LAB REPORT

ME2151-2
METALLOGRAPHY
Semester 5

1. Objective
This experiment was conducted to examine the microstructure of a piece of fusion
welded steel. An optical microscope was used for observation. The various
microstructural zones in the specimen were to be recorded by hand drawing and the
formation of these zone were to be explained based on the knowledge of Fe-Fe 3C
metastable phase diagram. Also, students were expected to gain experience in the
metallographic preparation of metallic specimens.
2. Result
The results, i.e. the drawings of the microstructure of various zones in the specimen, were
presented in the appendix. A general microstructural arrangement of various
distinguishable zones was presented, followed by the detail drawings of the individual
zones. The magnification used was stated at the corner of each drawing, and important
features were labeled.
3. Discussions
The specimen was a hot worked piece and welded by the electric arc welding process.
There were basically five discernable zones in the welded area, which were fusion zone,
grain growth zone, refinement zone, transition zone and unaffected zone. They are
presented schematically by the first graph in the appendix. The distinct zones were
formed when the specimen was welded. We know from the Fe-Fe 3C metastable phase
diagram (as shown in Fig. 1.) that the phase of Fe-C solid solution is dependent on the
temperature. When a temperature gradient was introduced in the specimen upon welding,
the microstructure was altered according to the temperature variation.
The fusion zone was at the place where the filler was deposited. The metal melted due to
the extremely high temperature (which can be as high as 3000 C) introduced by the
welding process. Further, as steel is a good conductor of heat, the weld cooled down very
rapidly and columnar grains were formed. Widmanstatten structure, which resulted form
fast cooling of austenite grain, was also observed, and it appeared dark under the optical
microscope.

Fig. 1. The Fe-Fe3C Phase Diagram

The grains in the grain growth zone were exceptionally large compared to those in other
zones. The reason was that the temperature in this zone was high but below the melting
point of the specimen. The austenite grains grow into larger size, and regions of coarse
ferrite grains and Widmanstatten ferrite and pearlite were formed upon cooling. The
former were in light color when observed under optical microscope while the latter
appeared dark. Moreover, the distinct demarcation between grain growth zone and fusion
zone resulted from the fact that material in this zone remained solid during welding while
that in fusion zone melted.
Next to grain growth zone was the refinement zone. Gains were the smallest in this
region, and different from the previous two regions, the ferrite and pearlite were no
longer mixed. The pearlite grains were observed as small dark regions located in between
or along the boundaries of the ferrite grains. This change in microstructure resulted from

the fact that smaller austenite grains were formed at lower temperature (compared to that
in the grain growth zone), which then transformed into distinct ferrite and pearlite grains
upon cooling.
A mix of both small and relatively large grains was observed in the next zone, which is
called transition zone. Ferrite grains of different seize were blended here with pearlite
scattered around. The larger grains had the feature of those in the unaffected zone.
The unaffected zone was the furthest away from the welding point. The grains in this
region were not heated beyond the eutectoid temperature; therefore, no phase change was
observed. The ferrite grains remained somewhat round in shape, in contrast to those
appeared longer in hard rolled metals.
4. Conclusion
The microstructure of a welded steel specimen was examined using optical microscope
and a basic insight of the Fe-Fe3C phase diagram was gained. With help of the diagram,
an understanding of the reasons for formation of various zones in the specimen was
obtained. Also, skills in grinding and polishing were acquired.
Moreover, it was observed that the grains are of larger size near the spot of welding. We
know that metal with large grains tends to be weak, so metal pieces are not to be
connected by welding when high performance is required.