1.0 INTRODUCTION The surface of a metallographic specimen is prepared by various methods of grinding, polishing, and etching.

After preparation, it is often analyzed usingoptical or electron microscopy. Using only metallographic techniques, a skilled technician can identify alloys and predict material properties. Mechanical preparation is the most common preparation method. Successively finer abrasive particles are used to remove material from the sample surface until the desired surface quality is achieved. Many different machines are available for doing this grinding and polishing, able to meet different demands for quality, capacity, and reproducibility. A systematic preparation method is the easiest way to achieve the true structure. Sample preparation must therefore pursue rules which are suitable for most materials. Different materials with similar properties (hardness and ductility) will respond alike and thus require the same consumables during preparation. Metallographic specimens are typically "mounted" using a hot compression thermosetting resin. In the past, phenolic thermosetting resins have been used, but modern epoxy is becoming more popular because reduced shrinkage during curing results in a better mount with superior edge retention. A typical mounting cycle will compress the specimen and mounting media to 4,000 psi (28 MPa) and heat to a temperature of 350 F (177 C). When specimens are very sensitive to temperature, "cold mounts" may be made with a two-part epoxy resin. Mounting a specimen provides a safe, standardized, and ergonomic way by which to hold a sample during the grinding and polishing operations.

A macro etched copper disc After mounting, the specimen is wet ground to reveal the surface of the metal. The specimen is successively ground with finer and finer abrasive media.Silicon carbide abrasive paper was the first method of grinding and is still used today. Many metallographers, however, prefer to use a diamond grit suspension which is dosed onto a reusable fabric pad throughout the
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polishing process. Diamond grit in suspension might start at 9 micrometres and finish at one micrometre. Generally, polishing with diamond suspension gives finer results than using silicon carbide papers (SiC papers), especially with revealing porosity, which silicon carbide paper sometimes "smear" over. After grinding the specimen, polishing is performed. Typically, a specimen is polished with a slurry of alumina, silica, or diamond on a napless cloth to produce a scratch-free mirror finish, free from smear, drag, or pull-outs and with minimal deformation remaining from the preparation process. After polishing, certain microstructural constituents can be seen with the microscope, e.g., inclusions and nitrides. If the crystal structure is non-cubic (e.g., a metal with a hexagonalclosed packed crystal structure, such as Ti or Zr) the microstructure can be revealed without etching using crossed polarized light (light microscopy). Otherwise, the microstructural constituents of the specimen are revealed by using a suitable chemical or electrolytic etchant. 2.0 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. 3. To prepare the specimen for hot mounting. 4. To conduct grinding, polishing, and etching process specimen. 3.0 EQUIPMENT / APPARATUS / COMPONENTS EQUIPMENT Metallographic Cutter Machine Mounting Compound Mounting Press Machine Rotary Grinder Polisher Nital Liquid Specimen To Be Mounted Specimen Drier SD6000 File Tool FUNCTIONS

1. 2. 3. 4. 5. 6. 7. 8. 9.

4.0 SAFETY PRECAUTIONS 1. Never use metallographic cutter machine and mounting press machine without permission. 2. Use glove when handling chemical. 5.0 PROCEDURES 5.1 Hot Mounting 1. The metal with size not more than 15mm x 15mm is cut using the Metallographic Cutter Machine. 2. The rough surface of metal is smooth with the file tool. 3. The Mounting Press Machine is switched on. 4. The Specimen is placed with the surface to be examined down. 5. Mounting release is sprayed on the mould. 6. A half scope of the mounting compound ( pallet or polymers ) is added into the mould. 7. The mould tightly closed and the knob loose up for half cycle to open it up. 8. The data in the machine is key in according to type of mounting compound being used. 9. Start button is pressed and the pressure is make sure is levelled at 270 bar during the heating operation. 10. The buzzer is on once the machine completes its operation. 11. The pressure button is pressed again and the specimen is took out carefully from the machine. 12. The mould is cleaned and the mounting release is sprayed, and the place it back on the machine. 5.2 Grinding Process 1. 2. 3. 4. 5. The specimen is fit into the apparatus of the specimen holder. The rotary pre-grinder machine is switched on 240 grit paper. The pipe source is turned on on machine. FWD is set at 200 rpm. The same procedures are repeated for 360, 600, 800, 1000, 1200 grit papers.

5.3 Polishing Process 1. The specimen is washed with warm soapy water followed by alcohol to prevent contamination of the disc. 2. The specimen is fit into the apparatus of the specimen holder for coarser polisher ( 3 microns ). 3. The diamond is used to paste for 3 micron. 4. The polisher machine is switched on and diamond lubricator is used during the lubricator. 5. The same procedures are repeated for finer polisher. ( 1 micron and diamond paste for 1 micron.

5.4 Etching Process 1. The specimen is make sure clean from dirt. 2. The specimen is washed using the Ultrasonic Cleaner and dry it by using Specimen Drier SD6000 if necessary. 3. The specimen is etched using a reagent. 4. A cotton bus is used to wipe over the surface a few times. 5. The specimen is immediately washed in alcohol and dry it using Specimen Drier SD6000.