METALLOGRAPHY

RICHA TRIPATHI 3rd year

What is Metallography ??
Is the study of the metallic structures of metals or alloys typically using microscopy so as to relate the physical and mechanical properties of alloys with the observed microstructure. It can determine: Size and shape of the grains Presence of micro defects: segregation,haircracks, non metallic inclusions Nature and distribution of secondary phases

In Metallographic study of sintered products the type and morphology of pores is studied. These pores affect the various properties. The Metallographic preparation of such material can lead to changes in the specimen surface Some examples of such changes are: Partial closing of pores by plastic deformation during grinding Break out of material around pore

Closing of pores with grinding debris

Rounding of pore edges

Sample Preparation:
An abrasive cut off wheel with water as coolant may be used for sectioning purpose. Thorough rinsing with water must be carried out in order to remove any cutting debris. Specimen mounting can be done as usual practice.

Grinding:

This can be done using SiC paper of 220 grit size using water as a coolant or an automatic grinding wheel. A speed of 300 rpm with a load of 90, 60 and 30 N is used for three grinding steps. After the grinding operation, the specimens are ultrasonically cleaned in alcohol bath.

Impregnation:
The process is necessary to seal the open porosity of the specimen so that abrasives, water and etchants are not entrapped later on. If the specimen is not moisture free, bleeding out during etching may occur which causes staining of the surface. Vacuum impregnation is carried out with epoxy resin.

Regrinding:
After impregnation, regrinding is carried out on 500 and 1000 grit silicon carbide paper.

Polishing:
This operation is generally carried out with 6, 3 and 1 m diamond polishing spray on an automatic wheel using a load of 90, 60 and 30 N for one minute each. Polishing on a cloth with a suspension of alumina may also be carried out. In unetched condition total porosity, pore size and shape, nonmetallic inclusions, additions like manganese sulphide for improved machinability, undissolved alloying elements, etc., may be observed.

Etching:
Etching is generally performed by immersion. This facilitates study of homogeneity of alloying, grain size and the presence of different phases.

General Summary of the Science of P/M

1.powder production 2.powder compaction
3.sintering/ infiltration

Morphology

Different particle size are blended to reduce porosity The particle shape is determined my rate of solidification. surface tension forces maintains the spherical shape of the droplet until solidification.

Scanning electron micrographs of copper powder. Water atomized

SEM picture of gas atomized powders

Effect of milling time on particle shape change of spherical Ti-6Al-4V alloy particles. (a) As-received powder. (b) After 1 h. (c) After 2 h. (d) After 4 h. (e) After 8 h. (f) After 16 h

Compaction
Impart shape to net or near net to powder mass Net Shape: Microstructure Die Compaction
MIM

Near Net Shape:

CIP Hot isostatic Pressing Extrusion Rolling

Particles may be flattened and distorted, depending on the nature of the powder and the compacting pressure. Typically, uniaxial compaction creates flattened pores that subsequently contribute to anisotropic dimensional change in sintering.

Isotatic Pressing

Advantages of HIP
Fine homogenous and isotropic microstructure Improved wear and corrosion resistance, through extended alloying possibilities Shear strength fatigue life improved

Higher resistance to impact wear and abrasions

Desification of powder parts to 100% of theoretical density Increased toughness

If heat is supplied during process, it promotes intergranular growth and diffusion, this process is known as sintering. Temperature should be slightly above the recrystallisation temperature but less than its melting point

Sintering Temperature and Time for Various Metals

Mechanical Properties
Hardness
This is determined by microhardness testers utilizing Knoop or diamond pyramid hardness indentors. It measures the true hardness of the structure by eliminating the effect of porosity, and this is a measure of resistance to wear.

Tensile Strength
The tensile properties of sintered products are directly influenced by porosity. Due to presence of porosity, the tensile properties are somewhat lower than those of wrought materials of the same composition and structure. Crack initiation takes place at the preferred site like pore and then propagates through it. Pores are of two types: (a) interconnected and (b) closed or isolated. interconnected porosity may give rise to internal corrosion.

Powder Metallurgy: Connecting Rods

29

Forged on left; P/M on right

MICROSTRUCTURE OF PM HIP PARTS

rapid solidification process, fine and regular microstructures can be obtained thanks to the PM HIP technology, with strength values similar to those of forged parts.

Cast

Forged

PM HIP

Cast, forged and PM HIP microstructures of duplex stainless steel

Produces a smaller grain size due to the high cooling rate.

Alloying elements do not segregate when the powder is handeld Increasing the cooling rate of liquid material can result in the formation of an ultrafine or microcrystalline grain size Applying pressure drops the transformation temperature and increase nucleation rate making it possible to obtain nano grain size sintered sample.

How to Strengthen Metals:

Key: prevent dislocations from moving through crystal structure!!! Finer grain boundries can be done by recrystallizing (and cold working) Increase dislocation density via COLD WORKING (strain hardening) Add alloying elements to give SOLID SOLUTION HARDENING. Add alloying elements to give precipitates or dispersed particles PRECIPITATION HARDENING (aka Heat Treat) DISPERSION HARDENING fine particles (carbon) impede dislocation movement.
Referred to as Quench Hardening, Austenitizing and Quench or simply Heat Treat. Generally 3 steps: heat to austenite T, rapid quench, then temper.

How do Metal Crystals Fail?? Answer: Slip due to dislocations

The Effect of Grain Boundries:

Dislocations pile up at GB and cant go further this effectively strengthens the crystal!

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