Metallographic Polishing by Mechanical Methods Fourth Edition

Text overviews and describes metallography. Topics include sectioning and mounting, machining with abrasives, nonabrasive preparation process, polishing with abrasives, brittle materials, principles of the design of manual preparation systems, and modifications required to manual preparation systems. Previous ed: c1982. DLC: Metallographic specimens Contents 4 About the Author 8 Preface to the Fourth Edition 10 Preface to the Third Edition 12 Acknowledgments 14 Chapter 1: Introduction 16 The Foundation of Metallography 16 Early Developments of Preparation Methods 17 Practical Methods of Producing Representative Surfaces 20 Appendix 1: Sorby: The Founder of Metallography 21 Chapter 2: Sectioning and Mounting 24 Deposition of Protective Surface Layers 24 Sectioning 26 Specimen Mounting 29 Mounting in Plastic Cylinders 30 Abrasion Rates 34 Polishing Rates 37 Electrical Conductivity 38 General Fields of Usefulness of Various Plastics 40 Molding Methods for Thermoplastics and Thermosetting Plastics 41 Molding Methods for Casting Plastics 42 Mount Dimensions 44 Mounting of Small and Thin Specimens 44 Marking for Identification 45 Removal of Specimens from Plastic Mounts 45 Appendix 1: Plating Methods 46 Appendix 2: Brashear Process for Silvering Prior to Electroplating 47 Appendix 3: Method of Preparing a Conducting Plastic 47 Appendix 4: Method of Manufacturing a Mold for Epoxy Resins from a Polyvinyl Chloride Dipping Compound 47 Appendix 5: Method of Manufacturing a Mold for Epoxy Resins from a Cold-Cure Silicone Rubber 47 Chapter 3: Machining with Abrasives: Principles 50 General Concepts 50 Characteristics of Abrasives 52 Mechanisms of Material Removal 54 Applications of the Model of Abrasive Machining 64 Surface Heating during Abrasive Machining 70 Chapter 4: Machining with Abrasives: Practice 78 Apparatus Used for Abrasion Processes 80 Abrasion with Elastically Soft Processes 81 Abrasive Machining Systems 81 Elastically Soft Abrasion with Conventional Abrasives 82 Abrasive Machining Devices Coated with Diamond Abrasives 99 Abrasion Using Elastically Hard Processes 108 Appendixes 115 Appendix 1: Methods of Determining Abrasion Rates 115 Appendix 2: A Bonded Fine Abrasive Device 115 Chapter 5: Machining with Abrasives: Surface Damage 118 Nature of the Deformed State in Metals 118 The Mechanics of Machining Chip Formation 126 Structure of the Deformed Layer on Machined Surfaces 131 Deformed Layer on Surfaces Formed by Manual Abrasive Machining 133 Deformed Layers Formed during Mechanized Semiautomatic Abrasion 147 Depth of the Deformed Layers on Abrasive-Machined Surfaces 147 Embedding of Abrasives 152 Appendix 1: Etching Methods 156 Chapter 6: Nonabrasive Preparation Processes 160 Etch Cutting and Machining 160 Spark Cutting and Machining 160 Microtome Cutting and Micromilling 164 Chapter 7: Polishing with Abrasives: Principles 168 Components of Polishing Systems 170 Polishing Abrasives 173 Methods of Using Abrasives for Polishing 177 Mechanisms of Polishing 180 Micromachining Mechanisms 181 Delamination Mechanisms 188 Chemical-Mechanical Mechanisms 189 Application of Diamond Abrasives in Manual Polishing Processes 191 Determination of Polishing Rates 191 Application of Diamond Abrasives in Carrier Pastes 194 Quantity of Polishing Fluid 196 Abrasive Particle Size 197 Type of Diamond 199 Quantity of Abrasive 201 Polishing Cloths 203 Specimen Pressure 209 Polishing Wheel Rotational Speed 210 Specimen Material 210 Proprietary Carrier Pastes 211 Summary of Optimal Conditions of Using Diamond Abrasives in Manual Systems 213 Application of Diamond Abrasives in Semiautomatic Polishing Processes 215 Material Removal Rates 215 Polishing Rates Obtained with Aluminum Oxide Abrasives 217 Polishing Rates Obtained with Colloidal Silica 218 Appendix 1: Method of Preparing a Carrier Paste for Diamond Abrasives 218 Appendix 2: A Water-Propylene Glycol Polishing Fluid 219 Appendix 3: Electromagnetic Vibratory Polishing Machines 219 Chapter 8: Polishing with Abrasives: Surface Damage 222 Structures of Surface Deformed Layers Formed on Metals with Face-Centered Cubic Crystal Structures 222 Modifications of the Structure of the Polishing-Deformed Layers on Metals with Noncubic Crystal Structures 228 Embedded Abrasive 229 Chapter 9: Brittle Materials: Principles 234 Mechanisms of Abrasion 234 Mechanism of Polishing 238 Surface Damage 239 Chapter 10: Principles of the Design of Manual Preparation Systems 242 Basic Concepts 242 Abrasion Artifacts 242 Abrasion Artifacts: Mechanized Preparation Procedures 256 Polishing Artifacts: Manual Preparation Procedures 257 Practical Preparation Procedures 270 Chapter 11: Modifications Required to Manual Preparation Systems 280 Surface Flatness 280 Metals with Abnormal Abrasion or Polishing Characteristics 288 Retention of Phases and Constituents 302 Chapter 12: Principles of the Design of Semiautomatic Preparation Systems 312 Procedures Based on the Use of Diamond Abrasives Charged in a Carrier Paste 313 Procedures Based on the Use of Diamond Abrasives Charged in a Suspension 315 Glossary 324 A 324 B 324 C 325 D 326 E 326 F 327 G 328 H 328 K 328 L 328 M 328 N 329 O 329 P 329 R 329 S 329 T 331 V 331 W 332 Z 332 Index 334 A 334 B 337 C 338 D 341 E 343 F 344 G 345 H 345 I 346 J 346 K 347 L 347 M 347 N 349 O 349 P 349 Q 352 R 352 S 353 T 357 U 359 V 359 W 359 X 360 Z 360 The quality and usefulness of micrographs depends greatly on the preparation and polishing of metallographic specimens, and the work of Leonard Samuels has been instrumental in achieving a more scientific understanding of the effects and mechanisms by which material is removed during preparation of metallographic specimens. This book provides comprehensive and authoritative coverage of mechanical polishing methods to ensure the quality and usefulness of micrographs. The 4th Edition covers the advances that have been made since the 3rd Edition was published in 1982. These advances have enabled manual preparation procedures to be reassessed, with the result that considerable simplifications have become possible. Major advances have also been made in the development of semiautomatic machines and preparation procedures over the last few years with the objective of increasing productivity and improving reliability. These processes use abrasive machining devices that are significantly different from those used in manual procedures. They also are discussed, but necessarily in a more limited way than for manual procedures because less basic information is available. Other updates and clarifications have been provided throughout the book to create a complete, easy-to-use, and up-to-date information resource on this topic. Ch. 1. Introduction -- Ch. 2. Sectioning And Mounting -- Ch. 3. Machining With Abrasives: Principles -- Ch. 4. Machining With Abrasives: Practice -- Ch. 5. Machining With Abrasives: Surface Damage -- Ch. 6. Nonabrasive Preparation Processes -- Ch. 7. Polishing With Abrasives: Principles -- Ch. 8. Polishing With Abrasives: Surface Damage -- Ch. 9. Brittle Materials: Principles -- Ch. 10. Principles Of The Design Of Manual Preparation Systems -- Ch. 11. Modifications Required To Manual Preparation Systems -- Ch. 12. Principles Of The Design Of Semiautomatic Preparation Systems. Leonard E. Samuels. Includes Bibliographical References And Index.