MECHANICAL ENGINEERING DEPARTMENT
MATERIAL LAB.
ME205
SAMPLE PREPARATION FOR OPTICAL MICROSCOPY
Dr. Farag I. Haider
Dr. Farag I. Haider ME205 1
Objective
To study the structural characteristics or constitution of a metal or an alloy in relation to its physical and
mechanical properties.
Dr. Farag I. Haider ME205 2
Introduction
There are two examination methods in metallography:
I) Macroscopy
2) Microscopy
In macroscopy the examination of the structural characteristics or chemical characteristics of a metal or an
alloy is done by the unaided eye or with the aid of a low-power microscope or binocular, usually under l0x.
In microscopy similar examination is done with the prepared metal specimens, employing magnifications
with the optical microscope of from 100x to as high as 2000x.
Dr. Farag I. Haider ME205 3
Specimen preparation
1- Grinding
A small piece of specimen is cut by a metal-cutting-saw. After cutting
operation, burrs on the edges of the specimen should be carefully
removed by a fine file or coarse grinding paper.
The silicon carbide grinding papers are held flat in a unit containing water
facility for lubrication purpose. Each unit contains four grades of papers,
starting with grade 400 (coarse) and finishing with grade 1200 (fine).
Grinding of the work piece is done by starting with the coarse papers and
then continuing with the fine papers. In each stage, grinding is done by
rubbing the specimen backwards and forwards on the grinding paper in one
direction only, until the surface is completely ground, that is, until only
grinding marks due to this particular paper can be seen to cover the whole
surface.
Dr. Farag I. Haider ME205 4
Specimen preparation
1- Grinding
The specimen is washed thoroughly to remove coarse silicon
carbide particles before proceeding to a finer paper.
The direction of grinding is changed from paper to paper, so that
the removal of previous grinding marks is easily observed.
The extra time spent on each paper should be increased as the
finer papers are used. At the end of the grinding sequence, the
specimen is washed thoroughly and dried. Now, the specimen is
ready for polishing.
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Specimen preparation
2- Polishing
The polishing is done on rotating wheels covered by a special cloth.
Alumina is employed as polishing agent.
The 1-micron size is commonly used, but the total polishing time shortened
by starting on the 7 or 3 micron grade.
The pad should be kept well supplied with lubricant.
The specimen should be held firmly in contact with the polishing wheel, but
excessive pressure should be avoided.
During polishing the specimen should be rotated or moved around the wheel
so as to give an even polish.
The specimen should be thoroughly cleaned and dried between each wheel.
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Specimen preparation
3- Etching
Before etching, it is essential to ensure that the polished surface is grease and smear free. If the final polishing
has involved the use of magnesia ( in the form of an aqueous paste of fine magnesia) or alumina (in the form of
an aqueous suspension of fine alumina), then thorough washing followed by drying off with acetone or alcohol
will give a suitable surface, although it must not be fingered afterwards.
Etching is generally done by swabbing.
Etching times will vary from specimen to specimen, however, a good general, procedure is to observe the
surface during etching, and to remove the specimen when evidence of the grains first appears.
Microscopical examination will then reveal whether the degree of etching is sufficient.
Further etching can then follow to strengthen up the details as required.
Dr. Farag I. Haider ME205 7
Specimen preparation
3- Etching
After each etching, the specimen should be thoroughly washed in running water, followed by drying
off with acetone or alcohol.
* As a guide the following etchants are commonly used:
Alcoholic Ferric Chloride -Copper alloys
Mixed Acids -Aluminum alloys
Nital (ethyl alcohol+ 2% HNO3) -Iron and steel
Dilute HCI -Zinc alloys
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Specimen preparation
Microstructural examination can provide quantitative information about
the following parameters:
1) The grain size of specimens
2) The amount of interfacial area per unit volume
3) The dimensions of constituent phases
4) The amount and distribution of phases.
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