Microstructure Analysis to Evaluate Material Properties
During microscopic examination or microstructure analysis, the structure of a material is studied under magnification. The properties of a material determine how it will perform under a given application and these properties are dependent on the material’s structure. Microstructure analysis at LTI ranges from simple determination of certain parameters such as grain size or coating thickness to full evaluation of failure mechanisms.
Evaluations Performed at LTI
- Grain size (ASTM E112)
- Extent of Carburization & Decarburization
- Intergranular Attack & Oxidation
- Alpha Case/Surface Contamination
- Percent Spheroidization
- Inclusion Rating (ASTM E45)
- Plating Thickness
- Carbide Precipitation
- Ferrite by Point Count (ASTM E562)
- Nodularity, Nodule Count
- Eutectic Melting
- Volume fraction of various phases or second phase particles in metals
Microstructure analysis performed at LTI is PRI/Nadcap and A2LA accredited and all results are documented in a Certified Test Report. Examinations are completed according to detailed procedures and applicable industry standards to ensure reliability.
Precise sample preparation is critical to the accuracy of any materials testing. LTI has a complete metallurgical sample preparation lab to properly prepare all metallurgical test specimens.
Effects of Industrial Processes and Treatments
Industrial processes and treatments such as casting, welding and heat treating are often applied to metals to prepare them for particular applications or to improve their characteristics and properties. There may be residual effects of these processes and treatments such as inclusion or contaminants that can be explained by microstructure analysis. In many cases, the investigation centers on the correlation between the resulting microstructure and the material properties.
Extent of Decarburization
For example, exposure of carbon and alloy steels to elevated temperatures during heat treatment can cause a loss or gain of carbon near the surfaces of the parts, if the atmosphere in the furnace is not properly controlled. Decarburization causes the surface to be soft and weak with little wear resistance, while unwanted carburization can cause the surface to become too brittle.
Also, if austenitic stainless steel does not see sufficient temperature for enough time or does not receive a sufficiently rapid quench during heat treating, the carbon in the alloy will form chromium carbides on the grain boundaries which will make the material brittle and susceptible to intergranular corrosion. A sensitization test will reveal this problem.
On the other hand, scanning electron microscopy is used to determine abnormalities such as inclusions, segregation, and surface layers, as well as fracture features. When used in combination with energy dispersive X-ray spectroscopy (EDS), the microstructure analysis can identify inclusion type and corrodents on the fracture face.
The Microscopic Examination Process
A carefully prepared specimen and magnification are needed for microscopic examination. Proper preparation of the specimen and the material’s surface requires that a rigid step-by-step process be followed. The first step is carefully selecting a small sample of the material to undergo microstructure analysis with consideration given to location and orientation. This step is followed by sectioning, mounting, grinding, polishing and etching to reveal accurate microstructure and content.
Detailed viewing of samples is done with a metallurgical microscope that has a system of lenses (objectives and eyepiece) so that different magnifications (typically 50X to 1000X) can be achieved. Scanning Electron Microscopes (SEMs) are capable of much higher magnifications and are utilized for highly detailed microstructural study.
- Microscopic Examination
- Photomicrographic Examination
- Digital Imaging – optical magnification from 7X to 1000X
- SEM Analysis – magnification to 300,000X
- Failure Analysis
- Weld Testing for Welder Qualification