DEPARTMENT OF MECHANICAL ENGINEERING

UNIVERSITY OF ENGINEERING & TECHONOLOGY

MAIN CAMPUS PESHAWAR

METALLURGY LAB MINI PROJECT REPORT

SUBMITTED BY
MUHAMMAD USMAN REG: 20PWMEC4876
MUHAMMAD SHABAN REG: 20PWMEC4897
MOHSIN JAVED REG: 20PWMEC4967

SUBMITTED TO
Engr. Muhammad Ismail

SUBMISSION DATE MARKS & SIGNATURE

21-07-2022
ABSTRACT
The report is about the micro-examination of mild steel specimen. We were given a specimen of mild
steel on which an unknown heat treatment process was done and we were asked to study and
examine the micro-structure of the specimen and then determine that which heat treatment process
is done in this specific specimen. First the specimen is cut down then mounting and polishing was done
on the specimen after that etching and then finally that structure was examined under metallurgical
microscope. The observations and the conclusion that we make after examining the micro-structure
of the given mild steel specimen are also discussed in the report

PROBLEM STATEMENT:
To analyze the given specimen of mild steel, on which unknown heat treatment process is done, and
determine that which heat treatment process is done on the given specimen.

METHODOLOGY:
To analyze the microstructure of given specimen we have to do certain operations on the given
specimen. First we have to cut down the given specimen of mild steel into a small specimen of about
3 to 4 mm. In order to make easy handling and holding of the given specimen we will mount the given
specimen in Bakelite powder using mounting press. After that we will polish the given specimen
starting from grit size of P-180 to P-800. While doing polishing we will examine the specimen under
metallurgical microscope after going through polishing using each sand paper of increasing grit size.
For fine polishing we will use diamond paste and a velvet cloth. After that, to make the microstructure
visible we will do etching using nitol solution. We will examine the microstructure under microscope
and the will compare this microstructure with the microstructure of different heat treatment
processes done on mild steel. Simply we will do the following steps in examining the micro-structure
of given specimen;

1. Cutting

2. Mounting

3. Polishing

4. Etching

5. Microstructure examination

PROCEDURE:
1. CUTTING:
We cut down the given rod of heat treated mild steel using cut-off wheel apparatus. First of all, the
small rod of given heat treated mild steel is clamped in the fixed jaws and switch ON the power supply
to run the spindle along with providing coolant to it, slowly move spindle towards 6 ourselves so that
a rod moves towards the cutting disc, made up of abrasive material like Al2O3. We also provide
coolant to avoid scratches and heating of the specimen. We cut down the specimen of about 3 to
4mm. Then remove the specimen from the jaws with gloves and open bypass valve to clean the
apparatus.
 Figure 1: Specimen Cut Down from Mild Steel Rod 2.

MOUNTING:
The mounting of the specimen was done by using mounting press apparatus. First, we untight the lock
nut and move the beam to the other side. Then, close the pressure relief valve and use handle to exert
pressure on plunger in the cylinder until it becomes out of the cylinder. Oil the specimen, carefully
place again in its position, and place the specimen on it with less scratched surface facing bottom side.
Then release the pressure relief valve to move the plunger a little bit downward. After that, we poured
about 2-2.5 tea spoon of Bakelite powder on the specimen. Then, used pressure relief valve to move
plunger downward and place spacer on it. Again tighten the lock nut and the beam and after that we
completely closed pressure relief valve, turn ON thermostat and adjust the buzzer to sound after 10
minutes. We generated the pressure and maintained it between 130-150 Psi using handle, because
pressure drops as powder melts, due to the high heat and temperature developed in the cylinder.
When the time completes, the buzzer sounded and we turned OFF the supply and thermostat. After
that, we supply low supply of water to allow slow cooling, so that the temperature of the coolant
water normalizes. Then, we used pressure relief valve to move plunger upward and carefully removed
the specimen by using gloves and placed it for 2-3 minutes under tap water. We completed mounting
process and made our specimen ready for planner grinding and then polishing.

Figure 2: Specimen Mounted in Bakelite Powder

POLISHING:
After making the mold of the specimen by using mounting press apparatus then we will perform the
polishing operation on the specimen in order to remove the scratches and make its micro-structure
visible. Polishing operation is done on the specimen to remove the scratches which are created during
cutting or sectioning operation in order to make its microstructure visible. For polishing, we used
abrasive paper of different designation depends upon no. of scratches.

P-180:

First of all, in order to remove the larger scratches from the specimen we use the sand paper of Grit
size P-180 which has larger size grits in order to remove the larger scratches from the specimen.

Figure 3: Micro-Structure after P-180 Polishing

P-320:

When very large scratches are removed then we move towards the sand paper of grit size P-320 which
have little bit smaller size grits in order to remove those smaller size scratches from the specimen.

Figure 4: Micro-Structure after P-320 Polishing

P-400:
When all the larger scratches are removed then we move towards the sand paper of grit size P-400
which have smaller size grits in order to remove the small scratches from the specimen.

Figure 5: Micro-Structure after P-400 Polishing

P-600:

When all the larger scratches are removed then we move towards the sand paper of grit size P-600
which have smaller size grits in order to remove the small scratches from the specimen.

Figure 6: Micro-Structure after P-600 Polishing

P-800:

When some small scratches are removed then we move towards the sand paper of grit size P-800
which have more smaller size grits than P-600 in order to remove very small size scratches from the
specimen.

Figure 7: Micro-Structure after P-800 Polishing

P-1200:

When all the small scratches are removed and now in order to make the surface completely scratch
free then we moves towards the sand paper of grit size P-1200 in order to make the surface completely
free from the scratches.

Figure 8: Micro-Structure after P-1200 Polishing

ETCHING:
Etching operation is performed in order to make the microstructure completely visible.

Chemical Used:

For the etching of the specimen which is made of steel the chemical that is normally used is nital
solution. Nital solution is an etching reagent that contains 98% alcohol mixed with 2% nitric acid.
Soaking Time:

We dipped the specimen in nital solution until its shiny surface become dull. It means that reaction
take place and then removes the specimen from the chemical. After etching the grain boundaries of
the microstructure now become visible and we study its microstructure under metallurgical
microscope.

Figure 9: Micro-Structure after Etching

FINDINGS:
The specimen was properly prepared, processed and then etched. Rough polishing followed by fine
polishing made the surface of the metal, mirror-like and completely scratches free. Such criteria are
necessary for microstructure examination. Grain boundaries are high energy sites and react to etchant
which, in this case was Nital Solution. After being exposed to Nital solutions, grain boundaries reacted
with the etchants and they became clearly visible.

Figure 10: Micro-Structure of the Specimen

A fascinating microstructure could be seen very clearly. After careful examination, we could see fine
layers of Pearlite. Along with these fine layers, black dots were seen. Since the carbon content was
below eutectoid composition, so these black dots is primary Alpha ferrite.

CONCLUSION:
To sum things up that we have discussed so far, as seen in the micrograph, white region is identified
as pearlite and especially fine pearlite. According to TTT diagram, a fine pearlite structure is obtained
when the specimen is Air cooled. And the processes in which cooling is done in open air, is Normalising.
So after going through all the discussion, we can in the end, conclude that the type of heat treatment
process done on the specimen is "Normalising”.