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The general aim of the first process step is to achieve the best possible material removal in the shortest amount of time. A good flatness of the surface after the grinding process can only be maintained by ensuring that the diamond is always in motion, always rolling, if possible. This rolling motion causes the necessary removal of of excess material.
Consumables used: Diamond 15 µm to 9 µm / Hard-woven or hard-pressed cloths
In the intermediate step, deformation and smear layers are removed. If the material is very hard, several intermediate steps may be necessary.
Consumables used: Diamond 9 µm to 3 µm / Hard-woven or lightly pile cloths
3. Final polishing
The last step is intended to remove deformations and especially smearing on the surface. This step is not easy but possible. However, a final-polished finish is not necessary for every task.
Consumables used: Diamond 3 µm to 0.5 µm / Oxide polishing 0.1 µm to 0.06 µm / Pile or flocked cloths, foamed for oxide suspensions In metallographic final polishing, a distinction is made between purely mechanical removal by the diamond grits and chemical-mechanical removal, which is achieved by slightly alkaline suspensions. Which agent is is the most suitable must be determined for the individual application.
In metallography, diamond polishing agents are differentiated according to their shape. There are poly- and monocrystalline diamonds. Agents containing polycrystalline diamonds have clear advantages over agents containing monocrystalline ones. The polycrystalline diamond has a uniform grain shape and many sharp edges. The removal rate of diamond agents depends on the number and size of diamond cutting edges that are working simultaneously. For the right choice of diamond abrasive (i. e. whether mono- or polycrystalline), it is important to determine its requirements beforehand. Basically, a good result can also be achieved with the cheaper monocrystalline agents, even though the way to get there requires more effort. Diamond agents also differ in the type of their carrier material. Which of the three common carrier materials is chosen depends on the circumstances.
Diamond paste: High concentration on the cloth, an additional lubricant is always necessary
Diamond suspension: Ensure well and uniform distribution on the cloth, pay attention to segregation in case of a longer stationary period Diamond spray: Ensure well and uniform distribution on the cloth, an additional lubricant is always necessary, higher consumption due to dosage
In metallography, oxide agents are primarily used for the final process step. A distinction is made between silicon dioxide and aluminium oxide suspensions. Both are available as "ready-to-use" aqueous or alcoholic suspension. The grain sizes are between 0.1 and 0.06 µm. There are no absolute rules for the application of the suspensions. Alcohol-based suspensions should be used for specimen susceptible to corrosion.
Silicon dioxide: All austenitic steels, aluminium alloys, titanium alloys, precious metal alloys Aluminium oxide: Brass, low to unalloyed steels, grey cast iron grades
With the use of oxide agents, a mechanical or chemo-mechanical removal can be achieved, which removes the smear and deformation layers that may still be present from previous metallographic polishing; the quality of this process ranges from good to very good.
The 'double' attack also results in short polishing times. Significantly lower material costs is another advantage over diamond agents
With metallographic vibratory polishing, preparations that are nearly deformation- and scratch-free can be carried out on materials which are prone to deformation. This method is also particularly suitable for samples for EBSD analysis.
With metallographic vibratory polishing, the relative movement between a sample and polishing base necessary for removal is achieved by a vibrating work surface. The working surface is set into vertical vibrations which are superimposed by torsional vibrations. These combined vibrations cause the samples, which are weighted down with a weight, to run in a circle on the working wheel.
The metallographic vibratory polisher QPol Vibro automatically finds the best frequency for the sample movement on the cloth depending on the mass to be moved. Due to the very gentle material removal, the method is particularly suitable for very soft and ductile materials such as copper or copper alloys, aluminium and aluminium alloys, Ni-based materials, as well as soft steels. However, this gentle and therefore very low material removal results in long processing times that sometimes take considerably more than 30 minutes.
Grinding and polishing is a standard technique in metallography. Expert knowledge in processing is available for almost all materials. However, a number of potential sources of error must be taken into account when searching for the appropriate procedure. The procedure is very time-consuming due to the multi-stage workflows, especially in manual processing. On the other hand, larger investments must be expected if a higher degree of automation is desired.
The following risks must be evaluated in each individual case:
The market for grinding and polishing equipment is very diverse and offers suitable solutions for a large variety of applications. Depending on application and capacity, simple semi-manual to fully automated systems are available. The wide range of applications also speaks for itself. With carefully matched consumables and suitable preparation parameters, excellent results can be achieved for almost all materials. Mechanical grinding and polishing often is the only preparation technique suitable for ceramics, composite materials and filled/reinforced plastics.
To provide assistance to the user, a few tips and tricks are listed below.
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