Skip to content
Aluminum alloys sample preparation

Aluminum Alloys - Metallographic Sample Preparation

Aluminum alloys can be prepared for metallographic analysis using OnPoint Abrasives' consumables and procedures. Below is a step by step procedure for metallographic sample preparation that can be used on a wide range of aluminum alloys such as 6061, 5052, and 3003.

Sectioning: Section specimen with MultiSec abrasive blade or multi-purpose diamond blade.

Mounting: Compression mount specimen using PhenoMount phenolic powder. Phenolic mounting compounds are available in black, green, and red color. For samples that require castable mounting, we recommend using EpoPro liquid epoxy system.

Grinding and Polishing: In this section, we've provided two methods for preparing your specimen for analysis, Traditional Method and Advanced Method.

The Traditional Method uses a series of Silicon Carbide grinding papers to first planarize and grind the surface to around 3-5 micron (1200 grit), before moving to polishing steps using suspensions and cloths. This method is effective for general purpose metallography, although it can introduce some relief, or rounding of the specimen's edge.

 TRADITIONAL METHOD FOR PREPARING ALUMINUM ALLOYS FOR METALLOGRAPHIC ANALYSIS
Step Abrasive Surface Lube Load/Sample RPM Time
1 240 Grit CarbiPro SiC Water 6 lbs 200 Planar
2 320 Grit CarbiPro SiC Water 6 lbs 200 1:00
3 400 Grit CarbiPro SiC Water 5 lbs 200 1:00
4 600 Grit CarbiPro SiC Water 5 lbs 200 1:00
5 800 Grit CarbiPro SiC Water 5 lbs 200 1:00
6 1200 Grit CarbiPro SiC Water 5 lbs 200 1:00
7 1µm Diamond ProDac Cloth Lubricant/Extender 5 lbs 150 2:00
8*

0.05µm Alumina

0.05µm ProPrep Colloidal Silica

 FinalFloc Cloth - 5 lbs 150 2:00

*For the final step, alternate between the alumina and ProPrep colloidal silica at 20 second intervals. Finish with a large dose of alumina when 0:30 seconds remain. 

Note: Clean specimen by gently scrubbing the surface with a cotton ball under running water. Repeat until all alumina is removed. Use of an ultrasonic cleaner is highly recommended for samples with high porosity content or intricate geometries.

Our Advanced Method uses one or two steps of SiC grinding paper to initially planarize the mounted specimen. This is followed by a series of "loose" abrasive polishing steps that utilize diamond and alumina suspensions along with polishing cloths. The less aggressive nature of this method preserves the specimen's edge and produces ultra-flat results. This can be critical for analysis such as coating thickness measurements or samples that are examined near the specimen's edge. It is viewed by many that the "advanced" methods of preparation offer superior results and higher consistency when compared to traditional methods.

 ADVANCED METHOD FOR PREPARING ALUMINUM ALLOYS FOR METALLOGRAPHIC ANALYSIS
Step # Abrasive Surface Lube Load/Sample
 RPM Time
1 180 or 240 Grit CarbiPro SIC Water 6 lbs 200 Planar
2 320 Grit CarbiPro SiC Water 6 lbs 200 2:00
3 9µm Diamond MasterPlan Cloth Lubricant/Extender
 5 lbs 150 5:00
4 3µm Diamond ProDac Cloth Lubricant/Extender 5 lbs 150 3:00
5*

0.05µm Alumina

0.05µm ProPrep Colloidal Silica

 FinalFloc Cloth - 5 lbs 150 2:00

 *For the final step, alternate between the alumina and ProPrep colloidal silica at 20 second intervals. Finish with a large dose of alumina when 0:30 seconds remain. 

Note: Clean specimen by gently scrubbing the surface with a cotton ball under running water. Repeat until all alumina is removed. Use of an ultrasonic cleaner is highly recommended for samples with high porosity content or intricate geometries.

Filters

$
$
Alumina Suspension 0.05 micron
$0.00 - $0.00
$0.00
$150.00
$150.00 - $150.00
$150.00

Alumabrasive Alumina Suspension - 1 Gallon - 0.05 µm

Alumabrasive Alumina Suspension is an ideal water-based polishing agent for soft materials such as copper, aluminum, and lead. It comes in a 1-gall...

View full details
$0.00 - $0.00
$0.00
$150.00
$150.00 - $150.00
$150.00
Alumina Suspension 1 micron
$0.00 - $0.00
$0.00
$150.00
$150.00 - $150.00
$150.00

Alumabrasive Alumina Suspension - 1 Gallon - 1 µm

Alumabrasive Alumina Suspension is an ideal water-based polishing agent for soft materials such as copper, aluminum, and lead. It comes in a 1-gall...

View full details
$0.00 - $0.00
$0.00
$150.00
$150.00 - $150.00
$150.00
Alumina Suspension 3 micron
$0.00 - $0.00
$0.00
$150.00
$150.00 - $150.00
$150.00

Alumabrasive Alumina Suspension - 1 Gallon - 3 µm

Alumabrasive Alumina Suspension is an ideal water-based polishing agent for soft materials such as copper, aluminum, and lead. It comes in a 1-gall...

View full details
$0.00 - $0.00
$0.00
$150.00
$150.00 - $150.00
$150.00
Alumina Suspension 1 micron
$0.00 - $0.00
$0.00
$28.00
$28.00 - $28.00
$28.00

Alumabrasive Alumina Suspension - 16 oz - 1 µm

Alumabrasive Alumina Suspension is an ideal water-based polishing agent for soft materials such as copper, aluminum, and lead. It comes in a 16oz c...

View full details
$0.00 - $0.00
$0.00
$28.00
$28.00 - $28.00
$28.00
Alumina Suspension 3 micron
$0.00 - $0.00
$0.00
$28.00
$28.00 - $28.00
$28.00

Alumabrasive Alumina Suspension - 16 oz - 3 µm

Alumabrasive Alumina Suspension is an ideal water-based polishing agent for soft materials such as copper, aluminum, and lead. It comes in a 16oz c...

View full details
$0.00 - $0.00
$0.00
$28.00
$28.00 - $28.00
$28.00
Alumina Suspension 0.05 micron
$0.00 - $0.00
$0.00
$48.00
$48.00 - $48.00
$48.00

Alumabrasive Alumina Suspension - 32 oz - 0.05 µm

Alumabrasive Alumina Suspension is an ideal water-based polishing agent for soft materials such as copper, aluminum, and lead. It comes in a 32oz c...

View full details
$0.00 - $0.00
$0.00
$48.00
$48.00 - $48.00
$48.00
alumina suspension 1 micron
$0.00 - $0.00
$0.00
$48.00
$48.00 - $48.00
$48.00

Alumabrasive Alumina Suspension - 32 oz - 1 µm

Alumabrasive Alumina Suspension is an ideal water-based polishing agent for soft materials such as copper, aluminum, and lead. It comes in a 32oz c...

View full details
$0.00 - $0.00
$0.00
$48.00
$48.00 - $48.00
$48.00
Alumina Suspension 3 micron
$0.00 - $0.00
$0.00
$48.00
$48.00 - $48.00
$48.00

Alumabrasive Alumina Suspension - 32 oz - 3 µm

Alumabrasive Alumina Suspension is an ideal water-based polishing agent for soft materials such as copper, aluminum, and lead. It comes in a 32oz c...

View full details
$0.00 - $0.00
$0.00
$48.00
$48.00 - $48.00
$48.00
$0.00 - $0.00
$0.00
$150.00
$150.00 - $150.00
$150.00

Alumabrasive Alumina Suspension 1 Gallon

Alumabrasive Alumina Suspension is a specialized water-based polishing medium for soft materials such as copper, aluminum, and lead. Its high-visco...

View full details
$0.00 - $0.00
$0.00
$150.00
$150.00 - $150.00
$150.00
$0.00 - $0.00
$0.00
$28.00
$28.00 - $28.00
$28.00

Alumabrasive Alumina Suspension 16oz

Alumabrasive Alumina Suspension is a specialized water-based polishing medium for soft materials such as copper, aluminum, and lead. Its high-visco...

View full details
$0.00 - $0.00
$0.00
$28.00
$28.00 - $28.00
$28.00
$0.00 - $0.00
$0.00
$48.00
$48.00 - $48.00
$48.00

Alumabrasive Alumina Suspension 32oz

Alumabrasive Alumina Suspension is a specialized water-based polishing medium for soft materials such as copper, aluminum, and lead. Its high-visco...

View full details
$0.00 - $0.00
$0.00
$48.00
$48.00 - $48.00
$48.00
$0.00 - $0.00
$0.00
$18.00
$18.00 - $18.00
$18.00

Alumabrasive Alumina Suspension 8oz

Alumabrasive Alumina Suspension is a specialized water-based polishing medium for soft materials such as copper, aluminum, and lead. Its high-visco...

View full details
$0.00 - $0.00
$0.00
$18.00
$18.00 - $18.00
$18.00
Polycrystalline Alumina Suspension AlumaPro MasterPrep Nanometer
$45.00 - $45.00
$45.00
$45.00 - $45.00
$45.00

AlumaPro Polycrystalline Alumina Slurry 16 oz - 0.05 µm

AlumaPro Polycrystalline Alumina is an optimal polishing slurry for metallographic sample preparation, recommended for polishing of ferrous metals,...

View full details
$45.00 - $45.00
$45.00
$45.00 - $45.00
$45.00
AlumaPro alumina 0.05 micron
$110.00 - $110.00
$110.00
$110.00 - $110.00
$110.00

AlumaPro Polycrystalline Alumina Slurry 64 oz - 0.05 µm

AlumaPro Polycrystalline Alumina is an optimal polishing slurry for metallographic sample preparation, recommended for polishing of ferrous metals...

View full details
$110.00 - $110.00
$110.00
$110.00 - $110.00
$110.00
Polycrystalline Alumina Suspension AlumaPro MasterPrep Nanometer
$195.00 - $195.00
$195.00
$195.00 - $195.00
$195.00

AlumaPro Polycrystalline Alumina Slurry- 1 Gallon - 0.05 µm

AlumaPro Polycrystalline Alumina is an optimal polishing slurry for metallographic sample preparation, recommended for polishing of ferrous metals...

View full details
$195.00 - $195.00
$195.00
$195.00 - $195.00
$195.00
Polycrystalline Alumina Suspension AlumaPro MasterPrep Nanometer
$70.00 - $70.00
$70.00
$70.00 - $70.00
$70.00

AlumaPro Polycrystalline Alumina Slurry- 32 oz - 0.05 µm

AlumaPro Polycrystalline Alumina is an optimal polishing slurry for metallographic sample preparation, recommended for polishing of ferrous metals...

View full details
$70.00 - $70.00
$70.00
$70.00 - $70.00
$70.00
240 grit silicon carbide grinding paper roll
$0.00 - $0.00
$0.00
$40.00
$40.00 - $40.00
$40.00

CarbiPro SiC Grinding Paper Roll (3-7/16-in x 60-ft) - 240 grit

CarbiPro's Silicon Carbide abrasive grinding paper is ideal for metallurgical grinding of a host of materials. This roll-form C-weight paper has a ...

View full details
$0.00 - $0.00
$0.00
$40.00
$40.00 - $40.00
$40.00
320 grit silicon carbide grinding paper roll
$0.00 - $0.00
$0.00
$40.00
$40.00 - $40.00
$40.00

CarbiPro SiC Grinding Paper Roll (3-7/16-in x 60-ft) - 320 grit

 CarbiPro's Silicon Carbide abrasive grinding paper is ideal for metallurgical grinding of a host of materials. This roll-form C-weight paper has a...

View full details
$0.00 - $0.00
$0.00
$40.00
$40.00 - $40.00
$40.00
400 grit silicon carbide grinding paper roll
$0.00 - $0.00
$0.00
$40.00
$40.00 - $40.00
$40.00

CarbiPro SiC Grinding Paper Roll (3-7/16-in x 60-ft) - 400 grit

CarbiPro's Silicon Carbide abrasive grinding paper is ideal for metallurgical grinding of a host of materials. This roll-form C-weight paper has a ...

View full details
$0.00 - $0.00
$0.00
$40.00
$40.00 - $40.00
$40.00
600 grit silicon carbide grinding paper roll
$0.00 - $0.00
$0.00
$40.00
$40.00 - $40.00
$40.00

CarbiPro SiC Grinding Paper Roll (3-7/16-in x 60-ft) - 600 grit

CarbiPro's Silicon Carbide abrasive grinding paper is ideal for metallurgical grinding of a host of materials. This roll-form C-weight paper has a ...

View full details
$0.00 - $0.00
$0.00
$40.00
$40.00 - $40.00
$40.00
1200 grit Silicon carbide grinding paper roll
$0.00 - $0.00
$0.00
$50.00
$50.00 - $50.00
$50.00

CarbiPro SiC Grinding Paper Roll (3-7/16-in x 75-ft) - 1200 grit

 CarbiPro's Silicon Carbide abrasive grinding paper is ideal for metallurgical grinding of a host of materials. This roll-form C-weight paper has a...

View full details
$0.00 - $0.00
$0.00
$50.00
$50.00 - $50.00
$50.00
800 grit silicon carbide grinding paper roll
$0.00 - $0.00
$0.00
$50.00
$50.00 - $50.00
$50.00

CarbiPro SiC Grinding Paper Roll (3-7/16-in x 75-ft) - 800 grit

 CarbiPro's Silicon Carbide abrasive grinding paper is ideal for metallurgical grinding of a host of materials. This roll-form C-weight paper has a...

View full details
$0.00 - $0.00
$0.00
$50.00
$50.00 - $50.00
$50.00
CarbonMount conductive mounting resin
$29.00 - $29.00
$29.00
$29.00 - $29.00
$29.00

CarbonMount Conductive Mounting Resin Powder - Graphite-Filled 1 lb

 CarbonMount is a graphite-filled, compression mounting resin powder for metallographic specimen preparation. Use CarbonMount to produce conductive...

View full details
$29.00 - $29.00
$29.00
$29.00 - $29.00
$29.00
CarbonMount conductive mounting resin
$140.00 - $140.00
$140.00
$140.00 - $140.00
$140.00

CarbonMount Conductive Mounting Resin Powder - Graphite-Filled 5 lb

 CarbonMount is a graphite-filled, compression mounting resin powder for metallographic specimen preparation. Use CarbonMount to produce conductive...

View full details
$140.00 - $140.00
$140.00
$140.00 - $140.00
$140.00