Microstructural Characterisation of an Automotive Spark Plug using EBSD

H S Ubhi H Jiang M Keeble , and S Fritze ,

1 1 2 2
1

Oxford Instruments plc, Halifax Road, High Wycombe, Bucks, HP12 3SE, UK. 2Buehler UK,

Introduction
A pre-requisite for successful metallography is good sample preparation. This study illustrates the methodology for mechanically polishing an automotive spark plug, utilising both bright eld and differential interference contrast optical microscopy to assess the surface condition, prior to SEM/EBSD characterisation.

Methodology
An automotive spark plug that had come out of service was sectioned and polished using the steps given in Table 1. The sample surfaces were examined using optical microscopy and the microstructures of the various components in the spark plug examined using the SEM/EBSD technique. The EBSD apparatus was attached to a FEGSEM and the EBSD data acquired using OI-HKL Nordlys detector combined with CHANNEL5 software.

EBSP

All Euler orientation map

Insulator - ceramic Terminal

Terminal

Ferrite

EDS linescan

NiO

EBSP

EBSP

Phase map

Al2O3

DIC image

NiO

The fraction of amorphous phase is 6.6%. Mean size of alumina grains is 3.4m with a maximum of 16.4m.
Insulator ceramic
IPF orientation map of steel IPF orientation map of steel

DIC image All Euler orientation map

Ferrite

Ni
EDS linescan

Ni

Casing - thread

EBSP

Terminal: Nickel plating with outer oxide lm formation

DIC image
200mm

Deformation in thread root from thread roll forming process.

Cored central electrode

IPF orientation map of Ni

Cr7C3
SEM BEI SEM BEI IPF orientation map DIC image

Centre Electrode tip

SEM BEI IPF orientation map IPF orientation map IPF orientation map

DIC image

DIC image

EBSP EDS Ni Cu
500mm

Ni PtNi

Pt
20mm

Local misorientation map

IPF orientation map

FSD image SEM SEI

Formation of intermetallic Cr7C3 particles in the copper core at the Cu/Ni interface. Nickel Sheath - mean grain size of 10.9m.

Phase map

EDS Cu

EDS Cr

Cr7C3 particles

Ni

20mm

20mm

10mm

Steel

IPF orientation map

Pole gures

Platinum tip, ne deformed structure, HAZ, local surface melting during service, weld metal large grains inter-granular cracks.

Steel

Local misorientation map

IPF orientation map

EBSP

SEM SEI

SEM BEI

Casing threads

Pt

Cored central electrode Casing/side electrode joint Casing/side electrode joint

Ni
IPF orientation map
500mm

Pole gures

DIC image

Pt Ni
IPF orientation map Phase map

Ni

CSL boundary map

200mm

Side electrode

200mm

Centre electrode tip Side electrode

DIC image

Pole gures

500mm

Platinum electrode, large grains, local surface melting during service.

Casing/side electrode joint: melting of casing, grain growth in electrode.

Table 1. Details of polishing steps

Sectioning: Isomet 5000
Step No. Surface 1 2 3 4 5 6 Apex DGD UltraPol Trident Trident ChemoMet ChemoMet Abrasive 75-15m 9m MetaDi Supreme 3m MetaDi Paste 1m MetaDi Paste 0.05m Alumina / Colloidal Silica 5 parts Colloidal Silica+2parts 30%H2O2 Metadi Fluid Metadi Fluid

Mounting: Simplimet 1000

Lubricant Water

Preparation: EcoMet-AutoMet
Force 6lbs 6lbs 7lbs 7lbs 7lbs 7lbs Time until plane 6 min 5 min 5 min 5 min 6 min

Microscopy: Nikon MA-200

Relative Rotation Comp. Comp. Comp. Comp. Contra Contra

Conclusions

Platen Speed Head Speed 250 200 200 200 80 80 60 60 60 60 60 60

Successful mechanical polishing was achieved for all the

components and veried by optical metallography.

SEM/EBSD characterisation was similarly successful in accessing

the processes and microstructures of the various components, e.g. coating of the terminal, inter-metallic formation at the interface between the copper and nickel in the central cored electrode, local melting as the erosion mechanism at the platinum electrodes.

www.oxford-instruments.com

Spark Technical Poster_AW.indd 1

28/6/10 15:41:49