METALLOGRAPHY

THE PRIMARY
OBJECTIVE OF
METALLOGRAPHY
EXAMINATION IS
TO REVEAL THE
CONSTITUENT AND
STRUCTURE OF METALS
AND THEIR ALLOYS BY
MEANS OF MICROSCOPE
 APPLICATION OF METALLOGRAPHY

1. GENERAL STUDY OR ROUTINE WORKS (PROCESS CONTROL)

For general study, specimens from locations that are most likely to reveal
the maximum variations within the material under study should be chosen.
For example, specimens should be taken from a casting zones wherein
maximum segregration might be expected to occur as well as specimens
from sections wherein segregration should be at a minimum.

2. STUDY OF FAILURES
If the cause for a failure is to be diagnosed, the test specimens should be
taken as closely as possible to the fracture or the initiation of the failure.

Specimens should be taken in many cases from a sound area for a

comparison of structures and properties.

3. RESEARCH STUDY
 KUALITAS MATERIAL LOGAM ?

- Komposisi Kimia
- Mikrostruktur
Mikrostruktur:
- Struktur logam dalam resolusi mikroskopik (1-100µm)
- Terdiri dari beberapa konstituen seperti:
fasa, butir kristal, cacat kristalsegresi, inklusi
 OPTICAL METALLOGRAPHY LEADINGS TO
INTERPRETATION OF
(A) PROCESSING AND FABRICATION HISTORY

(1) HEAT TREATMENT

Homogenity of high temperature phase, undissolved carbides,
quench cracks, retained austenite, excessive grain size,
decarburization, adequate severity of quench (depth of hardening
in steels, suppression of precipitation in aging systems)
(2) CASTING CONDITION
Cooling rate, directional effects, feeding, gas evolution, reaction
with mold, grain structures, shrinkage, form of graphite in cast
iron.
(3) FORMING PARAMETERS
Fabrication temperature range, flow lines, folds and shuts, directionality.
 OPTICAL METALLOGRAPHY LEADINGS TO
INTERPRETATION OF
(B) SERVICE HISTORY

(1) CHANGE IN STRUCTURE DURING SERVICE

Oxidation, decarburization, dezincification, corrosion,
precipitation, grain growth.
(2) TYPE OF LOAD
Single overload, cyclic loads, energy load, creep.
(3) FAILURE MODES
Interpret ductile or brittle failure in terms of observed defects to establish
contribution each may have made.
 OPTICAL METALLOGRAPHY REVEALS
FEATURE OF:

(1) GRAIN : SIZE, SHAPE, UNIFORMITY

(2) HOMOGENITY : SEGREGATION (MICRO OR MACRO), NON-
EQUILIBRIUM PHASES
(3) MICRO CONS- : IDENTIFICATION, MORPHOLOGY,
TITUEN DISTRIBUTION (PRECIPITATES, FILMS,
GLOBULES, DISPERSIONS)
(4) INCLUSIONS : TYPES, SIZES, DISTRIBUTION
(5) DEFECTS : POROSITY, CRACKS (INTER OR
TRANSGRANULAR, RELATION OF PATH TO
MICROSTRUCTURE), SEAMS, TEARS, FOLDS.
(6) STRAIN : UNIFORM OR LOCAL PLASTIC DISTORTION
 CROSS SECTIONS OR TRANSVERSE SECTIONS
TAKEN PERPENDICULAR TO THE MAIN AXIS OF
THE MATERIAL ARE PREPARED IN GENERAL
TO REVEAL THE FOLLOWING INFORMATION:
1) Variations in structure from center to surface
2) Distribution of nonmetallic impurities throughout the section
3) Decarburization at the surface of ferrous material
4) Depth of surface imperfections
5) Depth of corrosion
6) Thickness of protective coating
7) Structure of protective coating
 LONGITUDINAL SECTIONS TAKEN PARALLEL
TO THE MAIN AXIS OF THE MATERIAL IN
GENERAL TO REVEAL THE FOLLOWING
INFORMATION:

1) EXTENT OF DEFORMATION IN THE METALLIC IMPURITIES

2) DEGREE OF PLASTIC DEFORMATION, AS SHOWN BY GRAIN

DISTORTION

3) PRESENCE OR ABSENCE OF BANDING IN THE STRUCTURE

4) IN GENERAL, THE PERFECTION ATTAINED WITH ANY HEAT

TREATMENT.
 METHOD OF DESIGNATING LOCATION OF
AREA SHOWN IN PHOTOMICROGRAPH

Symbol in Diagram Suggested Designation

A Rolled surface
B Direction of Rolling
C Rolled edge
D Longitudinal (or lengthwise) section parallel to rolled surface
E Longitudinal section perpendicular to rolled surface
F Transverse section
G Radial longitudinal section
H Tangential longitudinal section
Peralatan / mesin poles untuk menyiapkan benda uji metalografi dan uji kekerasan.
Mikroskop optik untuk pengujian struktur mikro yang dilengkapi dengan kamera digital
dan perangkat komputer.
IN-SITU METALLOGRAPHY BY REPLICA TECHNIQUE

PROSEDUR PELAKSANAAN:

► Pemilihan titik / lokasi pengujian

► Penggerindaan tipis
► Pengampelasan
► Pemolesan
► Pengetsaan
► Pengambilan replika
► Pengujian replika menggunakan
Mikroskop optik atau SEM
(Scanning Electron Microscope)
PREDICTIVE REPLICATION
Struktur-mikro hasil uji coba in-situ
metallography dengan teknik replica pada
dinding dalam sebuah dryer drum yang
terbuat dari baja stainless austenitik
Preparasi spot uji pada permukaan header untuk in-situ
metallography dan hardness test (HRSG 1.3 UP Gresik)
 Foil Transcopy

Pengambilan replika pada spot pengujian dengan menempelkan foil

transcopy (HRSG 1.3 UP Gresik)
Persiapan spot uji in-situ metallography dengan teknik replika pada tube R-11 panel
10, posisi elbow (PLTU #2UP Paiton)
Pengambilan replika dengan menempelkan transcopy foil pada spot uji
yang telah disiapkan (lihat Gambar 3.2) (PLTU #2 UP Paiton)
 HAZ, 200x HAZ, 500x

BM, 200x BM, 500x

Hasil uji in-situ metallography pada inlet header HP Superheater-2 pada

lokasi 9/ posisi jam 12 (sambungan las/header girth weld) (HRSG 2.3 UP Gresik)
 Chrome carbide

100 X 200 X

Hasil uji in-situ metallography pada tube no. 19 / panel 2,

elevasi elbow (R-11, PLTU #1 UP Paiton)
 Butiran yang Chrome
lepas carbide

100 X 200 X

Hasil uji in-situ metallography pada tube no. 20 / panel 2,

elevasi 2441 mm (R-11, PLTU #1 UP Paiton)
 PENGUJIAN KOMPOSISI KIMIA LOGAM DAN PADUAN
SECARA KUALITATIF DAN KUANTITATIF
A. Identifikasi yang cepat (Rapid Identification of Metals & Alloys)
A.1. Teknik Magnetik, yaitu membedakan antara logam-logam magnetik dengan
logam-logam non-magnetik
A.2. Didasarkan Berat (Berat Jenis)
Logam ringan (berat jenis 1,5 – 4,75)
Logam sedang (berat jenis 6 – 9)
Logam berat (berat jenis 9,8 – 11,3)
Logam sangat berat (berat jenis 12 – 22)
A.3. Spark testing:
Didasarkan pada percikan api pada saat penggerindaan. Untuk baja
karbon, semakin tinggi kadar karbonnya maka semakin banyak cabang
percikan apinya
A.4. Chemical spot testing
Yaitu dengan meneteskan cairan kimia kepermukaan logam yang diuji, dan
perubahan warna yang terjadi menunjukkan jenis baja / paduan.
Contoh: untuk baja karbon, cairan kimia yang dipakai adalah 30 ml HNO3 +
30 ml air
B. Pengujian / Analisa Bulk Material yang dapat dilakukan di Laboratorium
atau di lapangan (portable)
B.1. Atomic Absorption Spectrometry (AAS): Analisa basah yang
digunakan untuk menentukan kadar unsur secara tersendiri (individual)
B.2. Combustion Technique: Untuk menentukan kadar unsur-unsur gas
seperti karbon, sulfur, posfor, dll
B.3. Spark Emission Spectrometry: Dapat menentukan kadar sejumlah
unsur-unsur pada setiap pengujian
B.4. Teknik Lainnya

C. Pengujian secara in-situ (lokal) kadar unsur-unsur pada suatu titik

(area) dari permukaan atau deposit / kerak / endapan
C.1. Scanning Electron Microscopy (SEM) yang dilengkapi EDS atau EDAX
(Energy Dispersive X-ray Spectroscopy)