Applied Mechanics Lab – MEC 424/Hakim/2024/V1
UNIVERSITI TEKNOLOGI MARA
SCHOOL OF MECHANICAL ENGINEERING
Program : Bachelor of Mechanical Engineering (Hons) - CEEM 222
Course : Applied Mechanics Lab
Code : MEC 424
Lecturer : MADAM FAUZIAH BT MD YUSOF
Group : EMD4M5C (CLUSTER 2)
MEC 424 - LABORATORY REPORT
TITLES: Introduction to Sample Preparation and Optical Microscope for
Metallographic Observation
No NAME STUDENT ID SIGNATURE
MUHAMMAD IBNU HAKEEM BIN
1 2023622674
ZAMRI
MUHAMMAD ZULHAKIMI BIN
2 2023491526
NOORDIN
MUHAMMAD ZAHIR ANWAR BIN
3 2023690552
ABDULLAH
MUHAMMAD SYAHMI JAZMI BIN
4 2023679984
JAMHARI
LABORATORY SESSION : 12/06/2025
(DATE)
REPORT SUBMISSION : 27/06/2025
(DATE)
*By signing above, you attest that you have contributed to this submission and confirm that all work you
have contributed to this submission is your own work. Any suspicion of copying or plagiarism in this work
will result in an investigation of academic misconduct and may result in a “0” on the work, an “F” in the
course, or possibly more severe penalties.
Marking Scheme
No A1 A2 A3 A4 A5 A6 A7 A8
1
2
3
4
5
LEGENDS
A1 -Abstract A3 – Theory A5 – Results A7 - Conclusion
A2 -Introduction A4 - Procedure A6 – Discussions A8 - Overall Impressions
1.0 ABSTRACT
This experiment is about introduction to sample preparation and optical microscope for
metallographic observation. This experiment was done to investigate the metallographic
observation from the specific sample using optical microscope with different magnification,
which is x50, x100, x200 and x400. The experiment involved with the cutting, moulding,
grinding (fine, coarse), polishing and etching process. Every process has their precaution to
ensure that the sample specimen is in good condition to get the clear grain size. In a conclusion,
we get the images become immense and clear when the magnification is increase. We also
identified the structure of images that has been formed from the surface of sample specimen
with different magnification.
2
TABLE OF CONTENT
1.0 ABSTRACT ................................................................................................................... 2
TABLE OF CONTENT ............................................................................................................. 3
LIST OF FIGURES ................................................................................................................... 4
LIST OF TABLES ..................................................................................................................... 5
2.0 INTRODUCTION ......................................................................................................... 6
2.1 OBJECTIVES ............................................................................................................ 6
3.0 THEORY ....................................................................................................................... 7
4.0 EXPERIMENTAL PROCEDURE ................................................................................ 9
4.1 APPARATUS ............................................................................................................ 9
4.2 PROCEDURE .......................................................................................................... 10
5.0 RESULTS .................................................................................................................... 13
6.0 DISCUSSIONS ............................................................................................................ 13
6.1 MOHD RAMZAI BIN ZAINAL ABIDIN (202212345)Error! Bookmark not
defined.
6.2 MOHD ROKHANMI ZAKARIA (201112131) ...... Error! Bookmark not defined.
6.3 NG YEE TATT (201112131) .................................. Error! Bookmark not defined.
6.4 BALASUBRAMANIAM A/L RAMASAMY (201112131) .................................. 14
7.0 CONCLUSIONS.......................................................................................................... 15
8.0 REFERENCES ............................................................................................................ 16
9.0 APPENDICES AND RAW DATA ............................................................................. 17
3
LIST OF FIGURES
Figure 1: Metallographic etching ............................................................................................... 7
Figure 2: Cutter Machine ........................................................................................................... 9
Figure 3: Auto Mounting Press Machine ................................................................................... 9
Figure 4: Grinder Machine......................................................................................................... 9
Figure 5: Polishing Machine ...................................................................................................... 9
Figure 6: Optical Microscope .................................................................................................. 12
4
LIST OF TABLES
Table 1 : Sample under Microscope with magnification ......................................................... 13
5
2.0 INTRODUCTION
The optical metallography is the examination to provide a magnified structure of the
microstructure and macrostructure of the materials. The relationships among structure and
properties, metallographic characterization is used in quality control, quality assurance,
material specifications and failure analysis. Due to that, this experiment is important to studies
ranging from fundamental research to production evaluations for the industry. All metallic
materials have their characteristics such as grain size, carbon content of steel and effect of heat
treatment.
The purpose of this experiment is to analysis the phases and grain size in the structure
because all the metal structure are not readily visible with the naked eyes but by the microscope,
the grain patterns can be seen. So that, the characteristics can be obtain by the studying
micrograph result of this experiment. Due to the objective to get the real structure, the metal
would have to go through under the grinding process or polishing and etching to obtain their
suitable surface such as mirror-like metal before analysis structure process by using optical
microscope. The optical microscope has function to obtain the schematic diagram by using
three different type of lens such as x50 x100, x200, and x400. The grain structure can be
determined through the schematic diagram
2.1 OBJECTIVES
1. To understand the procedure metallographic sample preparation.
2. To understand the basic function of optical microscope and its operation.
3. To perform an analysis from the observed microstructure.
4. To understand theoretical background of sample preparation and metallographic
specimens.
6
3.0 THEORY
Microstructure analysis is often an important concern in many businesses since it helps
determine whether a material has been handled correctly. Sampling, specimen preparation
(sectioning and cutting, mounting, grinding, rough and final polishing, etching), microscopic
observation, digital imaging and documentation, and quantitative data extraction using
stereological or image analysis techniques are all necessary for a proper metallographic
examination.
The initial stage of metallographic testing the outcome of any additional research
depends on sampling; the specimen to be examined must be representative of the substance
under consideration. Furthermore, the preparation of the specimen is equally important, and
there are no ways to get the intended metallographic result.
Metallography has historically been referred to as both a science and an art. This is
because both experience and intuition are crucial for revealing the material's actual structure
without causing major alteration or damage, as well as for making the features of interest
measurable.
Because etching is arguably the most variable process, selecting the best print
composition and controlling the etch temperature and duration are essential for reliable and
consistent results. To find the ideal parameters for this stage, a scientific procedure including
trial and error is frequently required.
Figure 1: Metallographic etching
7
The process above in Figure 1 is known as metallographic etching, a critical technique
used in material science to reveal the microstructure of metals and alloys. After a sample is
carefully polished to produce a smooth surface, it is chemically etched using a suitable reagent
that selectively attacks specific microstructural features. Grain boundaries, which are more
chemically reactive than the interior of the grains, are preferentially etched, forming surface
grooves. These grooves scatter light differently compared to flat areas, allowing the grain
structure to become visible under an optical microscope. This technique is essential for
analysing grain size, phase distribution, and other structural characteristics that influence the
mechanical and physical properties of materials.
8
4.0 EXPERIMENTAL PROCEDURE
4.1 APPARATUS
Figure 2: Cutter Machine
Figure 3: Auto Mounting Press Machine
Figure 4: Grinder Machine
Figure 5: Polishing Machine
9
4.2 PROCEDURE
• Cutting: The cutting procedure was used to bring the sample to the right size so that it
could be handled or moulded with ease.
1. The sample was measured to determine the correct cutting dimensions.
2. The cutter cover was opened, and the sample was placed securely in the clamps.
3. The clamps were tightened slowly to ensure the sample was firmly held.
4. The cutter cover was closed to ensure safe operation.
5. The main power switch of the cutting machine was turned on.
6. The pump and cutting buttons were activated to start the blade rotation and fluid
circulation.
7. Once the cutting fluid was properly flowing with the rotating blade, the handle was
slowly lowered to begin cutting.
8. The blade was pressed gently through the sample to ensure a clean cut and to protect
the blade and sample.
9. After cutting was completed, the cutting, pump, and light buttons were turned off.
10. The main power switch was turned off.
11. Once the blade had completely stopped rotating, the cutter cover was opened.
12. The clamps were loosened, and the cut sample was carefully removed.
• Moulding: To make the sample simpler to grip during the polishing process, a
moulding method was used.
1. The machine was switched on and the air flow was opened.
2. The surface of sample that wanted should be facing down.
3. The button was pushed to lower the sample down to the bottom and 10 grams of
phenolic powder was applied into the mounting machine.
4. The machine was pressed and locked to the left.
5. The green button was turned on and leaves for 18 minutes until the hot mounting
process done.
10
• Grinding
➢ Rough grinding (To remove the imperfections that grinding has left)
➢ Fine grinding (To remove all scratches and leave a mirror like finish on the
surface.)
1. Sandpaper with grit 240 (the lowest grade) was clipped onto the grinder.
2. The machine was turned on, followed by activating the water pump and motor to
ensure continuous cooling and cleaning during grinding.
3. The sample was pressed onto the rotating sandpaper in the opposite direction of
the existing scratches, applying moderate pressure.
4. Grinding continued until the initial surface marks were reduced and a more
uniform surface appeared.
5. The grinding process was repeated sequentially using finer grit sandpapers in the
following order: 320, 400, 600, and finally 1200.
6. At each stage, the sample was ground in the opposite direction to the previous step
to effectively remove earlier scratches.
7. After completing the final stage with grit 1200, a smooth and refined sample
surface was obtained, ready for polishing.
• Polishing
➢ Rough polishing (To remove the imperfections that grinding has left.)
➢ Fine polishing (To remove all scratches and leave a mirror like finish on the
surface.)
1. Polished cloth was placed on the plate. alumina powder.
2. The machine was turned on. 9.5-micron alumina powder was placed on a cloth.
Distilled water was turned on.
3. Specimen was held and grinded to the fabric.
4. After finishing that process, the cloth on the plate was cleaned by hand to remove
the powder.
5. Step 1 to step 5 was repeated using alumina powder which is 5-micron, 3 micron
and 1 micron
6. Finish up to 1 micron. A sample surface like a mirror has been produced.
11
• Etching: Metal surfaces are selectively targeted by a variety of etchants to expose
inclusions, phases, precipitates, grain boundaries, and analytical differences.
Figure 6: Optical Microscope
1. Nital liquid was placed in lab consumables.
2. Sample carved every 10s for 60s.
3. After finishing the etching process, the sample was washed with water, then dried
using a pressure air gun.
4. Then, the sample was placed under microscope. The results have been recorded
12
5.0 RESULTS
The samples shown under the Optical Microscope with different magnifications as shown in:
Description Sample
Sample under Optical
Microscope with magnification
X50
Sample under Optical
Microscope with magnification
X100
Sample under Optical
Microscope with magnification
X200
Sample under Optical
Microscope with magnification
X400
Table 1 : Sample under Microscope with magnification
13
6.0 DISCUSSIONS
6.1 MUHAMMAD IBNU HAKEEM BIN ZAMRI (2023622674)
6.2 MUHAMMAD ZULHAKIMI BIN NOORDIN (2023491526)
6.3 MUHAMMAD ZAHIR ANWAR BIN ABDULLAH (2023690552)
6.4 MUHAMMAD SYAHMI JAZMI BIN JAMHARI (2023679984)
14
7.0 CONCLUSIONS
15
8.0 REFERENCES
16
9.0 APPENDICES AND RAW DATA
17