Muhammad Khairuddin Bin Zaidy 2007284668 EMD 4M5

3.0 Experimental Procedure In this experiment, we as students were demonstrated about the basic procedure in metallurgical studies in terms of preparation of samples for metallographic observation and basic operation of optical microscope. Every step was demonstrated clearly in terms of its operation and purpose. 4.0 Findings 4.1 Find out why microstructures study is important in materials science especially in engineering field? Microstructure study in materials science is important because everyday many applied scientist or engineer encounter problem or task involving materials. Selecting the appropriate materials could be the factor between success and failure of the task. Although the materials look all the way same roughly, but under microscopic view the properties of materials could be different. 4.2 Explain why there are many types of etchant used in microscopic examination of metals? Give at least 3 types of etchants, their chemical composition and their purpose. Also explain what make one etchant differences to another? There are many type of etchant used in microscopic examination. This is because different type of metals contains different type of composition. Thus we have to use different type of etchant for different composition. Example: Etchant Nital Picral Vilellas Reagent Chemical Composition Ethanol : 100 ml Nitric acid : 1-10 ml Ethanol : 100 ml Picric acid : 2-4 grams Glycerol : 45 ml Nitric acid : 15 ml Hydrochloric acid : 30 ml Distilled water : 33 ml CuCl2 : 1.5 grams Hydrochloric acid : 33 ml Ethanol : 33 ml Purpose Most common etchant for Fe, carbon and alloys steels and cast iron Recommended for microstructures containing ferrite and carbide. Good for ferrite-carbide structures (tempered martensite) in iron and steel For etching martensitic stainless steels. Martensite will be dark and the ferrite will be colored.

Kalling's No. 1

4.3 How do different phases exist in an alloy during microstructure studies? Different phases exist in an alloy during microstructure studies if cause by different type of treatment that been apply to that alloy.

Muhammad Khairuddin Bin Zaidy 2007284668 EMD 4M5

5.0 Discussion 5.1 Sample Preparation A) Cutting This is the first step in sample preparation in raw specimen selection. When the specimen had been choosing, it will undergo cutting process. This is due to the physical properties of the specimen, as example, a rod of aluminum. It is heavy and long, thus it is hard to study the microstructure of the aluminum. So, we cut it into small pieces of rod before molded. There are many type of cutting machine such as cut-off machine and precisions cutter. Cut-off machine often used in big samples, while precisions cutter is used when we need no cut the samples in very precise measurement, up to millimeter, by using diamond-coated blade. . B) Molding

Cutting Machine

Technician cutting the specimen

Precision Cutter

In this step, sample that has been cut will be covered by a mean of mounting, through hot pressing technique. In this experiment, we used Simplimet 2000 Automatic Mounting Press. 1st, the specimen is positioned on top of the pressing place. Then, molding material is added to the pressing machine. Next, all details such as temperature, pressure and others is set on the machine. After desired time, the mounting process is done.

Automatic Pressing Machine Sample is positioned on machine

Muhammad Khairuddin Bin Zaidy 2007284668 EMD 4M5

C) Grinding After finished been molded, the specimen then go through grinding process. There are two types of grinding, rough grinding and fine grinding. Firstly sample will undergo rough grinding to remove rough scale and gross imperfections on the surface. Then, the sample will undergo fine grinding which will improve the surface of sample and it begins to shine and reflect light slightly. In this step, we used rough sand paper for rough grinding, then we used smooth sand paper for fine grinding.

Grinding Machine D) Polishing

This process is similar to grinding process, but polishing consists detailing more the sample. Polishing process also has 2 types; rough and fine. Rough polishing will remove all imperfections that grinding process has left. Then, fine polishing will remove all scratches and leave a mirror like finishing on the surface. In this step, we used very high number of grade of sand paper, which shows that the sand paper is very-very smooth.

Polishing Machine E) Etching

Mirror like finishing

In this step, we will complete the sample for study by etching the sample. Etchants are composed of organic or inorganic acids and alkalis dissolved in alcohol, water or other solvent. Various acids and alkalis are used o selectively attack the surfaces of metals to reveal grain boundaries, phases, precipitates, inclusions and variations in composition.

Sample of etchants that been used.

Muhammad Khairuddin Bin Zaidy 2007284668 EMD 4M5

6.0 Conclusion After completing this experiment, we can conclude that we understand all the steps required in preparing metallographic sample, from cutting process until etching process. We also understand the basic concept of etching. This solvent reacts with the composition of the specimen, and will help observer to identify the microstructure of the sample, such as grain boundary and others. We also understand the basic function of optical microscope and how its operate. This can help us in future when we have to examine microstructure of a specimen. Lastly, we also manage to use and perform

Muhammad Khairuddin Bin Zaidy 2007284668 EMD 4M5

analysis from the microstructures observed. From this analysis we can conclude several main points in different task of experiment.