 320, 400, 600 and 800 grit SiC.
 Super alloys - are generally of moderate hardness but have extremely
stable elevated temperature characteristics and corrosion resistance.

 the procedures for preparing super alloys is very similar to that for
most non-ferrous metals.
 Sample Preparation
The purpose of this practice is to understand how to prepare and
interpret metallographic samples systematically.

 Gather information about chemical composition, heat treatment, processing,

phase diagram.
 Cut representative sample.
 Mount sample, grind and polish.
 Examine un etched sample.
 Etch lightly and examine again.
 Etch further if necessary.
 Compare with microstructure expected from equilibrium phase diagram
Spheroidal Graphite Cast Iron
 Abrasive Material
Materials used for the abrading particles are:
 garnet: commonly used in woodworking
 emery: commonly used to abrade or polish metal
 aluminium oxide: perhaps most common in widest variety of
grits; can be used on metal (i.e. body shops) or wood
 silicon carbide: available in very coarse grits all the way through
to micro-grits, common in wet applications
 alumina-zirconia: (an aluminium oxide–zirconium oxide alloy),
used for machine grinding applications
 chromium oxide: used in extremely fine micron grit (micrometre
level) papers
 ceramic aluminum oxide: used in high pressure applications,
used in both coated abrasives, as well as in bonded abrasives.

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 PROCESS
The specimen must
1. Be free from scratches, stains and others imperfections which

tend to mark the surface.

2. Reveal no evidence of chipping due to brittle inter metallic

compounds and phases.

3. Be free from all traces of disturbed metal.

4. The specimen has to be grounded with the help of abrasive papers.

5. Polishing enhances the surface and makes it suitable to observe its

grain structure under Microscope.

 Grain
 The micro structure of many metallic or ceramic materials consists of many grains.

 A grain
 is portion of the materials within which the arrangement of the atoms is nearly
identical but the orientation or crystal structure of atoms

are different.

Microstructure of Aluminum
 A Grain Boundary
 The surface that separates the individual grains is a narrow zoon in
which the atoms are properly spaced.
 One method of controlling the properties of a material is by
controlling the grain size.

aluminum oxide
and titanium dioxide (Al2O3 . TiO2)
 Surface Defects

 Surface defects are the boundaries, or plans, that separate a material

into regions.
 Each region may have the same crystal structure but different
orientation
Polishing
Polishing

 Polishing is the process of creating a smooth and shiny

surface by rubbing it or using a chemical action, leaving a
surface with a significant reflection

 Aluminum Oxide(0.5, 0.1, 0.05μ)

Etching
 Industrial etching
 The surface is than exposed to chemical attack or ETCHING, with
grain boundaries being attacked more aggressively than reminder of
the grain to reveal the microstructure.
 Light from an optical microscope is reflected or scattered from the
sample surface depending how the surface is etched

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 Etching:

Sample Etchant Composition Remarks

material
Carbon steel (usually 2%) HNO3 1-5 ml Few seconds (5
(nitric acid) Ethyl alcohol 100ml Sec)

Carbon steel Picric Acid Picric acid 4g Few seconds (15

Ethyl alcohol 100ml Sec)

Aluminum Hydrofluoric acid HF (conc.) 0.5ml Swab for 15 sec.

H2O 99.5ml
Safety

Optical Metallography
involves the use of
etchants (standard
solutions containing a
variety of chemicals
such as strong acids and
solvents) which can be
very corrosive and
poisonous.
Safety

 You must wear gloves and

goggles and handle the
chemicals with extreme
care.
 You must not have direct
skin or eye contact with
the etchants. Etchants
must be used in well
ventilated area.
 Do not try to smell the
etchants.
Microscope
Polishing

 Polishing is the process of creating a smooth and shiny

surface by rubbing it or using a chemical action, leaving a
surface with a significant reflection

 Aluminum Oxide(0.5, 0.1, 0.05μ)

Surface Finish and Surface Roughness (Original Magnification 50x)