Introduction to Metallographic Lab Practices
COURSE OUTLINE
- Metallography - Sectioning, mounting, grinding, polishing, etching.
- Photomicroscopy - Basics of the metallograph. Illustrative techniques, brightfield, darkfield, polarized light and DIe. Introduction to digital imaging and storage options
- Microhardness testing - theory, scales, settings, calibration, and types of testing equipment
- Macrohardness testing - theory, scales, settings, calibration, and application of equipment
- Tensile testing - Basic theory with demonstrations of extenso meter and tensile tester use. Definition and application of UTS, yield, percent reduction and elongation values. A review of sample selection, preparation and type specification requirements will be included.
- Impact Testing - Basic theory and equipment. Sample type and testing specifications
COURSE OVERVIEW:
This introductory course is designed to familiarize you with the many aspects of a metallurgical laboratory. This "hands on" course is intended to introduce you to a variety of laboratory processes, as well as proper use of lab equipment. In addition you will learn about the different types of testing involved in a Q.C. Met Lab, how to maintain current and complete records, and why it is important that samples are properly identified.
WHO SHOULD ENROLL:
This is an introductory course developed to provide an overview of laboratory processes and use of equipment. It is designed for people who are new to metallurgy or who need a solid overview of metallurgical laboratory practices. It will be beneficial to those involved in purchasing, sales, or other non-technical areas.
Metallographic Interpretation
COURSE OUTLINE:
• Review of crystal structures, phase rule and equilibrium phase diagrams and their relationships with formation of various phases
• Detail discussion of time-temperature transformation diagrams
• Application of quantitative metallographic techniques in characterizing steels
• 4. Hardness and other tests for estimation of performance.characteristics
• Cold work recovery, recrystallization and grain growth in a variety of alloy systems
• Correlation of observed microstructures with thermomechanical history of the parts
• Identification of effects of microstructural changes by heat treatment on mechanical and physical properties
• Several case histories demonstrating use of metallography in failure analysis
WHO SHOULD ENROLL:
• Engineers
• Supervisors
• Managers
• Technicians
Class size is limited to maximize interaction with the instructor. Be sure to register early. Students are strongly encouraged to bring prepared samples to class.
SUGGESTED PREREQUISITES:
• Elements of Metallurgy
• Metallographic Techniques
• Principles of Metallography
Metallographic Techniques
COURSE OUTLINE:
• A summary of sample preparation procedures as applied to a variety of materials
• Instructions on sample sectioning, mounting, and evaluation procedures
• Discussion of special mounting techniques including vacuum impregnation, pressurization, and fluorescent dye additions where needed
• Understanding the relationship between metallographic procedures and the resulting
• microstructures
• Identification of phases using interference layering techniques
• Proper use of automated polishing equipment in determining sample integrity
• Demonstrated use of chemical etchants and electropolishing procedures
• Instruction on the use of optical metallurgical microscopes, metallographs, and photomicrographic procedures
• Hardness test methods to determine microstructural characteristics
• Understanding advanced sample preparation techniques and resultant microstructures
WHO SHOULD ENROLL:
• Engineers
• Technicians
• Metallographers
• QA
Class size is limited to 12 people to maximize interaction with the instructor and carefully guided hands-on lab work. Be sure to register early.
SUGGESTED PREREQUISITES:
• Metallurgy for the Non-Metallurgist
Practical Interpretation of Microstructures
COURSE OUTLINE:
• Terminology used in describing microstructures, such as: eutectic, dendritic, austenite, martensite, equiaxed, alloy segregation
• Use of the metallograph, including photography
• Microstructures of carbon steels and their correlation to heat treatment and mechanical properties
• Microstructures of stainless steels and heat resisting alloys: cast & wrought structures, sensitization, strengthening through cold work, welds
• Microstructures of titanium alloys: alpha, alpha-beta, overheated, alpha-case, hydride phase Microstructures of aluminum alloys: casting alloys, wrought alloys, eutectic melting
• Microstructures of copper alloys: brass, bronze Defects: cracks, corrosion, laps &: folds, overheating, surface conditions
WHO SHOULD ENROLL:
• Anyone who prepares or examines metallographic samples will benefit from this course.
Class size is limited to maximize interaction with the instructor and carefully guided hands-on lab work.
SUGGESTED PREREQUISITES:
• Metallurgy for the Non-Metallurgist
• Metallographic Techniques
Principles of Metallography
COURSE OUTLINE:
• Metallography: Its History and Aims: introduction; application of metallography; basic concepts; history of metallography
• The States of Matter: introduction; fluids; solids; crystalline solids; crystal structure; formation of crystalline solids
• Introduction to Phase Diagrams: terminology; solid solutions and mixtures; practical applications of phase diagrams; the iron-cementite phase diagram; solidification of alloy systems; the copper-silicon system; precipitation hardening; ternary systems; quasi-binary systems
• Microstructure and Classifications of Steels: formation of austenite; transformation of austenite; effect of alloys of transformation; derivation of continuous cooling transformation diagrams; retained austenite; effect of alloys of elements; effects of quenching and/or austenitizing temperature; what is an alloy steel; classification of steels
• Metallographic Specimen Preparation: specimen sectioning; coarse grinding; ultrasonic cleaning; specimen mounting; fine grinding; specimen polishing; mechanical polishing; specimen etching
• Fundamentals of Metallographs and Photomicrography: what is a microscope; resolution; image brightness; depth of focus; image aberrations; microscope objectives; eyepieces; the light source
• Quantitative Metallography: volume fractography; lineal analysis; lineal analysis vs. point counting; grain shape and surface area; grain size; spatial size distribution; comparative methods; measurement aids
• Auxiliary and Special Metallographic Techniques: hardness testing; radiographic techniques; analytical techniques; etching and stripping; ultrasonic hammers; electron microprobe; X-ray fluorescence; electron and ion microscopy
• Plastic Deformation and Annealing of Metals: plastic deformation; slip; dislocations; twinning; polycrystalline metals; effects of plastic deformation of properties; recrystallization; grain growth
• Specific Metal Groups: Preparation and Interpretation: ferrous metals; techniques; typical microstructures of iron-base alloys; nonmetallic inclusions; banite; pearlite; nonferrous metals and special purpose alloys; techniques
WHO SHOULD ENROLL
• Anyone working in a metallographic facility
• Technicians
• Supervisors &: Managers of Metallographers
Complete Metallography of Fasteners : Sample Preparation AND Interpretation of Structures and Imperfections
COURSE OUTLINE
- Selecting the proper section techniques in order to avoid introduction of defects
- Mounting materials
- Grinding and polishing to reveal the true microstructure and avoid edge rounding
- Selecting etchants and etching techniques appropriate for each material
- Optimizing the use of the metallograph
- Defect depth, case depth measurements
- Grainsize determination
- Microindentation hardness testing
- Microstructures of common fastener materials and changes due to heat treatment
- Manufacturing processes, such as thread rolling and fillet rolling, influence on the microstructure
- Imperfections caused by raw material, heading, heat treating, thread rolling, plating
EXTRA VALUE: Two courses, Metallography of Fasteners and Interpretation of Fastener Microstructures are combined into one 5-day class.
COURSE OVERVIEW:
• Hands on use of metallographic equipment
• Actual samples of structures and imperfections are provided . Detailed lab notebook with images for future reference
• Limited class size for optimized student/instructor interaction.
During this course participants receive intensive instructions in the principles of metallography, sectioning, mounting, grinding, polishing, etching, use of the metallograph and microindentation hardness testing. Each student will complete a laboratory work book recording manual and automatic preparation techniques. In addition microstructures of fastener materials and heat treatments will be presented and described. Microstructure change due to manufacturing processes will be examined and a variety of imperfections will be discussed.
Scanning Electron Microscopy
COURSE OUTLINE
• History of electron microscopy
• Comparing optical and electron microscopes How the SEM works
• How to prepare specimens
• Practical SEM operation
• Secondary and backscatter electron imaging How to take an effective micrograph
• Introduction to field emission and environmental SEM
• Record keeping and micrograph archiving
• X-ray microanalysis
WHO SHOULD ENROLL
• Metallographers
• Technicians
• Researchers
• Quality Control Specialists
• Managers who want to expand their technical knowledge
SUGGESTED PREREQUISITES
• Understanding of high school physics and chemistry
