Lab Session 2:

Polishing
The objective of polishing is to remove the disturbed metal and leave the surface optically flat.
One of the most important factor to remember during this stage is that contamination destroys
quality. This must be stressed all the time in the metallographic laboratory.

Rough Polishing
The first is rough polishing, which is used to remove the deep scratches from grinding.

Final Polishing
The second is final polishing, which remove scratches from rough polishing.
Standard polishing equipment consist of a horizontal rotating wheel covered with specific type of
cloth. The rotating wheel is wet with distilled water and loaded with an abrasive grit. The
abrasive size is regulated by the type of metal and whether the polishing stage is beginning or
finishing. The better quality finish is produced by holding the specimen flat against the wheel
and rotating it slowly in a direction opposite to the rotation of the wheel. Rotation of the
specimen like this during polishing will help to avoid directional polishing or comet tails.

Control Factors during Polishing Stage

General control factors during the polishing stage are:
1. Amount of abrasive applied.
2. Regulation of amount of water on the cloth.
3. Surface speed or revolutions per minute of the wheel.
4. Force applied to the specimen to make contact with the polishing.
 Amount of abrasive
The general tendency during polishing is to add too much abrasive. The highest quality surface
finish will be produced after fresh abrasive has had time to break up into consistent smaller-sized
particles. When the original abrasives are graded, they are absolutely the same size. With
continued use the particles strike the metal specimen and are fragmented to smaller sizes. This
may occur over a short period of time, for example, 60 to 90 seconds when polishing the harder
metals. Of course the amount of force used on the specimen surface regulates fragmentation. If
polishing wheels are overloaded with abrasive and left standing, oxidation may harden the
residue and scratch the next specimen polished. If this occurs, the wheel should be flooded with
demineralized or distilled water while turning slowly. After several seconds of applying water to
soften the buildup, the wheel may be scraped with aplastic or metal disk. Finish the operation by
adding the generous supply of water and turning the wheel at maximum speed for a few seconds.

Regulation of Water
Regulation of water is important if quality surfaces are to be developed. It is simple to determine
how much water to add. The correct amount is indicated by an inspection of the specimen
surface. Hold the specimen on the wheel firmly for a few seconds then lift it and observe the
evaporation time. The moisture should disappear in about 10 to 15 seconds. Too much moisture
will cause pitting around inclusions and soft phases. If the cloth is too dry the surface of metal
will be burnished or cold worked.

Polishing wheel speed

The polishing wheel speed should be selected by considering the hardness of the specimen. The
softer the specimen slower the wheel speed. The standard 8 inch diameter wheel may turn up to
1100 rpm. Some are variable speed and others are two speed (1100 and 550 rpm).
Wheel speed for metallographic polishing.
Revolutions per minute
Metal Rough Polishing Final Polishing

Soft Steel 550 550 and slower

Hard Steel 1100 550
Copper alloys 550 550 and slower
Aluminum alloys 550 550 and slower

Specimen to Wheel Force

Specimen to wheel force is another factor that will help contribute to a quality surface. It should
be recognized that there is no single force that will be correct. Sometimes the technicians uses
excessive force to fragment the newly applied abrasives and then a reduced force. Other times a
light force at the final polishing sequence may permit some of the particles to roll between the
cloth and the wheel.
Polishing Clothes
A careful selection of polishing cloths may help to reduce the cost of polishing while improving
the quality of job. Basically the polishing clothes should be selected because of their longevity or
service life and their ability to load and carry abrasive and remain reasonably free of
contamination that may cause scratches on the surface of the specimen. There are many different
types of cloths, but a few are easy to select.
Generally the rough-polishing sequence can use a cloth with a short snap. This could be a canvas
or nylon surface. The reason for the snap shot is to permit greater specimen surface contact to
increase cutting action.
Whatever type cloth is selected, It should be stretched tight over the wheel. To facilitate the
process of changing polishing cloths, some have pressure-sensitive adhesive backing. In any
event the bare wheel surface has to be cleaned during every change of cloth.
Intermediate stages of polishing could be accomplished with felt or billiard type of cloth. These
cloths are also used for final polishing with higher hardness specimen (Rc35 and harder).
Final Polishing is generally accomplished by a low-napped cloth and fine alumina. The harder
metals such as steel (Rc20 and harder)can be finished with 1.0 micron alumina.
The softer non-ferrous such as a aluminum, copper and lead alloys need to be finished with
0.05µ alumina.
Polishing sequence regulated by:
1. Amount of magnification.
2. Type of metal.
3. Time factor.
4. Cost factor.
5. Susceptibility to cloth contamination.

The metallographer should analyze each polishing sequence to look for signs that will indicate
completion. Continuation of work after the particular sequence is finished is a waste of time and
money. The final step should be considered completed when a 100X magnification reveals a
highly reflective surface and gray lines. A deep scratch will leave a wide black line.
List of typical polishing cloths.

Type of cloth Type of operation Recommended

Canvas For general rough polishing

Red felt
Billiard cloth
Nylon (nap less cloth)
Synthetic rayon (fibers are
Bonded to cotton backing)
Wood broad cloth (short pile
Synthetic velvet
For rough polishing on steel
For rough polishing on steel
Use with diamond abrasives for maintaining
Flatness and preventing relief
For final polishing with diamond and
Aluminum oxide abrasives
For final polishing with aluminum oxide
For final polishing of soft metals

Procedure
 Make sure that specimen and hands have been thoroughly cleaned before polishing.
 Begin with the 6-micron diamond paste (very small amount) applied on nylon cloth
polishing station and apply small amount of lubricant (one to two drops).
 When polishing the specimen, apply moderate amount of pressure and rotate the
specimen in clockwise direction against the cloth until all the scratches from fine
grinding are removed.
 Wash the specimen and the repeat the process for 1-micron diamond paste.
 Types of abrasives for metallographic polishing.
Types of abrasives for metallographic polishing.

Type Stage of Metal to be Cost Freedom Maximum

Polishing polished from recommended
Contamination polishing
Time each stage

Aluminum All All softer metals Low Yes 2 minutes

Oxide, Al2O3
Magnesium Final Aluminum and Low No 2 minutes
Oxide, MgO magnesium
Chromic All Steel and cast iron Medium No 3 minutes
Oxide Cr2O3
Iron Rough Steel and cast iron Low Yes 3 minutes
Oxide, Fe2O3 and medium
Diamond Rough Boron carbide High No 2 minutes
Medium Sintered Tungsten
Final Carbide-Steel,
Cast iron

Etching
The objective of etching is to accent the structural characteristics of a specimen. Etching is used
in metallography primarily to reveal the microstructure of a specimen under the optical
microscope. It is procedure for achieving contrast in the microstructure.
Microscopic examination of properly polished, unetched specimen will reveal only a few
structural features such as inclusions, cracks or other imperfections. Etching is used to highlight
and sometimes identify, microstructural features or phases present.
Etchants are usually dilute acid or dilute alkalis in a water, alcohol or some other solvent.
Etching occurs when the acid or base is placed on the specimen surface because of the difference
in rate of attack of the various phases present and their orientation. The etching process is usually
accomplished by merely applying the appropriate solution to the specimen surface for several
seconds to several minutes.
Nital, a Nitric Acid - Alcohol mixture, is the etchant commonly utilized with common irons and
steels. Nital is dripped onto the specimen using an eye-dropper or cotton swab. Ten seconds to
one minute is usually sufficient for proper etching depending on sample and nital concentration.
The sample is immediately washed under running water, rinsed with alcohol and dried by air
dryer. Do not touch, wipe or swab the specimen following etching; dry off the rinsing alcohol on
the specimen with the air dryer and then move on to the microscopic examination stage!

References

Heat treatment of metals by Smith, Russel and Bhatia.