Lab: Characterization of Materials-2

Lab Report 04: Cutting and Mounting of Metallic Sample in

Metallography

Submitted To: Dr. Syed Mujtaba ul Hassan

Submitted By:

Group Number 1:

1. Muhammad Danyal Shahid……………… (22)

2. Muhammad Ahtisham Aziz………...……. (21)

3. Abdul Ahad Naeem………………………. (01)

4. Fahad Uddin………………………………. (07)

5. Muhammd Kaleem Qureshi……………… (27)

Date:22-03-2023

Abstract Format Discussion Results

Department of Metallurgy and Materials Engineering

Batch: 2021-2025
Abstract:
The first step of metallography is sectioning of sample by different methods. If sample is
too small to handle Then mounting will be done for handling of sample. Mounting in material
science refers to the process of preparing a specimen for analysis by embedding it in a resin or
other material to hold it firmly in place during cutting, polishing, and testing It also discuss about
various materials used for mounting specimens, the preparation and mounting process, and the
different testing methods used for mounted specimens. Understanding the proper techniques and
materials for mounting in material science is crucial for obtaining accurate and reliable results in
material testing and analysis.
 TABLE OF CONTENTS

1.0 Introduction…………………………………………………………….... 1
1.1 Metallography……………………………………………………. 1
1.1.1 Sectioning…………………………………………........ 1
1.1.2 Abrasive Cutting……………………………………….. 2
1.1.3 EDM………………………………………………......... 2
1.1.4 Precision Cutting……………………………………….. 2
1.1.5 Laser Cutting…………………………………………… 2
1.2 Mounting………………………………………………………….. 3
1.3 Purpose……………………………………………………………. 3
1.4 Mounting Techniques……………………………………………... 4
1.4.1 Hot Mounting…………………………………………... 4
1.4.2 Hot Mounting – Process Cylinder…………………........ 4
1.4.3 Procedure of Hot Mounting…………………………….. 5
1.4.4 Two types of Hot Mounting Resin……………………... 5
1.4.5 Thermosetting Resins…………………………………... 5
1.4.6 Thermoplastic Resins…………………………………... 5
1.5 Cold Mounting……………………………………………………. 6
1.5.1 Procedure of Cold Mounting…………………………... 6
1.5.2 Resistance to Common Chemicals…………………….. 6
1.5.3 Types of Cold Mounting………………………………. 6
1.5.4 Epoxy Resins…………………………………………... 6
1.5.5 Acrylic Resins…………………………………….......... 6
2.0 Experimental Work……………………………………………………... 7
2.1 Apparatus…………………………………………………………. 7
2.2 Procedure…………………………………………………………. 7
3.0 Discussion………………………………………………………………... 9
4.0 References………………………………………………………………. 10
1.0 INTRODUCTION:

1.1 Metallography:

Metallography is the study of the microstructure of all types of metallic alloys. It can be
more precisely defined as the scientific discipline of observing and determining the
chemical and atomic structure and spatial distribution of the grains, constituents,
inclusions, or phases in metallic alloys.

Steps:

In sequence, the steps are:

 Sectioning,
 Mounting,
 Course Grinding,
 Fine Grinding,
 Polishing,
 Etching
 Microscopic Examination

1.1.1 Sectioning:

Preparing specimens for mounting and mechanical polishing often requires cutting
material into smaller pieces. Diamond and grinding cutoff saws are used to
section materials while still retaining a reasonably smooth cut surface, necessary
for proper grinding and polishing.

Types of Sectioning:
 Abrasive cutting:
 Precision cutting
 EDM
 Laser cutting
 Water jet cutting

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1.1.2 Abrasive cutting:

This method involves using a saw

blade or a grinding wheel to cut
through the metal sample. Abrasive
cutting is often used for larger
specimens or samples that are
difficult to cut using other
methods.

1.1.3 Electrical discharge machining

(EDM):

EDM is a non-traditional cutting method that

uses an electrical discharge to remove material
from the metal sample. This method is often
used for cutting very hard or brittle materials.

1.14 Precision cutting:

This involves cutting the sample using a high precision cutting tool, such as a wire
saw or an electrochemical cutting machine. This method is used for samples that
require very high precision or for samples that are too small for abrasive cutting.

1.1.5 Laser Cutting:

Laser cutting is a non-contact cutting method

that uses a laser to cut through the metal sample.
This method is often used for cutting very thin
or delicate samples.

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 1.2 Mounting:
To attach to a support: to arrange or assemble for use or display.

1.3 Purpose:
The purpose of mounting is to protect fragile or coated materials during preparation and to
obtain perfect edge retention. Mounting is used when the protection of layers is imperative, and it
enables a safer and more convenient handling of small, sharp, or irregularly shaped specimens, for
example.

Specimens are embedded in

resin to facilitate their handling and
to improve the preparation result.
For the best possible
result, specimens should be cleaned
prior to mounting. The best possible
adhesion of resin to the specimen
requires the surface to be free from
grease and other contaminants.

Specimens that need perfect edge retention or protection of layers require mounting. However, it
is worth considering whether the size or geometry of the specimen would make mounting
unnecessary or even difficult. If this is the case, it might be better not to mount it.

Another consideration is whether or not the specimen can tolerate heat. If not, it is advised to
refrain from using a mounting method that is likely to heat the specimen. Finally, consider that
time can be saved by not mounting the specimen.

When/Why Mounting?

• The specimen is small.

• The specimen has a complicated shape (it is therefore difficult to manage).
• Edge retention is necessary.
• Surface-hardened
• Layers
• Coatings (taper section)
• The specimen is porous or has cracks.
• Powder metallurgy
• Ceramics

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 • Petrographic specimens
• Failure analysis

It is necessary that the size of the specimen is made uniform (for certain specimen
holders for automatic preparation).

1.4 Mounting Techniques:

• Hot compression mounting

• Cold mounting

1.4.1 Hot Mounting:

Hot mounting is recommended to achieve a high quality mounts
(edge examination, hardness measurements), it offers a greater
hardness and allows to control the mounting diameter.

1.4.2 Hot Mounting - Process cylinder:

The clean and dry specimen is placed in a mounting cylinder in a hot mounting press, and the
appropriate mounting resin is added. A temperature of around 180° C and a force of about 250 bar
is applied during the embedding of the specimen. Water cooling is used to obtain the shortest
possible mounting time.

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1.4.3 Procedure of Hot Mounting:

• Clean the Specimen: The specimen should be cleaned before mounting in order to
improve adhesion to the mounting medium. Use acetone or at least alcohol. Cleaning in an
ultrasonic bath could be necessary. Remember to dry the specimen well. Clean specimens
should be handled with either gloves or tweezers.
• Adjust the specimen size to the cylinder size (~ 3.0-5.0 mm distance to cylinder wall).
• Adjust the specimen height – the final height of the mount should be approx. 20 mm.
• Select the most suitable hot-mounting resin.

1.4.4 Two Types of Hot-Mounting Resin:

• Thermosetting resins
• Thermoplastic resins

1.4.5 Thermosetting resins:

Thermosetting resins cure at

elevated temperatures. To avoid porous,
non-uniform mounts, it is important that the
pressure is always constant and at the right
level. Once the mount is cured, the only way to
remove the specimen is to destroy the mount.
1.4.6 Thermoplastic resins:

Thermoplastic resins soften or melt at

elevated temperatures and harden during
cooling. This resin type can be used to mount
pressure-sensitive specimens. The mounting
medium is first heated and then exposed to
force when it is soft. This ensures that the
mounting medium is pressed into open pores
and cracks.

Thermoplastic mounting media can be melted

again.

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1.5 Cold Mounting:
Cold mounting is recommended for the mounting of individual or series samples, fragile and
sensitive to heat.

1.5.1 Procedure of Cold Mounting:

• Clean the specimen. The specimen must be cleaned prior to mounting in order to improve
adhesion of the mounting medium to the specimen. Use acetone or at least alcohol.
Cleaning in an ultrasonic bath may be necessary. Remember to dry the specimen well.
Clean specimens should be handled with either gloves or tweezers.
• Adjust the specimen size to the mounting cup size.

1.5.2 Resistance to Common Chemicals:

All cold-mounting media are resistant to common etchants. Some cold-mounting media react with
organic solvents like acetone, alcohol, etc.

1.5.3 Types of Cold Mounting:

• Epoxy resins
• Acrylic resins
1.5.4 Epoxy Resins:

Epoxy resins are suitable for mounting of all types of materials and are especially recommended
for vacuum impregnation. Epoxies have the lowest shrinkage of all cold-mounting resins. The
curing time is relatively long, but adhesion to most materials is excellent. They polymerize through
a chemical reaction after being mixed in the correct proportions. The hardened epoxy is
duopolistic, and not affected by moderate heat or chemicals. Properties such as low vapor pressure,
transparency, good adhesion, low viscosity, and no shrinkage are all specific to epoxies.

1.5.5 Acrylic Resins:

Acrylics are easy-to-use resins with short curing times, very limited shrinkage, and excellent
mounting properties. They are well-suited for both serial mounting of irregularly shaped
specimens and for routine work or single specimens. Acrylics are available with and without a
mineral filler. Dye can be used if color coding is needed. When mixing acrylic resins, it is
recommended to add powder to the liquid (hardener) – this will result in the most uniform resin
mixture.

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2.0 EXPERIMENTAL WORK:

2.1 APPARATUS:
• Styrofoam Glass

• Stirrer

• Epoxy Resin

2.2 PROCEDURE:
Selection of Mounting Cup:
Cup material and size must be taken into
consideration.

Size:
A cup large enough to allow 5.0 mm distance from the specimen to the edge of the final
mount is needed to minimize the risk of radial cracks. A large cup, relative to the specimen size,
will cause the generation of excessive amounts of heat which can damage the specimen.
Shrinkage will also increase with a larger resin to specimen ratio.

Material:

Epoxy hardener will affect silicone cups and reduce the lifetime and transparency of
the mount. Selection of cup material for acrylic resins does not have the same restriction.

Mounting Process:

• Choose a mounting cup and place the clean and dry specimen in it.

• Measure the correct amounts of resin components carefully by either volume or weight.

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 • Mix the components thoroughly, pour the resin-mixture over the specimen, and leave the
filled mounting cups to cure.

• Mixing and curing times are important parameters in a high-quality mount, and
recommendations from the instruction manual should be followed.

Fixation of Specimen:

Fixation clips (metal or plastic) ensure that thin plates, foils, and wires remain upright.
Double adhesive foil can be used to keep irregularly shaped specimens upright. Liquid adhesives
may react with some types of cold mounting media. Specimens too small to be fixed by a clip (e.g.
some electronic components) can be held in a vertical position during embedding by cementing
them to the bottom of the mold with a trace of fast-drying glue.

Preparation of Epoxy:

Resin is mixed with hardener with the ratio of 100:40.

Resin: Hardener

100 : 40

Solidification Time:

It also takes 24 Hours for Complete Solidification.

Before After

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3.0 DISCUSSION:
Mounting in metallography is a crucial process in preparing a sample for microscopic
analysis. The mounting process involves encapsulating the sample in a resin or metal to provide a
uniform surface for grinding, polishing, and etching. The discussion for mounting in
metallography can cover several topics, including the types of mounting materials, the mounting
process, and the factors affecting the quality of the mounted sample.

One of the essential factors in mounting is selecting the appropriate mounting material. The choice
of mounting material depends on the type of sample being analyzed, the desired properties of the
mounted sample, and the preferred analysis method. Epoxy resins, acrylics, and thermoplastic
materials are commonly used for mounting in metallography. Metal mounting is also an option,
particularly for samples that need to withstand high temperatures or harsh environments.

The mounting process typically involves several steps, including selecting the appropriate
mounting material, preparing the sample, mixing the mounting material, and embedding the
sample in the mounting material. The preparation of the sample involves cutting, grinding, and
polishing the surface to obtain a flat even surface that is perpendicular to the axis of the sample.
The sample is then cleaned and dried before it is placed in the mounting material. The mounting
material is mixed according to the manufacturer's instructions and poured into a mold that is the
appropriate size and shape for the sample. The sample is then embedded in the mounting material,
and the mounting material is allowed to cure.

Several factors can affect the quality of the mounted sample, including the choice of mounting
material, the curing time of the mounting material, and the pressure applied during the mounting
process. Inadequate curing time or insufficient pressure can result in voids, cracks, or incomplete
filling of the mounting material, which can affect the accuracy and reliability of the analysis.

In summary, mounting in metallography is a critical process that requires careful consideration of

the mounting material, the mounting process, and the factors that can affect the quality of the
mounted sample. Proper mounting ensures that the sample is well-prepared for microscopic
analysis, enabling accurate and reliable results.

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4.0 REFERENCES:
[1] Struers, “Hot-Mounting Process”, (Online)
https://www.struers.com/en/Knowledge/Mounting/Hot-mounting#hotmountinghowto

[2] Agarscientific, “Cold Mounting Resins”. (Online)

https://www.agarscientific.com/sem/specimen-embedding/cold-mounting-resins

[3] Scribd, “Mounting”, (Online) https://www.scribd.com/document/270567674/Experiment-

5-Mounting-Autosaved

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