SECTIONING
PROBLEMS	PROBABLE CAUSES	POSSIBLE SOLUTIONS
Frequent wheel breakage	-Chisel effect. -Loose specimen clamping. -Excessive initial force applied. -Missing blotter.	-Insure coolant is flowing evenly on both sides. -Rigidly clamp specimen. -Reduce applied cutting pressure. -Insert blotter. -Clean flange of surface corrosion.
Short wheel life	-Wheel wearing down too fast.	-Select harder wheel. -Reduce applied cutting pressure.
Wheel not cutting	-Slow wheel breakdown.	-Reduce coolant rate. -Choose softer wheel. -Use swaying stroke.
Burning of sample	-Sample overheating.	-Increase coolant rate. -Reduce applied cutting pressure. -Select softer wheel.
Curved cut	-Excessive force applied.	-Reduce applied cutting pressure.
Non uniform wheel wear	-Flow of coolant not uniform.	-Clean hoses from cutting debris.
Motor stalling	-Sample being cut is too large.	-Decrease sample size.

COMPRESSION MOUNTING
PROBLEMS	PROBABLE CAUSES	POSSIBLE SOLUTIONS
Shrinkage	-Poor adhesion to sample surface.	-Decrease molding temperature. -Cool mount before ejecting sample.
Mold cracking	-Powders absorbed moisture. -Entrapped gases during molding. -Sample too large for mold area. -Samples have sharp corners.	-Preheat powders. -Release pressure for a moment during flow stage. -Reduce size of specimen. -Clearance between sample and mold should be approx. 1/8". Reduce specimen size.
Top die damaged	-Not enough mounting media added.	-Add sufficient mounting powder.
Mold blistering	-Not enough applied pressure. -Curing time is insufficient.	-Increase pressure. -Increase curing time.
Mounts sticking to mold cylinder	-Mold temperature too high.	-Reduce molding temperature. -Apply releasing agent.
Staining and dull surfaces	-Mold temperature too high.	-Reduce molding temperature.
Unfused mount	-Molding temperature too low. -Insufficient curing time.	-Vary pressure applied. Adjust if necessary. -Lengthen curing time.
Cotton ball effect	-Mounting temperature did not reach maximum temperature	-Verify temperature. Adjust if necessary. -Increase curing time.

AMBIENT MOUNTING
PROBLEMS	PROBABLE CAUSES	POSSIBLE SOLUTIONS
Air entrapment	-Agitation of blend between resin and hardener is too rapid.	-Gently blend the resin and hardener. Alternative is to use pressure vessel or vacuum system
Mold cracking	-The proportion of resin and hardener is incorrect. -Insufficient air cure. -Oven curing temperature is too high.	-The reaction between the resin and hardener is too exothermic. -Measure accurate proportions of resin and hardener.
Mounts are soft	-Incorrect proportion of resin and hardener were used. -Poor mix between resin and hardener.	-Increase hardener proportion to resin ratio. -Homogenize more thoroughly the mixture of resin and hardener.
Mounts sticking to sample holders	-Mold temperature too high.	-Apply releasing agent.
Staining and dull surfaces	-Incorrect proportion of resin and hardener. -Oxidized hardener.	- Measure accurate proportions of resin and hardener. -Seal hardener container.
Top of mounts sticky	-Incorrect proportion of resin and hardener. -Poor mix between resin and hardener.	- Measure accurate proportions of resin and hardener. -Homogenize more thoroughly the mixture of resin and hardener.
Poor adhesion between resin and specimen	-Not using the appropriate medium for mounting specimen. -Samples were not cleaned prior to mounting sample -Mounting shrinkage.	- Clean samples thoroughly before mounting sample. -Use mounting medium that has good adhesion and no shrinkage.

GRINDING AND POLISHING
PROBLEMS	PROBABLE CAUSES	POSSIBLE SOLUTIONS
Scratches	-Sharp abrasive particles released from the material being used to grind or polish. -Contamination of the previous steps in grinding or polishing.	-Repeat step until all scratch lines are uniform. -Increase the preparation time for the current step. (Not the pressure) -Verify the cutting edge of the abrasive being used is effective. If necessary change. -Change polishing cloth. Use a more thorough technique in cleaning between steps. -Clean samples thoroughly in between each step.
Smearing/Buffing	-Surface of specimen not being cut. -pH of alumina suspension is too high.	-Increase quantity of applied lubricant. -Use a less napped cloth. -Use a coarser grain particle. -Decrease the pH of alumina suspension.
Relief	-Preparation time too long. -Type of polishing cloth used.	-Preparation time should be kept to a minimum. -Use a shorter nap cloth.
Staining	-pH of alumina suspension is alkaline	-Neutralize pH of alumina suspension.
Pull outs	-Insufficient steps between grain sizes. -Type of polishing cloth used. -Polishing time is too long or to short. -Excessive use of lubricant.	-Increase grain size steps. -Use a napless polishing cloth. -Decrease the polishing time. Possibly depending on the application, may have to increase the polishing time. -Reduce quantity of lubricant used. -Moisten cloth with lubricant prior to applying diamond abrasive.
Rounding of the edges	-Samples were not mounted. -Incorrect mounting medium was used. -Polishing times were too long. -Excess pressure applied to specimen. -Type of polishing cloth used.	- Mount the samples. -Use mounting medium that has good adhesion. -Keep polishing time to minimum. -Use shorter and tighter weaved polishing cloth.
Cracks	-From cutting the specimen. -Clamping of the sample. -Wrong mounting medium used. -Shrinkage.	-Use appropriate cut-off wheel. -Use protective layer between sample and clamp from cut-off equipment. -Use cold mounting system with the aid of a vacuum system or pressure vessel. -Use mounting medium that has the least shrinkage properties.
Porosity	-Worn out abrasive. -Type of polishing cloth used. -Type of mounting medium.	-Change abrasive discs more often. Alternative, use diamond discs. -Use a shorter nap polishing cloth. -With cold resin, use vacuum or pressure vessel systems.
Embedded abrasive	-Excess pressure applied to specimen. -Type of polishing cloth used. -Excessive use of polishing abrasive. -Lubricant has low viscosity.	-Reduce pressure applied to specimen. -Use a shorter nap cloth. -Decrease the amount of polishing abrasive, especially for soft metals. -Use a higher viscosity lubricant.
Comet tails	-Too much pressure. -Too much speed. -Over polishing on worn abrasive cloths. -Use of same orientation during all polishing steps.	-Reduce pressure applied. -Reduce speed. -Change abrasive cloth more frequently. -Change orientation of the sample for every step.
Scratch lines are long and dull	-Sharp abrasive particles from the material being used to grind or polish. -Contamination of the previous steps in grinding or polishing.	-Repeat step until all scratch lines are uniform. -Increase the preparation time for the current step. (Not the pressure) -Verify the cutting edge of the abrasive being used is effective. If necessary change. -Change polishing cloth. Use a more thorough cleaning technique between steps. -Clean samples thoroughly in between each step.