Yildiz Technical University

Department of Marine Engineering

[Metallographic Preparation and Microscopic Examination]

Authors:
130A3058 Cem A. Dansık
120A3034 Ayberk Ardıç
120A3046 Fuat T. Ergin
150A3039 Ömer F. Özdemir

Instructor:
Dr. Oktay Yılmaz
Abstract
Metallographic characterization experiment demonstrates us the internal structure of a material. After
observing the steps the material went through the experiment we can identify the characteristics of the
material and how to change these properties for our benefit.
With the metallographic characterization experiment we can find the substances of the material below;

 Properties
 Classification
 Quality control
 Process control
 Damage analysis
 The process we can do to improve properties of the material

In the experiment we did, took a sample, molded the sample, gradual sanding, shining, and
cauterization and microscopic analyzed a material.

Keywords: Characterization, metallurgic, metal, properties of a material

Cem A. Dansık
Yildiz Technical University, Turkey, lA313058@std.yildiz.edu.tr,
Ayberk Ardıç
Yildiz Technical University, Turkey, lA312034@std.yildiz.edu.tr,
Fuat T. Ergin
Yildiz Technical University, Turkey, lA312046@std.yildiz.edu.tr,
Ömer F. Özdemir
Yildiz Technical University, Turkey, lA315039@std.yildiz.edu.tr,

Team Member Roles and Responsibilities

Member Responsibilities
Cem A. Dansık To contribute in general, To prepare the content of Abstract, Conclusion
Ayberk Ardıç To contribute in general, To prepare the content of Introduction
Fuat T. Ergin To contribute in general, To prepare the content of The Method of Experiment,
Experiment Procedure
Ömer F. Özdemir To contribute in general, To prepare the content of Calculation and Result

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1. Introduction
Any iron-carbon alloys containing more than %2 is called cast iron. These alloys have low melting
temperatures so they are easier alloys to cast then other alloys. These alloys are cheap and resistant to
abrasion and corrosion. These properties make them very commonly used
One way to classify an alloy is using metallographic characterization method. In cast irons there are 4
factors controlling the microstructures. These are; carbon content, impregnation amount, alloy element
and lastly during the solidifying part and after the solidifying cooling rate and heat procedures after the
casting. These variables control the type and morphology of the carbon content. Carbon can be
combined with cementite or in the graphite. According to these parameters cast irons can be classified
in 5 classes. Iron (FE) – Carbon (C) Phase Diagram is shown in Figure 1.

White Cast Iron: All the carbon in the alloy is combined with cementite.
Tempered Cast Iron: Part of the carbon or all are in state called tempered carbon state. This state is a
no uniform state. We can make tempered iron after we do heat procedure to white cast iron. It can be
divided in to 2 types; ferritic and perlitic.
Gray Cast Iron: Big chunk of the carbon is in free graphite lamel state.
Spherical Graphite Cast Iron: Carbon is in spherical graphite form. To make this carbon lamels in
melted alloy is processed with heat. This turns them into spherical graphite. This is different than
tempered cast iron because spheres are made by solidifying.
Cylindrical Graphite Cast Iron: This cast iron is between gray and spherical cast irons.

Fig. 1. Iron (FE) – Carbon (C) Phase Diagram

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2. The Method of Experiment
We are going to analyze a material using the metallographic characterization method. First of all the
experiment we choose the material we are going to use. The material we are using is casted iron. Then
we have to decide how to take the sample. To hold the material easily and to examine every part equally,
we put the material in a Bakelite mold. After we put the material in the Bakelite mold we have to wait
24 hours for mold to get solid. When all the preparations are made for the material we do gradual
sanding, shining and cauterization. After all these procedures material is ready for microscopic
analyzing. The stereo microscope we are using is shown in the Figure 2.

Fig. 2. Stereo microscope

2.1. Experiment Procedure

1. With a saw, sample is cut in the dimensions we need.
2. Sample gets cleaned with water.
3. We put the sample in the Bakelite mold.
4. For 1 part hardener, 5 part resin is stirred in a different cup.
5. Stirred mixture then poured in to mold and we leave it for 24 hours to get solid.
6. Solid part gets removed from the mold.
7. We create a reference point for the sample and we put the sample in the sanding machine.
8. Every point should be sanded equally.
9. In order we use 180, 320, 600, 1000, 1200, 1500 sanding papers.
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10. Every sanding procedure should be around 10 minutes.
11. The water should be on in the sanding procedure.
12. Before the shining procedure, velvet cloth gets moisturized with an abrasive liquid and pure water
mixture.
13. Surface of the sample is then shined with this cloth.
14. After the shining sample is cleaned with water and alcohol.
15. Cauterization is done with a cotton dipped in nitrite acid.
16. While doing cauterization sample should be checked every 5 seconds.
17. After these procedures sample is ready for analyzing.

2.2. Calculation and Result

The visuals obtained as a result of the stereo microscope examination are given in Figure 3 to Figure 10
with their explanations.

Fig. 3. Microstructure of a cast iron that consists of 3.07% C, 0.06% Mn, 2.89% Si, 0.006% P, 0.015% S,
0.029% Mg
C) Cementit, L) Ledeburite, F) Ferrite, P) Pearlite
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 Fig. 4. Showing the deformation of the sheet sample during cutting micro structures
a) microstructure of ferrite grains, b) microstructure showing elongated grains and broken carbides

Fig. 5. Microstructure showing coaxial ferrite and pearlite grains in steel

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Fig. 6. Microstructure showing ferrite grains of cold rolled low carbon steel sheet
a) 30%, b) 50%, c) 70%, d) 90%

Fig. 7. Microstructure of dual phase steel sheet with austenite islets

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Fig. 8. Microstructure of rolled 1020 steel showing elongated bands of ferrite and pearlite grains
a) Ferrite grains, b) Pearlite grains

Fig. 9. Microstructure of forged steel

a) Longitudinal plane, b) Transverse plane

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 Fig. 10. a) Low carbon steel microstructure showing the effect of incorrect sanding, b) Correctly sanded steel
microstructure

3. Conclusions
In modern day industry it is very important to designate the properties of a material. Especially alloys
we use in heavy industry. These alloys are used in infrastructure, buildings etc. because they are
cheap, easily produced, easy to find and sturdy materials. In this experiment we did metallographic
characterization test. We learned; how to do the test step by step, what do we have to be careful about,
tools and materials we used in the test, microstructure of steel, difference between steel and cast iron,
how to classify an alloy are all shown in this experiment.

References
Erçetin, Ali (2014). AA 204 Alüminyum Alaşımının Doğal Yaşlandırma Yöntemi İle Mekaniksel Özelliklerinin
İncelenmesi

Güler, Rabia (2014). Lecture notes on Metallography