The properties of gray iron are highly dependent on the size, shape and distribution of the graphite flakes. In spite of the importance of the graphite structure, quantitative analysis of the flakes has been underutilized in the foundry industry. In this study, methods for analyzing the characteristics of graphite flakes in gray iron are described. A metallographic sample preparation technique that works on a wide variety of irons and is not user specific was developed. This technique uses a dry grinding/etching process, followed by a polish with 1.0 micrometer diamond abrasive.
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