Metallurgy Lab
Metallurgy Lab
Metallurgy Lab
MANUAL
METALLURGY LAB
METALLOGRAPHY OF
HYPER EUCTECTOID STEEL
METALLURGY LAB
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (2 % Nital
2 % HNO3 and 98 % Ethyl or Methyl Alcohol) to preferentially reveals the
microstructure.
METALLURGY LAB
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of two types of grains Pearlite (dark areas) and
Proeutectoid Cementite network (light areas)
METALLURGY LAB
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
Composition : C 1.2 %
Composition : C 1.2 %
S 0.06 to 0.1%
S 0.06 to 0.1%
P 0.1 to 0.2%
P 0.1 to 0.2%
Mn 0.5 to 1.0%
Mn 0.5 to 1.0%
Microstructure Details :
Microstructure Details :
Etchant :
Etching Time :
Etchant
: 2% Niltal
Etching Time
: 15 seconds
METALLURGY LAB
METALLOGRAPHY OF
HYPO EUTECTOID STEEL
METALLURGY LAB
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (2 % Nital
2 % HNO3 and 98 % Ethyl or Methyl Alcohol) to preferentially reveals the
microstructure.
METALLURGY LAB
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of two types of grains Pearlite (dark areas) and Pro
eutectoid Ferrite (light areas)
METALLURGY LAB
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
Composition : C 0.2%
Composition : C 0.2%
S 0.06 %
S 0.06 %
P 0.06%
P 0.06%
Mn 0.5 to 1.0%
Mn 0.5 to 1.0%
Microstructure Details :
Microstructure Details :
Etchant :
Etching Time :
Etchant
: 2% Niltal
Etching Time
: 15 seconds
METALLURGY LAB
METALLURGY LAB
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
10
METALLURGY LAB
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (2 % Nital
2 % HNO3 and 98 % Ethyl or Methyl Alcohol) to preferentially reveals the
microstructure.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of Ferritic matrix with graphite flakes.
11
METALLURGY LAB
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
Si 2.0 to 3.5%
Si 0.9 to 1.65%
S 0.06 to 0.1%
S 0.06 to 0.1%
P 0.1 to 0.2%
P 0.1 to 0.2%
Mn 0.5 to 1.0%
Mn 0.5 to 1.0%
Microstructure Details :
Microstructure Details
:Cementite
: 2% Niltal
Etching Time
: 15 seconds
Etching Time :
12
METALLURGY LAB
METALLOGRAPHY OF
MALLEABLE CAST IRON
13
METALLURGY LAB
PROCEDURE:
14
METALLURGY LAB
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (2 % Nital
2 % HNO3 and 98 % Ethyl or Methyl Alcohol) to preferentially reveals the
microstructure.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of Ferritic matrix with graphite flakes.
15
METALLURGY LAB
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
Si 2.0 to 3.5%
Si 0.9 to 1.6%
S 0.06 to 0.1%
S 0.06 to 0.1%
P 0.1 to 0.2%
P 0.1 to 0.2%
Mn 0.5 to 1.0%
Mn 0.5 to 1.0%
Microstructure Details :
Microstructure Details
:Tempered
: 2% Niltal
Etching Time
: 15 seconds
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METALLURGY LAB
METALLOGRAPHY OF
GRAY CAST IRON
17
METALLURGY LAB
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METALLURGY LAB
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (2 % Nital
2 % HNO3 and 98 % Ethyl or Methyl Alcohol) to preferentially reveals the
microstructure.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of Ferritic matrix with graphite flakes.
19
METALLURGY LAB
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
Si 2.0 to 3.5%
Si 2.0 to 3.5%
S 0.06 to 0.1%
S 0.06 to 0.1%
P 0.1 to 0.2%
P 0.1 to 0.2%
Mn 0.5 to 1.0%
Mn 0.5 to 1.0%
Microstructure Details :
Microstructure Details :
Graphite flakes in the Pearlite matrix
Etchant :
Etchant
: 2% Niltal
Etching Time :
Etching Time
: 15 seconds
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METALLURGY LAB
METALLOGRAPHY OF
NODULAR CAST IRON
21
METALLURGY LAB
22
METALLURGY LAB
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (2 % Nital
2 % HNO3 and 98 % Ethyl or Methyl Alcohol) to preferentially reveals the
microstructure.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of Ferritic matrix with graphite flakes.
23
METALLURGY LAB
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
Si 2.0 to 3.5%
Si 2.0 to 3.5%
S 0.06 to 0.1%
S 0.06 to 0.1%
P 0.1 to 0.2%
P 0.1 to 0.2%
Mn 0.5 to 1.0%
Mn 0.5 to 1
Mg - 0.10%
Mg - 0.10%
Microstructure Details :
Microstructure Details :
Graphite
Nodules
in
the
Pearlite
matrix
Heat Treatment (if any) : Nil
Etchant :
Etchant
: 2% Niltal
Etching Time :
Etching Time
: 15 seconds
24
METALLURGY LAB
METALLOGRAPHY OF
ANNEALED STEEL
25
METALLURGY LAB
Annealing is the one of the basic heat treatment process. This process consists of
heating the steel just above upper critical temperature, holding at this temperature
for a definite period and slow cooling to room temperature usually in the furnace.
Annealing is very slow cooling Process and therefore similar equilibrium cooling.
Annealing process refines grain structure, induces softness, and improves electrical
and magnetic properties.
.
26
METALLURGY LAB
PROCEDURE:
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (2 % Nital
2 % HNO3 and 98 % Ethyl or Methyl Alcohol) to preferentially reveals the
microstructure.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of Pearlite surrounded by pro eutectoid ferrite.
27
METALLURGY LAB
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
Composition : C 0.2 %
Composition : C 0.2 %
S 0.06 to 0.1%
S 0.06 to 0.1%
P 0.1 to 0.2%
P 0.1 to 0.2%
Mn 0.5 to 1.0%
Mn 0.5 to 1.0%
Microstructure Details :
Microstructure
Details:
Coarse
Etchant :
Etchant
: 2% Niltal
Etching Time :
Etching Time
: 15 seconds
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METALLURGY LAB
METALLOGRAPHY OF
HARDENED STEEL
33
METALLURGY LAB
Hardening is the one of the heat treatment Technique which involves heating the
steel to 30 -500C above upper critical temperature, austenizing for a sufficient time
and cooling with a rate just exceeding the critical cooling rate of that steel to room
temperature or below room temperature .Due to this, the usual diffusion
transformations are stopped and the austenite by a diffusion less process transforms
to martensite.
,cooling the specimen in circulated water (i.e. providing cooling rate grater than
critical cooling rate) result in hard martensite grains.
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METALLURGY LAB
PROCEDURE:
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (2 % Nital
2 % HNO3 and 98 % Ethyl or Methyl Alcohol) to preferentially reveals the
microstructure.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of Martensite with needle like structure.
35
METALLURGY LAB
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
Composition : C 0.2 %
Composition : C 0.2 %
S 0.06 to 0.1%
S 0.06 to 0.1%
P 0.1 to 0.2%
P 0.1 to 0.2%
Mn 0.5 to 1.0%
Mn 0.5 to 1.0%
Microstructure Details :
Microstructure Details :
Martensite with needle like structure
Etchant :
Etchant
: 2% Niltal
Etching Time :
Etching Time
: 15 seconds
36
METALLURGY LAB
METALLOGRAPHY OF
ALUMINIUM
37
Metallography of Aluminium
METALLURGY LAB
METALLOGRAPHY OF ALUMINIUM
AIM:
Identification of micro constituents present in the aluminum
EQUIPMENT & MATERIALS:
Specimen Cut off Machine, Specimen Mounting Press, Belt Grinder, Polishing
Stand, Disc Polishing Machine, Drier, Metallurgical Microscope, Bakelite Powder
Emery Papers (120, 220, 400, 600, 800 Grit) Etchant (Sodium hydroxide 10gm +
water 90ml).
THEORY:
The best known characteristic of aluminium is its light weight; Aluminium has good
malleability and formability, high corrosion resistance and high electrical and thermal
conductivity. Pure aluminium has a tensile strength of about 13,000psi. One of the
important characteristic of aluminium is its machinability and workability.
PROCEDURE:
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (Sodium
hydroxide 10gm + water 90ml).to preferentially reveals the microstructure
38
Metallography of Aluminium
METALLURGY LAB
.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of
39
Metallography of Aluminium
METALLURGY LAB
METALLOGRAPHY OF ALUMINUM
BEFORE ETCHING
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
: Aluminum
: Aluminum
Composition :
Microstructure Details :
Etchant :
Etchant
: Ferric chloride
Etching Time :
Etching Time
: 15 seconds
40
Metallography of Aluminium
METALLURGY LAB
METALLOGRAPHY OF
PURE COPPER
41
METALLURGY LAB
Arsenical copper
PROCEDURE:
42
METALLURGY LAB
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
The specimen is Etched for specified time using a suitable etchant (Sodium
hydroxide 10gm + water 90ml).to preferentially reveals the microstructure
.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of
43
METALLURGY LAB
METALLOGRAPHY OF COPPER
BEFORE ETCHING
AFTER ETCHING
Magnification : 450 X
Magnification : 450 X
Specimen
Specimen
: Copper
: Copper
Composition :
Composition :
Microstructure Details :
Microstructure Details :
Etchant :
Etchant
: Sodium Hydroxide
Etching Time :
Etching Time
: 15 seconds
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METALLURGY LAB
METALLOGRAPHY OF
- BRASS
45
Metallography of
- Brass
METALLURGY LAB
METALLOGRAPHY OF - BRASS
AIM:
Identification of micro constituents present in the -Brass.
EQUIPMENT & MATERIALS:
Specimen Cut off Machine, Specimen Mounting Press, Belt Grinder, Polishing
Stand, Disc Polishing Machine, Drier, Metallurgical Microscope, Bakelite Powder
Emery Papers (120, 220, 400, 600, 800 Grit), Etchant (Ferric chloride).
THEORY:
Brasses are alloys of copper; contain zinc as a principal alloying element.
The equilibrium solubility of Zn in Cu is around 38% and is sharply influenced by
cooling rate. Under the conditions of usual cooling rates encountered in industrial
practice, the solubility limit may go down to 30%. With Zn additions exceeding the
solubility limit, a second phase is formed Beta intermediate phase exhibits orderdisorder transformation between 453 and 4700C. Below this temperature, the
structure of is ordered and above this is disordered. With more than 50 % Zn
another phase (intermediate phase) is formed Brasses are classified either on the
basis of structure i.e. brasses and Brasses or colour i.e red brasses and
yellow brasses.
- brasses are soft, ductile malleable and have fairly good corrosion
resistance. Commercial Brasses contain zinc between 32 to 40%. They are
hard and strong as compared to - brasses and are fabricated by hot working
process .these two phases alloys become single phase (disordered) alloys at
higher temperatures. Disordered has more ductility and malleability as compared
to and therefore, brasses are hot worked at a temperature of above 600 0C.
Since zinc is cheaper than copper, brasses are cheaper compared to
Brasses.
46
Metallography of
- Brass
METALLURGY LAB
PROCEDURE:
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of Brass.
47
Metallography of
- Brass
METALLURGY LAB
METALLOGRAPHY OF - BRASS
BEFORE ETCHING
Magnification : 450 X
Specimen
: Brass
Composition : Zn 30%
Microstructure Details :
AFTER ETCHING
Magnification : 450 X
Specimen
: Brass
Composition : Zn 30%
Microstructure Details: consists of
Brass.
Etchant :
Etchant
Etching Time :
Etching Time
48
: Ferric Chloride
: 15 seconds
Metallography of
- Brass
METALLURGY LAB
METALLOGRAPHY OF
BRASS
49
Metallography of
- Brass
METALLURGY LAB
METALLOGRAPHY OF BRASS
AIM:
Identification of micro constituents present in the Brass.
EQUIPMENT & MATERIALS:
Specimen Cut off Machine, Specimen Mounting Press, Belt Grinder, Polishing
Stand, Disc Polishing Machine, Drier, Metallurgical Microscope, Bakelite Powder
Emery Papers (120, 220, 400, 600, 800 Grit), Etchant (Ferric chloride).
THEORY:
Brasses are alloys of copper; contain zinc as a principal alloying element.
The equilibrium solubility of Zn in Cu is around 38% and is sharply influenced by
cooling rate. Under the conditions of usual cooling rates encountered in industrial
practice, the solubility limit may go down to 30%. With Zn additions exceeding the
solubility limit, a second phase is formed Beta intermediate phase exhibits orderdisorder transformation between 453 and 4700C. Below this temperature, the
structure of is ordered and above this is disordered. With more than 50 % Zn
another phase (intermediate phase) is formed Brasses are classified either on the
basis of structure i.e. brasses and Brasses or colour i.e red brasses and
yellow brasses.
- brasses are soft, ductile malleable and have fairly good corrosion
resistance. Commercial Brasses contain zinc between 32 to 40%. They are
hard and strong as compared to - brasses and are fabricated by hot working
process .these two phases alloys become single phase (disordered) alloys at
higher temperatures. Disordered has more ductility and malleability as compared
to and therefore, brasses are hot worked at a temperature of above 600 0C.
Since zinc is cheaper than copper, brasses are cheaper compared to
Brasses.
50
Metallography of
- Brass
METALLURGY LAB
PROCEDURE:
A Scratch free surface is obtained after fine polishing for sufficient period (15
minutes)
After fine polishing specimen is thoroughly washed with water and dried.
PRECAUTIONS:
While going to the next grade of emery papers, the specimen has to be
rotated through 900.
After etching the specimen should be washed away with in a few seconds.
OBSERVATION:
The microstructure of the given specimen observed at magnification 450 x
found to be consists of Brass.
51
Metallography of
- Brass
METALLURGY LAB
METALLOGRAPHY OF - BRASS
BEFORE ETCHING
Magnification : 450 X
Specimen
Brass
Composition : Zn 32 40%
AFTER ETCHING
Magnification : 450 X
Specimen
: Brass
Composition : Zn 32 40%
Microstructure Details: consists of
Microstructure Details :
Etchant :
Etchant
Etching Time :
Etching Time
52
: Ferric Chloride
: 15 seconds
Metallography of
- Brass
METALLURGY LAB
53
METALLURGY LAB
The end Quenching continues, until the bar is cooled sufficiently (handling
temperature)
54
METALLURGY LAB
Flat edge is ground on the surface of the specimen (0.015) in deep Rockwell
hardness values are determined at every 1/16 inch along the length of the
specimen from the Quenched end.
PRECAUTIONS:
Keep the equipment dry and when not in use by draining the water
through water outlet.
OBSERVATION:
Graph is drawn between distances from quenched end to Rockwell hardness and
is found to be decreasing from the end.
55