NUSATEK has the capability to perform micro structure analysis on actual products on-site by replica metallographic technique. The preparation for evaluation of the microstructure will include several grinding steps with subsequently higher finish in each step followed by either mechanically or electrolytically polishing the material. The last polishing step will leave the surface with a mirror finish from which an etchant can develop the characteristics of the microstructure.
Even though the judgment can be made on-site it will often be more efficient to take replica samples for microscopy that are copies of the surface areas prepared and bring them to the laboratory for evaluation. A copy of the microstructure is taken by either a softened plastic film or by moulding with plastics or silicone rubber.
Nusatek has skillful and well trained Replica teams which are well experienced to perform and analyze replica tests to determine creep damage, metallurgy failure investigation on steel and verify material condition, with more than 5 years in Petrochemical, Refinery, Fabricators and Oil & Gas Industries. We have experience in performing replica tests on various types of materials such as carbon steel, low alloy steel, Cr Mo material, stainless steel, and duplex stainless steel.
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Metallography examination can be done directly on site as a non-destructive test method, where it is called in-situ metallography replica testing. Replica testing is commonly recommended when a part is not permissible to be cut, or is still fit for use until a specific time for replacement, undergoing remaining life assessment monitoring or has crack damage and microstructure changes due to overheating or stress.
Replica testing procedure replicates the microstructure on a cellulose acetate after surface preparation and etched with a suitable solution on the required metal’s surface for investigation. The replicate slide is reviewed on the portable microscope on-site. Then a Hardness test is performed on the finished surface of the tested replica area by using a Krautkramer MIC 10 instrument.
Nusatek provides metallurgists with skillful technical expertise to perform and analyze the replica tests. Analysis of the replica test results is supported with on-site hardness test valuation. The metallurgist reviews the replica slide by using a high powered optical microscope in the laboratory to verify and confirm the structure. Nusatek has a complete metallurgical lab to verify microstructure. We will provide a written report of the replica test with photomicrographs of the microstructure including Hardness test values.
