In situ Metallography

Suryadi, ST., MT.

In Situ Metallography
Introduction
Basic theory
Applications
Introduction
Part of Non-Destructive Evaluation (NDE).
Alternative, non-destructive technique to study
microstructure.
Introduction
Useful method to inspect microstructure of a component
when it is not possible to cut it.
Favourable in remaining life assessment of an operating
component.
Basic theory
Tools for In-situ metallography:
Portable grinding and polishing machine
Etchant
Replica
Portable microscope
Replication technique
Thin sheet (25 to 50 microns thick) replication tape
(cellulose tape) softened in acetone or methyl acetate is
carefully spread on the etched surface and uniformly
pressed.
The solvent evaporates after sometime and the dry
replica is peeled off. The contact surface of replica will
contain the impression of the minute contours on the
etched surface.
Replication technique
Replica
Single stage negative replica
The contours on the impression side of the replica are exactly
opposite to those on the sample surface i.e., hills appear as
valleys and vice versa.
Thin layer of metals like gold, aluminum or chromium is vapor
deposited on the impression side of the replica to achieve a
better contrast for OM observation.
The thin metallic layer also makes the replica electrically
conductive suitable for SEM observation.
Replica
Double stage positive replica
The replica contains the same contours with the sample
surface i.e., hills as hills and vice versa.
It is made by coating thin layer of carbon on the impression
side of the replica.
The carbon coated replica is then put in acetone to dissolve
the cellulose acetate leaving carbon replica floating in acetone.
This carbon replica is picked on grids for further observation
in electron microscope.
Contrast of observation could be enhanced by coating the
carbon replica using gold or palladium-gold.
Replica
Extraction replica
The precipitate morphology, their composition and
identification could be studied by preparing an extraction
replica and observing it under SEM.
The polished surface is heavily etched to dissolve a layer of
matrix leaving loosely precipitates on the surface. 1% solution
of Formvar (Polyvinyl Chloride) in chloroform is then carefully
sprayed on the surface.
When dried the thin formvar film is peeled off from the
surface by backing it with softened cellulose acetate film.
The loosely held precipitates get stuck on the dry formvar film
and could be analyzed under SEM/TEM.
Applications
Remaining life assessment.
Health assessment of critical components operating at
high Temperature And High Pressure in process plants
Damage assessment of fire affected equipment.
Quality check for metallurgical processes such as heat
treatments.
Generate the data on imported components for
indigenisation.
Failure Investigations.
Useful For Repair Welding Decisions.
Damages identified by microstructure
Graphitization
Degradation of Pearlite
Creep
Grain Growth
Hydrogen Attack
Stress Corrosion Cracking
Sigma phase
Example
Weld
Base metal
HAZ
Weld bead
Thank you