Self-Study Scanning Electron Microscope

Machine Tools and Anil Kumar HB - 1BM17ME020

Machining
Anush S – 1BM17ME021
15ME4DCMTM Aravind Raju – 1BM17ME024

2019 Aryan Mitra – 1BM17ME025

Abstract Results and Discussion

SEM is a scientific instrument that uses a beam of highly energetic After the documentation of the as-received condition and
electrons to examine the surface and phases distribution of followed by non-destructive evaluation, the failed component will
specimens on a micro scale through the live imaging of secondary be subjected to detailed macroscopic examination. These
electrons (SE) and back-scattered electrons (BSE). One of the main examinations start with the visual examination and progress to
activities of SEM Laboratory at MINT is for failure analysis on metal low magnification stereomicroscope.
part and components. The capability of SEM is excellent for
Fracture surface markings usually reveal the direction of crack
determining the root cause of metal failures such as ductility or
growth as shown in Figure 1. Regions surrounding the point of
brittleness, stress corrosion, fatigue and other types of failures. SEM
origin that exhibit a difference in texture are frequently observed.
is excellent for determining the root cause of metal failures such as
Introduction A multiple crack initiation sites are present along the bottom at
ductiliittleness, stress corrosion, fatigue and other types of failures.
"A", final fracture takes place just above “C”. These are indicative
A Failure analysis is the evaluation of information pertaining to the
of a change in fracture mechanism. This is frequently the case
failure of a mechanical or structural component. In failure analysis, when subcritical crack growth mechanisms such as fatigue, stress
careful examination of the failed component, its design, its corrosion cracking are responsible for the initial cracking.
fabrication and its operating history can help to explain how and why
a component failed. Failed parts are usually disposed without
attempting to determine the causes of the failure. Because of these,
failure rates and the costs associated with maintenance are high. One
of the most important instruments used to carry out failure analysis
is scanning electron microscope (SEM). It is used primarily for the
study of topographic and morphological characteristics of any
material. The important of SEM in failure analysis is due to its ability
to provide three-dimensional image for the purpose of fractographic Figure 1 Low Magnification SEM Macrograph of the Fracture
study where the depth of field is needed on an irregular fracture Surface from a Failed Bolt
surface (De Carvalho et al., 2003). Low magnification examination of corrosion failures could also
identify the type of corrosion. The location and the severity of the
attack and characteristics of the corrosion deposits can also be
identified.

The fracture features that are indicative of a specific fracture

mechanism can be classified into one of four basic categories.

Analysis Procedure
Figure 2 SEM Photomicrographs of Fracture Surfaces
When failed components are received in the laboratory it is customary
Exhibiting (a) Dimpled Fracture, (b) Brittle Transgranular
to document their condition. The failed component is then cut and
Fracture, (c) Intergranular Fracture, and (d) Fatigue Striations
sectioned without damaging the surface so that it remains as-
received condition. The sample was mounted to the stub by carbon Conclusion
tape to maintain their conductivity without the use of gold coating.
Scanning electron microscope (SEM) is an important tool for
The mounted as-received samples with an appropriate size can be
microscopic examinations. Its usefulness in fractographic
placed on sample holder directly in the SEM vacuum chamber. This
examinations is due to its ability to provide a wide magnification
procedure is applicable for determination of elemental composition
range typically from approximately 10X to 100,000X with the
on deposit precipitated on the sample surface. Besides that, for
depth of field needed on an irregular fracture surface.
fractographic study, the sample usually cleaned by pickling acid to
remove any dirt and the brownish rust precipitated on the sample.
References
Morphological examination and compositional microanalysis is
carried out using SEM on both as-received and cleaned samples to De Carvalho, M. C., and de Deus, E. P. 2003. Fracture analysis of
detail inspection on failure region of the components. a flow control device used in the petrochemical industry.