Preparation of Free-Standing Metallographic Samples for High-Throughput Characterization

Author(s):

Clinton J. Strosser, Nathaniel Rorer, and Brady G. Butler

Abstract:

High-quality, free-standing metallographic specimens have remained challenging to produce in laboratories that rely on rapid, multitechnique characterization. Conventional epoxy or phenolic resin mounts simplify handling but frequently interfere with electron microscopy and mechanical testing, where coplanarity, electrical grounding, and mechanical stiffness are critical. In this work, an efficient procedure was developed for creating free-standing metallographic mounts using thermoplastic adhesives, with specific attention given to surface alignment, adhesion strength, and ease of removal. The method was designed to support high-throughput testing pipelines in which specimens must be prepared, characterized, and reprocessed in rapid succession. Emphasis was placed on adhesive selection, temperature control, and mitigation of entrapped air to preserve surface integrity for techniques including electron backscatter diffraction, nanoindentation, Vickers hardness testing, and micro-impact experiments. This approach provided a reproducible and adaptable pathway for producing polished, mechanically stable, and reworkable specimens suitable for advanced metallographic studies.