METALLOGRAPHY

YEDĐTEPE UNIVERSITY DEPARTMENT OF

MECHANICAL ENGINEERING

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 YEDITEPE UNIVERSITY ENGINEERING FACULTY
MECHANICAL ENGINEERING LABORATORY

Metallography

1. Objective:

• To familiarize the student with the metal

microscope and metallographic techniques.
• To study the processing method of a
manufacturing part by surface observation of the
part.

2. Equipment:

Buehler ISOMET 11 sample cutting device.

Buehler BETA 49 sample polishing device.

Olympus CK40M-32 microscope.

Data acquisition system (PC).

3. Theory:

3.1 Optical Microscopy

With optical microscopy, the light microscope is used to study the microstructure;
optical and illumination systems are its basic elements. For materials that are opaque to
visible light (all metals and many ceramics and polymers), only the surface is subject to
observation, and the light microscope must be used in a reflecting mode. Contrasts in the
image produced result from differences in reflectivity of the various regions of the
microstructure. Investigations of this type are often termed metallographic, since metals were
first examined using this technique.
Small grooves form along grain boundaries as a consequence of etching. Since
atoms along grain boundary regions are more chemically active, the dissolve at a greater rate
than those within the grains. These grooves become discernible when viewed under a
microscope because the reflect light at an angle different from that of the grains themselves.

3.2 Sectioning and Cutting

Following proper documentation, most metallographic samples need to be sectioned to

the area of interest and for easier handling. Depending upon the material, the sectioning
operation can be obtained by abrasive cutting (metals and metal matrix composites), diamond
wafer cutting (ceramics, electronics, biomaterials, minerals), or thin sectioning with a
microtome (plastics).

Proper sectioning is required to minimize damage, which may alter the microstructure
and produce false metallographic characterization. Proper cutting requires the correct

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selection of abrasive type, bonding, and size; as well as proper cutting speed, load and
coolant.

The first step in preparing a specimen for metallographic or micro structural analysis is to
locate the area of interest. Sectioning or cutting is the most common technique for obtaining
this area of interest. Proper sectioning has the following two characteristics:

• Flat and cut close to the area of interest

• Minimal micro structural damage
o Smeared (plastically deformed) metal
o Heat affected zones (burning during cutting)
o Excessive subsurface damage (cracking in ceramics)
o Damage to secondary phases (e.g. graphite flakes, nodules or grain pull-out)

Lubrication during abrasive cutting and diamond wafer cutting are required to minimize
damage and to remove the cutting debris or swarf. For abrasive cutters the proper cutting fluid
can have the added benefit of coating the cast iron bases and fixtures to eliminate corrosion
and rusting of the cutter. Abrasive cutting fluid - The ideal cutting fluid for abrasive cutting is
one that removes the cutting swarf and degraded abrasive blade material. It should have a
relatively high flash point because of the sparks produced during abrasive sectioning

3.3 Metallographic Specimens

Figure 1. Sample D64 Commercial SAE 1010 hot rolled steel.

Original magnification 500x (reduced 40%)

Figure 2. Sample D74 Commercial SAE 1035 hot rolled steel.

Original magnification 500x (reduced 40%)

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 Figure 3. Sample D29 Commercial SAE 1045 steel annealed from
1800oF. Original magnification 500x (reduced 40%)

Figure 4. Sample D84 Commercial SAE 1070 hot rolled steel.

Original magnification 500x (reduced 40%)

Figure 5. Sample D94 1.4 %C annealed steel. Original

magnification 200x (reduced 40%)

Figure 6. Sample D47 Commercial SAE 1045 steel water quenched

from 1550oF. Original magnification 500x (reduced 40%)

Figure 7. Sample D59 Commercial SAE 1045 steel water quenched

from 1550oF then tempered for 1 hr at 1150oF. Original magnification 500x (reduced 40%)

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 Figure 8. Sample C21 Gray cast iron. Unetched cast iron sample
from metallurgy building sewer flange. Original magnification 100x (reduced 40%)

Figure 9. Sample C22 Hypereutectic gray cast iron etched using Nital
to reveal pearlite. Original magnification 200x (reduced 40%)

Figure 10. Sample J1. As-cast white cast iron. Composition is: 3.11
w/o C, 1.05 w/o Si, 0.41 w/o Mn, Bal. Fe. Original magnification 100x (reduced 40%).

Figure 11. Sample B12 Binary 40a/o Ag, 60 a/o Cu alloy, which was
slowly cooled from the liquid phase. Original magnification 500x (reduced 40%)

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4. Procedure:

Students will be given a number of specimens taken from manufactured parts. These
will be examined visually, using the microscope and digital camera. Sketches of the surfaces
will be made by the class members. Characteristic markings on the surfaces should enable the
student to identify what method of manufacture was used for each of the parts.

4.1 Specimen preparation

• Careful and meticulous surface preparations are necessary to reveal the important
details of the microstructure.
• The specimen surface must first be ground and polished to a smooth and mirror like
finish.
• This is accomplished by using successively finer abrasive papers and powders.
• The microstructure is revealed by a surface treatment using a chemical reagent in a
procedure termed etching1.

4.2 Recommended Abrasive Cutting Procedure

1. Select the appropriate

abrasive blade
2. Secure specimen - improper
clamping may result in
blade and specimen damage
3. Check coolant level and
replace when low or
excessively dirty. Since
abrasives blades
breakdown during cutting
they produce a significant
amount of debris.

Figure 12. Buehler polishing device.

4. Allow blade to reach its operating speed before beginning the cut.
5. A steady force or light pulsing action will produce the best cuts and minimize blade wear
characteristics as well as the maintain sample integrity (no burning).

4.3 Microscope Procedure

1. Turn the microscope on.
2. Push in the light path selector.
3. Place the specimen on the stage plate.
4. Move the 10x objective lens into place to focus on the specimen.
5. Adjust the brightness.
6. Adjust the coarse and fine adjustment knob until object is focused.
7. Observe object.
8. Adjust the longitudinal feeding ring to move the image front to back or vice versa.

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Etching will not be used in this experiment.

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 9. Adjust the transverse feeding ring to move the image left to right or vice versa.

5. Results and Conclusions:

Your results should include the following:

1. The complete description of all the equipment (e.g. cutting device, microscope) used.

2. Description of the manufactured parts and the observed surface characteristics which
provide the basis for identification with a particular manufacturing method.