. sample
.
:
. vibrating scriber
, mounting sample tag mounting .
, .
Report form .
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- : , , , ,
- : , , , ,
- : , , ,
- : , Grain size, , , ,
: Metallography .
- Macro, Microhardness test, Inclusion rate, Grain size , Image
analysis -
.
5. Report
, , nega. Film .
6.
:
. .
7.
, , , , , .
8.
E-7 Standard Terminology Relating to Metallography
E-45 Standard Practice for Determining the Inclusion Content of
Steel
E-112 Standard Test Methods for Determining Average Grain
Size
E-340 Macroetching Metals and Alloys
E-381 Standard Method of Macrotech Testing Steel Bars, Billets,
Blooms, and Forgings
E-384 Test for Microhardness of Materials
E-407 Microetching Metals and Alloys
E-562 Recommended Practice for Determining Volume Fraction by
Systematic Point Count
E-588 Recommended Practice for Detection of Large Inclusions in
Bearing Quality Steel by the Ultrasonic
Method
E-768 Standard Practice for Preparing and Evaluating Specimens for
Automatic Inclusion Analysis of Steel
E-807 Standard Practice for Metallographic Laboratory
Evaluation
E-883 Standard Guide for Reflected-Light Photomicrography
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III.
1.
Metallography .
Lapping, Grinding, Polishing 3
.
Lapping
rolling chip
.
. Ceramic
.
Grinding
. Polishing grinding .
Polishing
grinding scratch
.
.
.
(Sectioning or cutting) : Abrasive cutter, diamond cutter
. .
Rough grinding : Belt surface disc grinder
.
Mounting : .
Fine grinding : sand paper rotating disc .
P #1000 ( #600, USA) sand paper .
lapping machine
.
Polishing : (#1000 sand paper) polishing cloth
polishing .
sand paper, Polishing cloth
Etching : Polishing .
.
Photographing : .
2. (Sectioning and cutting)
abrasive cutoff machine, band saw,
diamond saw . ,
. Polishing
Coarse polishing relief formation nap , low nap medium nap cloth
6micon
diamond paste .
2 6 1micron diamond 3
1micron diamond paste polishing .
hand polishing comet tailing polishing
,
.
.
, spray gun .
Gun .
.
1 diamond polishing 2 fine polishing
, 0.3 0.05 micron alumina slurriy final polishing .
2 diamond polishing 0.05 micron alumina polishing final polishing
.
final polishing .
Polishing
. alumina
.
.
.
. polishing
Copyright(C)2005 R&B Inc. Al right reserved 30
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.
.
. 2 mount cavity holder crevice
tap
water . air .
.
final polishing . polishing
. colloidal silica alumina
polishing pad , , holder polishing 10-15
. . Pad
.
. trouble shooting .
14. trouble shooting
Alumina
Colloidal silica polishing polishing 10- 15 .
spot polishing
pit soluble
mount crack
oven
. polishing
15. Carbon composites
/
6 diamond on medium-nap pad 3-5 psi 3-5 minutes
1 diamond on medium-nap pad 3-5 psi 2-5 minutes
0.05 alumina on nap pad 3-5 psi 30-60 seconds
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16. Silicon carbide fibers in a silicon nitride (5% Mullite)
matrix
Cutting : fiber fine grit diamond blade
/
30 diamond on a metal mesh cloth 10-12 psi 5-10 minutes
6 diamond on a CERMESH pad Colloidal silica 10-12 psi 5-10
minutes
1 diamond on POLYPAD pad Colloidal silica 10-12 psi 5-10
minutes
Colloidal silica 10-12 psi 2-5 minutes
17. Boron-Graphite composites
/
18. Cast iron
/
320 grit SiC paper 400 grit SiC paper 600 grit SiC paper 800 grit
SiC paper 1200 grit SiC paper
Water Water Water Water Water
5 psi 5 psi 5 psi 5 psi 5 psi
1 minute 1 minute 1 minute 1 minute 1 minute
3 diamond on POLYPAD pad 5 psi 3-5 minutes 1 diamond on TEXPAN pad
5 psi 3 minutes
0.05 alumina on napless pad 5 psi 15-20 seconds
19. 1095 Carbon steel (Pearlite and martensite phases)
/
120 grit SiC paper 240 grit SiC paper 320 grit SiC paper 400 grit
SiC paper 600 grit SiC paper
Water Water Water Water Water
5-10 psi 5-10 psi 5-10 psi 5-10 psi 5-10 psi
1-3minutes 1 minute 1 minute 1 minute 1 minute
9 diamond on napless pad 5-10 psi 3-5 minutes
3 diamond on napless pad 5-10 psi 3 minutes
0.05 alumina on napped pad 5 psi 15-20seconds
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20. Stainless steel
/
320 grit SiC paper 400 grit SiC paper 600 grit SiC paper
Water Water Water
6 diamond on napless pad 5 psi 3 minutes
1 diamond on napless pad Colloidal silica 5 psi 2 minutes
0.05 alumina on napped pad 5 psi 30seconds
21. Aluminum Aluminum
/
320 grit SiC paper 400 grit SiC paper 600 grit SiC paper
Paraffin wax water Paraffin wax water
Water
6 diamond on napless pad 5 psi 3 minutes
1 diamond on napless pad 5 psi 2 minutes
0.05 alumina on napped pad 5 psi 30seconds
22. Alumina Cutting : Fine grit diamond blade
/
6 diamond on napless pad Colloidal silica 10-12 psi
5-10minutes
1 diamond on napless pad Colloidal silica 10-12 psi 5 minutes
23. Zinc Zinc
/
320 grit SiC paper 400 grit SiC paper 600 grit SiC paper
Water Water Water
3 diamond on napless pad 5 psi 3minutes
1 diamond on napless pad 5 psi 90seconds
0.05 alumina on napped pad 5 psi 1minutes
Copyright(C)2005 R&B Inc. Al right reserved 33
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. Trouble shooting
polishing .
1. Scratch ()
grinding/polishing . scratch
scratch ( scratch )
.
polishing cloth
a) b)
a) After PG scratches from PG are still visible Mag: 200x , After
diamond polishing,
b) Scratches from FG still remain. The very deep scratch from PG
Mag: 200x
2. Deformation ()
.
. line
fine polishing
. .
Grinding/polishing
a) b)
a) Short deformation lines, restricted to single grains. Mag: 100x
DIC b) Well defined, sharp deformation lines Mag: 200x, DIC
3. Smearing
smearing .
, polishing cloth ,
, .
a) b)
a) Smearing on soft, ductile steel. Mag: 15x, DIC b) Smearing on
soft, ductile steel. Mag: 25x, DIC
. Polishing cloth (nap )
polishing cloth .
smearing .
4. Edge rounding ( )
.
coating
. .
mounting
polishing
nap polishing cloth
a) b)
a) Due to a gap between resin and sample the edge is rounded.
Stainless steel. Mag: 500x, Etchant: Beraha I
b) Good edge retention, Stainless steel. Mag: 500x, Etchant: Beraha
I
5. Relief
2 . phase
polishing polishing cloth .
polishing (nap ) polishing cloth
.
B4C fibers Mag. 200x, Same as figure a) but without relief Mag.
200x
6. Pull out
grain particle cavity .
particle inclusion carbide
.
Pull out .
Cutting mounting
.
Grinding .
step grinding, polishing
step
Polishing cloth napless type cloth .
Copyright(C)2005 R&B Inc. Al right reserved 36
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cloth polishing
pull –out .
Mag: 500x
metallography .
.
8. Embedded abrasive
grinding polishing .
.
polishing cloth
a) b)
a) Aluminium, with 3 diamond, Mag: 500x
b) Same as above, after final Most of the diamonds are still left
in the sample. Mag: 500x
9. Lapping track
Lapping track .
. disc cloth
.
cloth cloth
Copyright(C)2005 R&B Inc. Al right reserved 37
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. 10%
.
Zink alloy: Mag: 200x Lapping track after final polishing. Mag:
500x
10. Staining
etching
.
mounting
.
.
.
Staining of sample due to gap between resin and sample. Mag:
20x
11. Comet tails
.
polishing
Kellers etchant
10-30
15
Kallings reagent
50 ml 50 ml
Marble's reagent Distilled water
~
Picral Ethanol Picric acid
Vilella's reagent Glycerol
Nitric acid HCl
~
28.
Wro. Stainless steel NH4OH 6 volts DC , 30-60
Aus. stainless steels
5-60 Carbides sigma phase
Copper alloy 5-14% H3PO4
Water 1-4 volts DC
Titanium
35 ml perchloric ac.
5-10 °C, 10-40
2 grams potassium hydroxide
30-60 mA/cm2 2-30
Stainless steel cathode 5-10 volts DC 15-20 ,
Pt SS cathode 3-6 volts DC
5-60
15 parts Nitric acid 40 parts glycerol
SS cathode 2-4 volts DC, 0.5
A/dm2 5-15
SS cathode 6 volts DC,
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29. Tint
200g CrO3 +20g sodium sulfate + 17ml HCl + 1000mL water
1-5 , 10% aq .NaOH pre- etching 50% aq.HNO3
100ml + 10ml HF , molybdate .
200 ml water + 20ml HNO3 +3g ammonium molybdate
20 – 80ml ethanol
5g ammonium molybdate + 10g sodium thiosulfate+ 20ml ammonia +
200ml water
Al-Si-Cu-Ni cast alloy , 20C 5-8min
Cobalt and alloy a. HCl and water(1:1) Ingredient, b. 0.6-1g
potassium metabisulfate Ingredient, c .1-1.5g FeCl3
100ml stock solution ingredient b ingredient c 20C 60-150
Copper and Alloy
Klemm’s I reagent : 50ml sat. aq. sodium thiosulfate 1g potassium
metabsulfite
-brass 3min -brass 60min
Klemm’s II reagent : 50ml sat. aq. sodium thiosulfate 5g potassium
metabsulfite
-brass 6-8min
Klemm’s III reagent : 50ml sat. aq. sodium thiosulfate 5g potassium
metabsulfite
Bronze alloy 305min
Iron and alloy
60-80 ml 35% aq. sodium bisulfite + 40- 20ml water
Beaujard’s and Tordeux’s tint etch. 20C 10-25
Klemm’s I reagent : 50ml sat. aq. sodium thiosulfate 1g potassium
metabsulfite
20C 40-100
Klemm’s II reagent : 50ml sat. aq. sodium thiosulfate 5g potassium
metabsulfite
20C 30-90
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30. Molten Salt
SiC 10-3 torr , 1200°C
UO2 10 torr, 1600 °C, 1
Si3N4 10-5 torr , 1250 °C, 15
2.
32. Al Al
Kellers Etch Distilled water Nitric acid Hydrochloric acid
Hydrofluoric acid
190 ml 5 ml 3 ml 2 ml
10-30
Al
25 ml 25 ml 25 ml 1 drop
10-60 Al, Al-Mg
Mg-Si
92 ml 6 ml 2 ml
15 Al-Cu
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33. Brass Bronze
Ammonium hydroxide (dilute solutions) Dilute Immersion Attack
polishing
Distilled water Ferric chloride Hydrochloric acid
100 ml 5 grams
Brasses, bronzes, aluminum brass, alpha -phases in brass
Ethanol Hydrochloric acid Ferric chloride
100 ml 5-30 grams
or swabbing
34. Cast Iron
Nital Ethanol Nitric acid
100 ml 1-10 ml
35. Cu Cu
Distilled water Ammonium hydroxide ,3% Hydrogen peroxide
25 ml 25 ml
5-25 ml ~ Grain boundaries use less H2O2 Grain contrast use more
H2O2
Distilled water Nitric acid
50 ml 50 ml ~ Copper and copper alloys
Distilled water or Ethanol Hydrochloric acid Ferric chloride
100-120 ml 25-50 ml
36.
Nital Ethanol Nitric acid
100 ml 1-10 ml
Picral Ethanol Picric acid
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37.
Picral Ethanol Picric acid
100 ml 2-4 grams
~
Ethanol Nitric acid Hydrochloric acid Picric acid
80 ml 10 ml 10 ml
1 gram
~
38. Sn Sn
Ethanol or methanol or Distilled water Hydrochloric acid
100 ml
antimony-copper alloys
Distilled water or methanol Hydrochloric acid Ferric chloride
100 ml 5-25 ml
10 grams ~ Sn-Cu
39. Zn Zn
Distilled water or Ethanol Hydrochloric acid
100 ml 1-5 ml Zinc and zinc alloys
Distilled water Sodium Hydroxide
100 ml 10 grams 1~5 Low alloy zinc and pure zinc
Distilled water CrO3 Na2SO4
Swabbing
CERAMICS
40. Oxide ceramics
Thermal etching in air ~ Al2O3, Al2O3-MgO
Molten Salt Potassium hydrogen fluoride melt
5-10, Pt crucible
15 ml 85 ml 5 ~2 boiling Al2O3
Distilled water Sulfuric acid
41. Carbide Ceramics
Molten Salt Sodium or potassium bicarbonate melt
10 , Pt crucible
SiC
10 ml 10 ml
42. Nitride Ceramic
Thermal etching in high purity nitrogen 1600 Si3N
Molten Salt Potassium hydroxide melt
~, Pt crucible
43. Boride Ceramics
. replica ×50∼×500,
(SEM) ×100∼×10,000 .
Replication
Replica 1974 ISO 3057
(Non-Destructive Testing-Metallographic Replica Techniques of
Surface Examination) ,
1987 ASTM ES 12 1990 ASTM E 1351(Standard Practice for
Production and Evaluation of Field Matallographic Replicas) .
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