4.

0 TITLE : MICROSTRUCTURE OF LOW CARBON STEEL AND

ALUMINUM

4.1 - Abstract
In the microstructure examination optical microscope was used to examine
different specimens of metallic and non-metallic materials. From the examination, the
grain boundary size was calculated. The sketch of a sample under microscopic view is
provided in the report. The purpose of this experiment was to inspect the
microstructures of different materials.

4.1.1 - Introduction

What is microstructure ?

When describing the structure of material, make it clear with distinction between
its crystal structure and its microstructure. The crystal structure describes the
appereance of the materials on an atomic lenght scale. The term of microstructure is
used to describe the appearance of material on the nm-cm scales. A reasonable
working definition of microstructure is the arrangement of phases and defetcs within a
materials.
Using a range of microscopy techniques micostructural can be
oberved. The microstructural features of a given material may vary greatly when
observed at different length scales. For thisreason, it is crucial to consider the length
scale of the observations you are making when describingthe microstructure of a
material.

Why is the microstructure of a material important?

The most important aspect of any engineering material is its structure. The
structure of a material is related to its composition, properties, processing history and
performance. And therefore, studying the microstructure of a material provides
information linking its composition and processing to its properties
and performance. Interpretation of microstructures requires an understanding of the
processes by which various structures are formed. Physical Metallurgy is the science
which provides meaningful explanations of the microstructures, through
understanding what is happening is inside a metal during the various processing steps.
Metallography is the science of preparing specimens, examining the structures
with a microscope and interpreting the microstructures.The structural features present
in a material are a function of the composition and form of thestarting material, and
any subsequent heat treatments and or processing treatments the materialreceives.
Microstructural analysis is used to gain information on how the material was
produced and the quality of the resulting material.

What is microstructural analysis for ?

Microstructural analysis is used in failure analysis to determine the cause of
failure. Failures can occur due to improper material selection and poor quality control.
Microstructural examination of a failed component is used to identify the material and
the condition of the material of the component.Through microstructural examination
one can determine if the component was made from specified material and if the
material received the proper processing treatments. Failure analysis, examining the
fracture surface of the failed component, provides information about the cause of
failure. Failure surfaces have been well documented over the years and certain
features are associated with certain types of failures. Using failure analysis it is
possible to determine the type of stress that caused the component to fail and often
times determine the origin of the fracture

OBJECTIVE :
A) To understand the process of preparation of aluminium and mild steel specimens
for microstructure studies.
B) The main objective of this project is to study about the view of structure of mild
steel and aluminium had.

4.1.2 METHOD AND MATERIALS

In the study of metallic materials it is to analyze the phases exist and grain size in
the structure. Details of the structure of metals cannot be seen by naked eyes, but
grain structures in metals may be seen with the microscope. The metal use in the
metallurgical examination must be prepared and polished carefully before a good
microscopic image can be seen. It is important to ensure that the surface is totally flat
and smooth before microstructure observation under the microscope. Any irregularity
will appear as a dark image and may create confusion to the observer who attempts to
analyze a structure. In order to obtain this smooth flat surface, several preparatory
steps are required. The materials that we use are arcylic resin, 20x10x5 mm of
aluminium and mild steel, plastic mould, sand paper of various grade, polishing
machine, Bx41 microscope.
For the method :
a) Cutting
Cutting process is carried out in order to get the desired size of the sample so that it
can be easily molded/handle.
b) Molding
Molding process is carried out to make the sample easier to hold throughout the
polishing procedure.
c) Grinding
Rough grinding: To remove rough scale and gross imperfections on the surface of
sample.
Fine grinding: To improve the specimen's surface until it begins to shine and reflect
light slightly.
d) Polishing
To remove the imperfections , scratches and leave a mirror like on the surface.
e) Etching
Various etchants are used to selectively attack the surfaces of metals to reveal grain
boundaries, phase, precipitates, inclusion and variations in composition.

4.4 - Procedure
Two speicements were provided which is one is aluminium and another one is mild
steel.
A) Moulding
1. clean the spiecemens and dried.
2. Use small plastic suitable mould.
3. The cleaned aluminium specimen is placed into one of the mould.
4. Poured acrylic resin into the mould.
5. The aluminum specimen would be at the bottom.
6. The sample was cooled at room temperature for 1 hours.
7. The raisen had cured and imbaded the space of the mould.
8. The sample was removed from the moulding ring and proceed with grinding.
9. Repeat the step with mild steel speciemen.
Refer appendix 2a

B) Grinding
1. We use rotation water lubricated disc equip with core silicon carbide paper and
water.
2. Used 180 grade of paper.
3. Make sure to press the sample calmly and evenly to the paper to avoid any tilt.
4. Make sure not to grains our fingertips accidently.
5. After its had achieved and even relatively rough surface, samples ready with
next step with finer paper.
6. Insert new 320 grade of paper on to the disc
7. Rotate the sample with 90 degree.

8. The function of water flushing during grinding is to keep the samples cooled
and prevent the paper being loaded with material particles.
9. Grinding continue with 600, 800 and 1000 grade until the blemish and all the
scratches had been removed.
10. The samples were ready for polishing
Refer appendix part 2b

C) Polishing
1. The specimen and hand were ensured have been thoroughly cleaned before
polishing.
2. The polishers consist of rotating discs covered with soft cloth impregnated with
diamond particles and oily lubricant.
3. On the counter rotating motion pressed the sample in high pressure on to the
polishing cloth.
4. After about a minutes, the sample already about a shiny appeared, but still there
is many scratches had been found.
5. Washed the samples.
6. Continued the polishing with less pressure untill the scrathed cannot be seen by
naked eyes.
7. Wash the samples and wipe it with cotton wool to avoid any scratches and
damages.
8. Dried both samples.
Refer appendix part 2c

D) Etching

1. droped some nital and nitrc acid on the mild steel sample and some kellers
reagent and water on the aluminium sample.
2. Etching occurs when the acid or base is places on the specimen surface because
of the difference in rate of attack of the various phases present and their
orientation.
3. The etching process is usually accomplished by merely applying the appropriate
solution to the specimen surface for several seconds to several minutes.
4. Ten seconds to one minute is usually sufficient for proper etching depending on
sample and nital concentration.
5. The sample is immediately washed under running water, rinsed with alcohol
and dried in an air blast.
6. Do not touch wipe or swab the specimen following etching.
7. Dry off the rinsing alcohol on the specimen with the air blast.
8. Then move on to the microscopic examination stage.
Refer appendix part 2d

4.4.1 - Mellography observation

1. The sample was examined in the microscope. Initially the specimen was
examined through the stereomicroscope that gave a three-dimensional
impression of the specimen surface. With a properly etched specimen, grains
were differentiated and impurity particles could be seen clearly.
Refer appendix part 3

2. Metallurgical microscope was used to view the specimen at various magnifications

and the microstructural aspect of the material was noted.

3. The microstructure of the specimen was sketched.

4.5 - RESULTS
Bx 41 microscope

Microstructure result

In the experiment, the microstructure of mild steel and aluminuium were

determined. The type of the microstructure formed has been identified. The view of
the microstructure can be seen through microscope.
Detailed viewing is done with a Bx 41 microscope. A Bx 41 microscope has a
system of lenses which is objectives and eyepiece so that different magnifications at
20X to 100X can be achieved. The important characteristic of the microscope are:
a) Magnification
b) Resolution
c) Flatness of field

Sample for mild steel

Sample for aluminium

4.5.1 - COMPARISON

Sample for mild steel

Sample for aluminium

Type of materials

Actual

Theoritical

Mild steel

Aluminium

Observation of mild steel

After ecthing a mild steel, only grain boundaries are chemically attacked severaly
and so they appear as a dark lines in the optical microstructure. The polished sample
dark ( pearlite) and light (ferrite) regions are observed in the microstructure. The dark
pearlite regions have been more severaly attacked by the etachant and thus do not
reflect much light.

Observation of aluminium
Keller s reagents is highlights common features in aluminum and aluminum
alloys, and is sometimes effective at showing grain boundaries.

4.5.2 - DISCUSSION

From the experiment that have been done, we can understand the preparation
procedure of microstructure test. To prepare the metallographic sample, the specimen
must through several processes. The processes are molding, grinding, polishing and
etching. These processes are essential in order to get best result.
During molding process was carried out to facilitate handling of the specimen
during grinding, polishing and etching process.Grinding process was carried out in
order to maintain the flatness of the sample. There are two types of grinding which is
rough grinding and fine grinding. During polishing process, edge rounding need to be
avoid by select an appropriate preparation sequence and also the removal of
deformation need to be ensure in order to reveal the true structure.
Etching is the process that reveal microstructural features such as grains
boundaries, phases, precipitates and other microstructure constituents from the
polished specimen through selective chemical attack on its surface. A properly
prepared specimen will reveal properties such as grain size, separation and the shape,
size and the distribution of the phases and inclusion that present.
Metallographic samples are study by using optical microscope. The light
microscope was used to study the microstructure. The optical illumination systems are
its basic elements. For materials that are fading to visible light, there are only the
surface is subjected to observation and the light of the microscope must be used in a
reflective mode. Contrasts in the image produced result from differences in
reflectivity of the various regions of the microstructure.

4.6 - CONCLUSION

As conclusion, the objectives of the experiment were successfully achieved. The

method of preparation of metallographic sample was understood. There are 5 process
need to be through by the specimen which are cutting, molding, grinding, polishing
and finally etching. The other aim which is to understand the concept of etching and
the purpose of etching also successfully achieved. Etching process was carried out to
selectively attack the surface of metals to reveal grains boundaries, phases,
precipitates, inclusions and variations in composition.
Other than that, the basic function of optical microscope and it operation also
understood. The structure of the material can be observed with the Bx 41 microscope.
Finally, the objective of the used and performed analysis from the microstructure's
observed also successfully achieved. The microstructure of the sample obtain was a
mixture of ferrite and pearlite which is a hypoeutectoid steel.

4.7 - REFERENCE

William F.Smith,Javad Hashemi,Foundation of Material Science and Engineering,

fifth edition.

https://www.scribd.com/doc/31580070/a-project-report-on-microstructure-analysisof-gray-cast-iron-aluminium-and-brass-using-optical-micrographs

http://www.substech.com/dokuwiki/doku.php?id=etching_metallographic_specimens

https://www.youtube.com/watch?v=fc8zrgYJCJw

https://www.youtube.com/watch?v=UuHofNW40Yw

4.8 - APPENDIX

2 a)

2 b)

After moulding
process

Grinding

2 c)

Washed the

Polishing

Washed both
specimens

Droped of nitric
acid on mild steel

2 d)

Droped of
sodium
Microscoping
hydoxide on
examination
aluminium

Washed both
specimens