Abrasive Grinding Consumables
Our selection of abrasive grinding consumables is engineered for precision and efficiency in metallographic sample preparation. We offer high-quality silicon carbide (SiC), alumina, and zirconia abrasive papers, each tailored for specific grinding needs.
Abrasive Grinding Consumables
Key Tips for Abrasive Grinding
- Choose the Right Abrasive: Use SiC for rapid material removal with minimal deformation, alumina for enhanced durability on harder materials, and zirconia for aggressive grinding with extended lifespan.
- Monitor Grit Progression: Start with coarser grits for bulk material removal and gradually move to finer grits to reduce scratches and improve surface quality.
- Ensure Proper Lubrication: Use water or grinding fluids to prevent overheating, extend paper life, and maintain surface integrity.
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Introduction
Selecting the right abrasive grinding paper is essential for achieving precise and consistent metallographic results, as different abrasives impact material removal rates, surface quality, and preparation efficiency. Silicon carbide (SiC) papers are ideal for soft to medium-hard metals and alloys, offering a sharp cutting action and self-sharpening properties for efficient grinding. Alumina (Al₂O₃) papers are tougher and more durable than SiC, making them suitable for very soft materials like copper, aluminum, gold, and silver, as well as refractory metals such as rhenium, tungsten, and vanadium. Their lower fracturing tendency reduces the risk of abrasive embedding in softer specimens. Zirconia abrasives are recommended for tough, high-strength materials that require aggressive grinding and extended lifespan. Choosing the appropriate abrasive ensures minimal surface deformation, streamlining the preparation process and improving microstructural analysis.
Abrasive Grinding Guideline
| Material | Objective | Recommendation |
|---|---|---|
| Soft non-ferrous metals (Al, Cu, Brass, Zn, etc.) | Minimize abrasive embedding & deformation | P120, P220, P500, P1200 grit ALO paper |
| Soft ferrous metals (Low carbon, SS, case-hardened steel) | Reduce deformation & secondary phase damage | 240, 320, 400, 600, 800, 1200 grit SiC paper |
| Hard ferrous metals (High carbon, tool, case-hardened steel) | Planarize & minimize deformation | 180, 240, 320, 400, 600 grit SiC paper |
| Super alloys (High Ni & Co alloys, Ti alloys) | Minimize deformation | 70µm diamond disk, 9µm SIRIUS, 3µm ORION composite disk |
| Ceramics, CMCs, minerals | Minimize surface & subsurface damage | 30µm polycrystalline diamond on Metal Mesh cloth |
| MMCs, PMCs | Reduce fracturing & matrix deformation | 240 or 320 grit SiC paper |
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Process Description
The metallographic specimen preparation process is influenced by key machine parameters: grinding/polishing pressure, relative velocity distribution, and grinding direction. Understanding these factors helps optimize material removal while minimizing damage.
GRINDING PRESSURE: Grinding pressure depends on the applied force and the specimen's surface area. For harder specimens, pressure is best defined as force divided by the specimen area.
- Higher pressure increases material removal but also leads to more surface and subsurface damage.
- For SiC papers, as abrasive grains dull, increasing pressure can extend paper life.
- Frictional heat from higher pressure can aid in chemical-mechanical polishing (CMP) of ceramics, minerals, and composites.
- Friable materials (e.g., nodular cast iron) may benefit from higher pressure and lower velocity to retain inclusions and secondary phases.
GRINDING DIRECTION: Grinding orientation affects preparation results, particularly for coated specimens. By controlling these parameters, metallographic grinding can achieve efficient material removal while preserving microstructural integrity.
- Brittle coatings: Abrasive should move through the coating into the substrate to keep the coating in compression.
- Brittle substrates with ductile coatings: Abrasive should move through the substrate into the coating to prevent delamination.
RELATIVE VELOCITY: Modern grinding/polishing machines use disk-on-disk rotation, creating variable velocity distributions based on head and base speeds.
- For minimal damage & better flatness, match head and base speeds (e.g., 200 rpm in the same direction).
- For high stock removal, a slower head speed with a higher base speed is more aggressive but may lead to non-uniform material removal and increased damage.
- For polishing, reducing speed to 100/100 rpm is recommended.
- CMP processes benefit from higher speeds if brittle phases are absent.
| Head Speed (rpm) | Base Speed (rpm) | Velocity Distribution | Characteristics | Application |
|---|---|---|---|---|
| 150 | 300-600 | High |
- Fast material removal - Uneven grinding across surface |
- Hard specimens - Coarse grinding |
| 200 | 200 | Minimal |
- Even stock removal - Low material loss - Minimal surface damage |
- Flatness control - Retains inclusions & brittle phases |
Recommended Procedures
For best results for fixed-abrasive grinding, start with the finest abrasive possible, typically 240 or 320 grit, using coarser grit only for heavy stock removal. Apply an appropriate lubricant to the abrasive surface; water is the most common choice, while water-soluble oils are recommended for water-sensitive specimens. To maintain surface integrity, always rinse specimens thoroughly before proceeding to a finer abrasive.
CERMESH METAL MESH CLOTH APPLICATION:
- Apply CERMESH metal mesh cloth to a flat base: (1) Peel back the protective paper at one corner, align, and place it carefully, and (2) Gradually remove the protective backing while guiding the cloth into position.
- Pre-charge the cloth with DIAMAT polycrystalline diamond.
- To prevent tearing, start grinding at 50% force to set the specimen onto the cloth.
- Gradually increase force and add abrasive as needed.
- At the end of the grinding cycle, rinse the cloth with water to remove swarf and debris.
Troubleshooting
| Symptom | Cause | Solution |
|---|---|---|
| Uneven grinding |
- Improper specimen tracking - Mismatched head/base speeds |
- Adjust specimen positioning for even paper wear - Synchronize head and base speeds, same direction - Grind at 200/200 rpm, polish at 100/100 rpm |
| Excessive vibration |
- High load or low speed - Machine design limitations - Inadequate lubrication - Mismatched head/base speeds |
- Reduce load or increase speed - Consult vendor for machine upgrades - Increase lubricant flow or use water-based lubricant - Synchronize head and base speeds, same direction - Grind at 200/200 rpm, polish at 100/100 rpm |
| Abrasive grain embedding |
- Common in soft material grinding - Mismatched head/base speeds |
- Use alumina papers instead of SiC - Synchronize head and base speeds, same direction - Grind at 200/200 rpm, polish at 100/100 rpm |
Silicon Carbide
Silicon Carbide (SiC) is a synthetic abrasive formed through a high-temperature reaction between silica and carbon. With a hexagonal-rhombohedral crystal structure and a hardness of approximately 2500 HV, SiC is an excellent material for cutting and grinding. Its natural brittleness allows it to fracture easily, continuously exposing sharp edges for self-sharpening. This property makes SiC ideal for maximizing cutting efficiency while minimizing surface and subsurface damage. It is commonly used in metallographic preparation, found in abrasive blades and coated grinding papers available in grit sizes from coarse 60 to fine 1200.
- Available Diameters: Offered in 8", 10", 12", and 14" sizes to accommodate various grinding equipment.
- Grit Range: Covers 60 to 1200 grit, providing options for coarse grinding to fine surface preparation.
- Backing Options: Available in plain, PSA (pressure-sensitive-adhesive), and foil formats to suit different mounting preferences and workflows.
SiC Abrasive Paper (PSA - Pressure Sensitive Adhesive) - 100/pkg
| Description | 8-inch Diameter |
10-inch Diameter |
12-inch Diameter |
14-inch Diameter |
|---|---|---|---|---|
| 60 grit SiC paper w/ PSA adhesive | SIC-060P8-100 | SIC-060P10-100 | SIC-060P12-100 | SIC-060P14-100 |
| 80 grit SiC paper w/ PSA adhesive | SIC-080P8-100 | SIC-080P10-100 | SIC-080P12-100 | SIC-080P14-100 |
| 120 grit SiC paper w/ PSA adhesive | SIC-120P8-100 | SIC-120P10-100 | SIC-120P12-100 | SIC-120P14-100 |
| 180 grit SiC paper w/ PSA adhesive | SIC-180P8-100 | SIC-180P10-100 | SIC-180P12-100 | SIC-180P14-100 |
| 240 grit SiC paper w/ PSA adhesive | SIC-240P8-100 | SIC-240P10-100 | SIC-240P12-100 | SIC-240P14-100 |
| 320 grit SiC paper w/ PSA adhesive | SIC-320P8-100 | SIC-320P10-100 | SIC-320P12-100 | SIC-320P14-100 |
| 360 grit SiC paper w/ PSA adhesive | SIC-360P8-100 | SIC-360P10-100 | SIC-360P12-100 | SIC-360P14-100 |
| 400 grit SiC paper w/ PSA adhesive | SIC-400P8-100 | SIC-400P10-100 | SIC-400P12-100 | SIC-400P14-100 |
| 600 grit SiC paper w/ PSA adhesive | SIC-600P8-100 | SIC-600P10-100 | SIC-600P12-100 | SIC-600P14-100 |
| 800 grit SiC paper w/ PSA adhesive | SIC-800P8-100 | SIC-800P10-100 | SIC-800P12-100 | SIC-800P14-100 |
| 1000 grit SiC paper w/ PSA adhesive | SIC-1000P8-100 | SIC-1000P10-100 | SIC-1000P12-100 | SIC-1000P14-100 |
| 1200 grit SiC paper w/ PSA adhesive | SIC-1200P8-100 | SIC-1200P10-100 | SIC-1200P12-100 | SIC-1200P14-100 |
SiC Abrasive Paper (Plain Backed) - 100/pkg
| Description | 8-inch Diameter |
10-inch Diameter |
12-inch Diameter |
14-inch Diameter |
|---|---|---|---|---|
| 60 grit SiC paper plain backed | SIC-2108-060 | SIC-2110-060 | SIC-2112-060 | SIC-2114-060 |
| 80 grit SiC paper plain backed | SIC-2108-080 | SIC-2110-080 | SIC-2112-080 | SIC-2114-080 |
| 120 grit SiC paper plain backed | SIC-2108-120 | SIC-2110-120 | SIC-2112-120 | SIC-2114-120 |
| 180 grit SiC paper plain backed | SIC-2108-180 | SIC-2110-180 | SIC-2112-180 | SIC-2114-180 |
| 240 grit SiC paper plain backed | SIC-2108-240 | SIC-2110-240 | SIC-2112-240 | SIC-2114-240 |
| 320 grit SiC paper plain backed | SIC-2108-320 | SIC-2110-320 | SIC-2112-320 | SIC-2114-320 |
| 360 grit SiC paper plain backed | SIC-2108-360 | SIC-2110-360 | SIC-2112-360 | SIC-2114-360 |
| 400 grit SiC paper plain backed | SIC-2108-400 | SIC-2110-400 | SIC-2112-400 | SIC-2114-400 |
| 600 grit SiC paper plain backed | SIC-2108-600 | SIC-2110-600 | SIC-2112-600 | SIC-2114-600 |
| 800 grit SiC paper plain backed | SIC-2108-800 | SIC-2110-800 | SIC-2112-800 | SIC-2114-800 |
| 1200 grit SiC paper plain backed | SIC-2108-1200 | SIC-2110-1200 | SIC-2112-1200 | SIC-2114-1200 |
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Alumina
Alumina, derived from naturally occurring bauxite, exists in two primary phases: the softer gamma phase (Mohs 8) and the harder alpha phase (Mohs 9, ~2000 HV). Due to its high hardness and durability, alumina is primarily used as a final polishing abrasive in metallographic preparation. Unlike silicon carbide (SiC), alumina breaks down more readily into submicron or colloidal particles, making it well-suited for achieving fine surface finishes. While larger bonded or coated alumina grit sizes are commercially available, they are not ideal for metallographic applications. As these abrasives wear, they become dull, leading to slower cut rates and increased surface and subsurface damage.
- Available Diameters: Offered in 8", 10", and 12" sizes to accommodate various grinding equipment.
- Grit Range: Covers 120 to 1200 grit, providing options for coarse grinding to fine surface preparation.
- Backing Options: Available in plain and PSA-backing formats to suit different mounting preferences and workflows.
| Standard Grit | 120 | 180 | 240 | 320 | 360 | 400 | 600 | 800 | 1200 |
|---|---|---|---|---|---|---|---|---|---|
| European (P-grade) | P120 | P180 | P220 | P320 | P500 | P800 | P1200 | P2400 | P4000 |
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Alumina Abrasive Paper (PSA - Pressure Sensitive Adhesive) - 100/pkg
| Description | 8-inch Diameter |
10-inch Diameter |
12-inch Diameter |
|---|---|---|---|
| P120 grit AlO paper w/ PSA adhesive | ALO-120P8-100 | ALO-120P10-100 | ALO-120P12-100 |
| P220 grit AlO paper w/ PSA adhesive | ALO-220P8-100 | ALO-220P10-100 | ALO-220P12-100 |
| P500 grit AlO paper w/ PSA adhesive | ALO-500P8-100 | ALO-500P10-100 | ALO-500P12-100 |
| P1200 grit AlO paper w/ PSA adhesive | ALO-1200P8-100 | ALO-1200P10-100 | ALO-1200P12-100 |
Alumina Abrasive Paper (Plain Backed) - 100/pkg
| Description | 8-inch Diameter |
10-inch Diameter |
12-inch Diameter |
|---|---|---|---|
| P120 grit ALO paper plain backed | ALO-2108-P120 | ALO-2110-P120 | ALO-2112-P120 |
| P220 grit ALO paper plain backed | ALO-2108-P220 | ALO-2110-P220 | ALO-2112-P220 |
| P500 grit ALO paper plain backed | ALO-2108-P500 | ALO-2110-P500 | ALO-2112-P500 |
| P1200 grit ALO paper plain backed | ALO-2108-P1200 | ALO-2110-P1200 | ALO-2112-P1200 |
Zirconia
Zircon, or zirconium silicate, is a durable but less common abrasive used for coarse grinding. While it has a longer lifespan due to its toughness, it is not as hard or sharp as other abrasives and requires higher pressures to be effective. In metallographic applications, 60 and 120 grit zircon abrasives are the most commonly used for coarse grinding. Metallographic abrasives are typically classified by grit size or average particle size in microns. Grit size corresponds to the number of wires or mesh openings per a specified area, with higher grit numbers indicating finer particles. For example, a 120 grit particle measures approximately 105 microns, whereas a 1200 grit particle is around 2.5 microns. The European P-grading system differs from the ANSI or CAMI standard by excluding wire width in its calculations, making finer grit numbers significantly larger in the P-grade system (e.g., 1200 grit corresponds to P4000 grit).
- Available Diameters: Offered in 8", 10", and 12" sizes to accommodate various grinding equipment.
- Grit Range: Covers 60 to 220 grit, providing options for coarse to medium grinding applications.
- Backing Options: Available in PSA-backing.
| Standard Grit | 120 | 180 | 240 | 320 | 360 | 400 | 600 | 800 | 1200 |
|---|---|---|---|---|---|---|---|---|---|
| European (P-grade) | P120 | P180 | P220 | P320 | P500 | P800 | P1200 | P2400 | P4000 |
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Zirconia Abrasive Paper (PSA - Pressure Sensitive Adhesive) - 25/pkg
| Description | 8-inch Diameter |
10-inch Diameter |
12-inch Diameter |
|---|---|---|---|
| 120 grit Zirconia paper w/ PSA adhesive | ZR-120P08-25 | ZR-120P10-25 | ZR-120P12-25 |
| 220 grit Zirconia paper w/ PSA adhesive | ZR-220P08-25 | ZR-220P10-25 | ZR-220P12-25 |
Zirconia Abrasive Belts
| Description | Part Number | Quantity |
|---|---|---|
| 60 grit Zirconia Abrasive Grinding Belts (4-inch x 36-inch) | ZRO2-B060 | 5/pkg |