Metallography Exp.

Abu Dhabi University
MEC 300 Material Science
Experiment 1
Metallography Experiment
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.
Apparatuses:
A) Abrasive Cutting Machine

The abrasive cutting machine is used to cut and section, for
preparation of metallographic samples with least metallurgical
change. It has a cutting capacity of up to 60mm diameter and has a
spindle speed of 2800 rpm.
B) Hydraulic Specimen Mounting Press

The Specimen Mounting Press is used to mount the sample in
a plastic mould for convenient preparation of the
metallographic specimen. It has a heating and cooling cycle.
C) Belt Grinder
The belt grinder is used for flat Coarse grinding prior to
fine grinding. The surface imperfection from abrasive
cutting and moulding are removed using the belt
grinder.
D) Variable Speed Polisher

The variable speed polisher as the name suggests,
polishes the metallurgical specimen and prepares it for
the etching process.
E) Microscope
The microscope is used to study the properties of the prepared
metallurgical specimen.
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. The metallographic sample
preparation process include sectioning, mounting, course & fine grinding, polishing, etching and
microscopic examination.
Grain Size Calculation

In single phase specimens, the ASTM grain size of the metal can be estimated by comparing the
image at 100X with standard microstructure examples corresponding to standard grain sizes from
1 to 10. Also, suitable eyepieces etched with a square 0.01" x 0.01" in size can be used to
calculate the number of grains per square inch, N.
The ASTM grain size number, n, can be calculated using the following relationship:
N (M/100)2 = 2(n - 1)
N = number of grains per square inch at MX
n = ASTM grain size number
M = Magnification
For single phase materials, ASTM grain size number is given to denote the grain sizes. These
are not the actual grain size values, but the latter can be derived from the ASTM grain size
number, n; the larger the grain size number, the smaller the grains.
If there are N grains per square inch at a magnification M then there are (N) 1/2 grains along a 1
inch length. The size of each grain at magnification M is then 1 / (N) 1/2 inches.
The actual size of the grain is given by
Actual Grain Size = 1 / (N M) 1/2
Experimental Procedure:
A) Sectioning Use the abrasive cutting machine to cut a sample for the metallurgical study.
1.
2.
3.
4.
5.
Open the cover of the abrasive cutting machine.

Place the object and hold it in place using the vice.
Make sure the valves for the coolant is open.
Close the cover of the machine and start the cutting process.
Once the sample is cut, open the cover and take the specimen out by using safety gloves.
B) Mounting Use the Hydraulic specimen mounting press to mount the sample
1. Open the mounting device by rotating the handle anticlockwise.
2. Release the pressure on the mounting device to place the sample on the cylinder in the
device.
3. Add a spoon of the mounting powder on top of the specimen.
4. Close the mounting device and apply a pressure of 1500 psi.
5. Set the heating cycle to 8 minutes and cooling cycle to 5 minutes.
6. Start the heating cycle by pushing the cycle start button. The pressure will drop during the
heating cycle and apply pressure to return it back to 1500 psi.
7. Press the cycle start button again after an alarm is turned on. The alarm indicates that the
heating cycle is over and that the cooling cycle can be started.
8. Another alarm is turned on once the cooling cycle is completed.
9. Open the mounting device and raise the cylinder to extract the mounted specimen.
C) Grinding Use the Belt Grinder to grind the sample
1. Turn the machine on.
2. Use your hand after wearing the glove to hold the sample on the belt to have a uniform
grinding.
3. Lift the sample from the belt to determine the progress of grinding.
4. Continue with the process until all the lines scratched in by the belt grinder are parallel on
the sample surface.
5. Turn the machine off and wash the sample.
D) Polishing Use the Variable Speed Polisher to polish the sample.
1.
2.
3.
4.
Safety goggles must be worn when using the Polishers!

Make sure your specimen and hands have been thoroughly cleaned before Polishing!
Turn the water on adjusting to less than one drop per second!
When polishing the specimen, hold it with both hands, apply a moderate amount of
pressure, and don't let it go. The Rough Polishing Stages (5-25 microns) should take
between 1 and 2 minutes each! If you let go of the specimen it may fly, harm you or others
in the laboratory and become damaged forcing you to start over again with coarse grinding
- hold it tight and be careful!
5. Continue with the process until all the lines scratched in by the belt grinder are parallel on
the sample surface.
6. Turn the machine off and wash the sample.
E) Etching The following table illustrates the composition of chemicals and the application
procedure for different materials required to do the etching process.
F) Microscopic Examination Use the Microscope to get the detailed view the sample
structure.
1. 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.
2. After getting a clear detailed view of the sample grains structure, use the impeded camera
to get the image of the grains structure to use it later on for the analysis.
Data Analysis:
1. Determine the ASTM grain size number for the tested sample.
2. Determine the actual grain size for the tested sample.
Discussion & Conclusion:

1. Lets assume that you have tested two specimens; then you found that ASTM Grain Size
Number for Specimen#1 is 3 and for Specimen#2 is 9.Based on the observed
microstructures, which of the two specimens would you expect to be:
Strongest? Why?
Hardest? Why?
More Ductile? Why?
Stiffer (Elastic Modulus)? Why?
2. What is the purpose of etching metallographic samples?
3. Why metallographic samples are sometimes mounted in plastic mould?
5
4. If the ASTM grain size number of a single phase monel alloy (nickel solvent) is given as 5,
approximate the average grain size for this alloy?(M = 100X)
5. If the grain size of a piece of brass is 0.07 mm, what is the ASTM grain size number? (M =
100X) For this piece of brass, how many grains will be there per square inch at a
magnification of 250X?
6. Briefly explain the effect of grain size on the strength of a metal.

Metallography Exp.

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Abu Dhabi University

MEC 300 Material Science

A) Abrasive Cutting Machine

B) Hydraulic Specimen Mounting Press

Abu Dhabi University

MEC 300 Material Science

D) Variable Speed Polisher

Abu Dhabi University

MEC 300 Material Science

Grain Size Calculation

Actual Grain Size = 1 / (N M) 1/2

Abu Dhabi University

MEC 300 Material Science

Open the cover of the abrasive cutting machine.

Safety goggles must be worn when using the Polishers!

Abu Dhabi University

MEC 300 Material Science

Discussion & Conclusion:

Abu Dhabi University

MEC 300 Material Science

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