Faculty of Engineering

Industrial Engineering Department

Metrology Laboratory

Exp. #1 Angular Measurement Sine bar

Student Name : Jalal Abu Taha

ID # : 20090029037

Date : 21 / 2 / 2012

Objectives:
1. Selecting a representative specimen. 2. Grinding and polishing the specimen. 3. Etching the polished mirror-finished surface of a specimen to reveal its structure. 4. Using the metallurgical microscope.
5.

Examining the structure of the specimen under the microscope, and To be able to understand the behaviour of the grains when exposure the rays come from microscope.

Materials and Equipments:

We used in this lab (grinder-polisher machine) it a disk like shape and it rotatets in specific velocity we can determine it manually, in grinder machine we use a salt paper with different grades (120-1200) to make the specimen smoothest start from 1200, and we use water (H2O) continuously during and after grinding for different reasons like: (to keep the surface clean and to cold the specimen). But in polisher machine we use fine piece of cloth like velvet cloth to make the surface smoother and during this process we used (diamond spray), which it is a very hard material with small grains and toxic odour, which make the surface of the specimen smoother and has a mirror like surface. In Etching process we used a chemical materials (Natal and HNO3) these chemicals attack the boundaries to make it appears when we using Microscope.

In the final step we used (Metallurgical Microscope) which connected with a computer and includes two lens:
1.

Fixed piece lens, which has a fixed magnification

2. Objective lens, which has vary magnification (5X 100X).

Fig(1): metallurgical microscope

Fig(2): metallurgical microscope dimensions We used in this lab a steel cylindrical shape specimen, with a diameter of 20mm or 20 mm square and a thickness not more than 12 mm, see fig below:

12 mm

fig(3): geomtry of specimen

Procedure:
You will have a ready cylindrical specimen with a diameter 20mm and thickness 12 mm, I mean you didnt do the cutting step and mounting step. After that take the specimen and go to grinder machine which contains sand paper, then during use hand-grinding operations on progressively finer grades of sand paper, the specimen should be washed in water and rotated through 90 at each change of sand paper, to prevent the carry-over of relatively coarse grinding particles from a paper to the next finer grade sand

paper, and be careful to your fingers because you may be hurt yourself if you dont catch the specimen correctly, notice that water is very important in this step for cleaning the surface and remove the grinding particles that produces from grinding and to colder the specimen to avoid deformation that may be happened cause high temperature. Then wash the ground surface of the specimen with water, clean it with alcohol, and dry it with an air dryer, in order to prevent any dirt or contamination or grinding particles from being carried over the polishing cloth in the next step.

After that polish the ground surface of the specimen using the rotating disk polishing machine, a constant drip of suspended polishing powder in water is necessary to keep the cloth covering the disk wetted thoroughly , during the polishing operation. The machine should rotate with a reasonable speed and light pressure should be used in pressing the surface of the specimen against the wetted cloth of the disk. Scratches may be formed on the polished surface, if a heavy pressure is applied, caused by the deeply embedded grit particles in the cloth. Moreover, the use of light pressure and reasonable rotating polishing machine speed are less likely to cause the specimen being suddenly thrown by the centrifugal force of rotation across the laboratory. After finished this step clean the specimen with alcohol, shake it to remove the surplus alcohol, and then dry it with the air dryer. Never touch the specimen surface by the fingers. Then use proper method to apply the Etching solution to the prepare surface of the specimen, by immersion of the surface in the Etching solution, after etching wash quickly the etched surface with water, then swab it with alcohol and dry it. After that put the specimen under the objective lens of the metallurgical microscope and use the proper magnification power, then sketch the microstructure of the etched surface of the specimen, as it observed through the

eye-piece lens of the metallurgical microscope. A photograph of the etched surface will be quicker and better, if it is available.

fig(4):Specimen have a morphous surface

Results and Discussion:

Fig (5): metallurgical microscope Metallurgical Services offers it's expertise on study of metallography structure of metals. A CARL ZEISS microscope with a computer interface, instant micrograph under magnification ranging from 50X to 1000X can be obtained for detailed study and analysis. From metallurgical microscope that we see above we obtain the following images for the grains:

Fig(6): microstructures grains of Aluminum

Fig(7): microstructures grains of Annealed Mild Steel

Fig(8): microstructures grains of Cast Iron.

Fig(9): microstructures grains of Cold Worked Copper

Fig(10): microstructures grains of Martensite

Fig(11): microstructures grains of Mild Steel

Fig(10): microstructures grains of Stainless steel1

As we show the grains have different colors, from white to black with different grades, the rays (light) which come from microscope interact with grains, and the grains which appears in dark black it is absorbs more light and the grains which appears in white reflects all light and dont absorb anything, so we reach from this that as the grains absorbs more light they appears darker, and the grains which absorbs less light they appears lighter (white), and rest of the grains appears between black and white degrees subject to absorbing amount of light. Metallurgical Services offers it's expertise on study of metallography structure of metals. A CARL ZEISS microscope with a computer interface, instant micrograph under magnification ranging from 50X to 1000X can be obtained for detailed study and analysis.
Test Facilities
Instruments Metallurgical Microscope (AXIOVERT 100 A) Microscope Magnification (100 - 400) No. 1 1 Make German Indian

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Charges
Rate per Specimen (Rs) Rates from 1st April 2008 300/2500/350/200/50/-

Test

Micro / Inclusion (Method A) Examination per location Inclusion Rating Method D Micro Examination with 3 copies of photograph Only Photograph - 3 Copies Mounting Charges for small pieces Macro Examination on Plate Upto 25mm thick Above 25mm thick

120/150/-

Macro Examination on Pipes / Tubes Upto 4" NB Over 4" NB to 8" NB Over 8" NB to 12" NB Over 12" NB to 18" NB Over 18" NB Macro Examination on Mock-up sample Macro Examination on Forging Macro Examination on Fillet

120/140/170/200/225/175/275/175/Charges on request 450/1000/1250/150/500/450/1800/1700/750/2500/250/1000/2500/250/250/5,500/-

Failure Analysis

Macro Examination with Photographs Step Macros without photographs (each step) Step Macro with photograph (each step) Macro Measurement (MLP / Penetration, etc) each Depth of Attack Micro for Duplex Grain Structure Ferrite by Metallograph Banding Index Internetallic Phases Inclusion Rating E & S, Method D Inclusion Rating E & S, Method A Nodule Count, Nodularity / area fraction Area Fraction (three phase) Mesh Size Coating / plating thickness / mesh size Austenitic Grain Size with photographs (up to 3 samples)

Every additional sample

3000/-

Etching reagents

composition

Metals and alloys which can be etched

Etching time (seconds)

Nitric (natal)

Conc. Nitric acid Absolute methyl or ethyl alcohol

4 cc 96 cc

Carbon steels and cast irons

10-30

Carbon steels and low Picric acid Absolute methyl 4 gm alloy steels (etch pearlite, Picric (picral) or ethyl alcohol 96 cc do not reveal ferrite grains) Hydrochloric acid nitric acid 10 cc Hydrochloric+ nitric acid+ water 3 cc 18/8 stanless steel water picking retainer (flour trace) 100 cc (used about 70-80C) Copper and its alloys such Ferric chloride 10 gm as bronzes, high zinc Ferric chloride conc. Hydrochloric acid 30 cc brasses and aluminum water 200 cc bronze Aluminum hydroxide 5 parts Aluminum hydroxide+ water 5 parts Copper and its alloys hydrogen peroxide hydrogen peroxide 2 parts Hydrofluoric acid 2 cc Hydrofluoric acid+ nitric nitric acid 5 cc Aluminum an its alloys acid 100 cc Ethylene glycol+ nitric acid Ethylene glycol Distilled water Conc. Nitric acid 75 cc 24 cc Magnesium and its alloys 1 cc

15-60

15-60

15-60 (used freshly prepared solution)

Table (1): Etching reagents for micro-examination

Conclusions:

This lab was very successful and able to achieve its goals, we become having a deeper understand for microstructures of metals, we become familiar with metallurgical microscope and knowing it has focal force (50X1000X), and we knew that the mirror like surface for metals reflect the light so we cant see the structure under microscope unless we do etching process. We learnt that the high temperature affect to the microstructure, so we tried to decrease it as much we can by water, and removing grinding object is important step. We was very pleased when we saw microstructure grains with different grades between black and white because we have deeper understand of the structure. Now we have ability to make conversion between several tests with base on tables and pictures we got them from internet: (www.tcreng.com), (www.metallurgiclab.com/metallographic testing) The resources of error in this lab was: - Human resources , I mean may be the person who make the experiment dont follow procedure exactly and make something wrong, like using water during grinding, using diamond spray, rotate the specimen 90 each steps, finger touch as we mention in the procedure. - The surface finish of specimens, we have more accurate reading when the surface finish become better, and we have wrong reading if the surface finish isnt good, I mean the surface must be mirror like surface before etching step. - May be the microscope or computer or other device have defects, or etching solution isnt suitable for the specimen, or time of etching is wrong, size of specimen..etc

Suggestions:

I suggest that to make deeper understand for this experiment we must let the student to participate in the lab and do some possible steps of the lab such as grinding or polishing, the student can do it without helping because it is easy test and not complex. The chairs in the lab must be more comfortable to ensure that the student will rest and then will have more understand.

References
Strength and mechanics of material book Manual of lab material.

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