Our abrasive cutting consumables deliver precise, efficient cuts for metallographic sample preparation. Choose from high-performance abrasive and diamond blades, plus cutting fluids ideal for metals, ceramics, and composites. Engineered to minimize deformation, our products ensure clean results for microstructural analysis.
Match the blade to material type and hardness for clean cuts and reduced wear.
Ensure proper coolant flow to minimize heat and prevent damage.
Clamp the specimen firmly to prevent movement and uneven cuts.
The first step in preparing a specimen for metallographic or microstructural analysis is to locate the area of interest. Sectioning or cutting is the most common technique for obtaining this area. Our MEGA abrasive sectioning systems are designed to work seamlessly with these consumables, providing precise, low-deformation cutting for a wide range of materials. Proper sectioning has the following characteristics:
Selecting the right abrasive blade depends on material hardness, composition, and whether it's ferrous or nonferrous. Blades are characterized by abrasive type (alumina or silicon carbide), bond type (resin or resin-rubber), and hardness. Resin-bonded blades offer cleaner cuts with continuous abrasive renewal, while resin-rubber blades provide longer life. All blades feature a 32 mm (1.25-inch) arbor, sold in packages of 10, and are compatible with our MEGA abrasive sectioning equipment.
| Material | Composition | Recommended Blade | Blade Image |
|---|---|---|---|
| Soft non-ferrous metals (aluminum, brass, zinc, etc.) | Alumina/resin bonded | MAX-E |
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| Hard non-ferrous metals (titanium, zirconium, etc.) | Silicon carbide/resin-rubber bond | MAX-C |
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| Soft steels | Alumina/resin bonded | MAX-E |
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| Hard and case hardened steels | Alumina/resin bonded | MAX-VHS |
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| General purpose blade for steels and ferrous metals | Alumina/resin bonded | MAX-D |
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| Universal thin resin/rubber blade | Alumina/resin-rubber bond | MAX-A |
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| Industrial general purpose thin blade | Alumina/resin-rubber bond | MAX-I |
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| Material / Application | 10-inch | 12-inch | 14-inch | 16-inch |
|---|---|---|---|---|
| Soft non-ferrous (aluminum, brass, zinc) | MAX-E250 | MAX-E300 | MAX-E350 | MAX-E400 |
| Hard non-ferrous (titanium, zirconium) | MAX-C250 | MAX-C300 | MAX-C350 | MAX-C400 |
| Soft steels | MAX-E250 | MAX-E300 | MAX-E350 | MAX-E400 |
| Hard and case-hardened steels | MAX-VHS250 | MAX-VHS300 | MAX-VHS350 | MAX-VHS400 |
| General steels and ferrous metals | MAX-D250T | MAX-D300 | MAX-D350 | MAX-D400 |
| Universal thin blade | MAX-A250 | MAX-A300 | MAX-A350 | MAX-A400 |
| Industrial general purpose thin | MAX-I250 | MAX-I300 | MAX-I350 | MAX-I400 |
| Blade Type | Specification | 10-inch | 12-inch | 14-inch | 16-inch |
|---|---|---|---|---|---|
| MAX-A | Thickness (in) | 0.039 | 0.055 | 0.063 | 0.090 |
| Max Speed (RPM) | 3820 | 3185 | 2730 | 2860 | |
| MAX-C | Thickness (in) | 0.059 | 0.078 | 0.078 | 0.100 |
| Max Speed (RPM) | 3440 | 3185 | 3460 | 2390 | |
| MAX-D | Thickness (in) | 0.059 | 0.078 | 0.078 | 0.100 |
| Max Speed (RPM) | 4585 | 3820 | 3275 | 3800 | |
| MAX-E | Thickness (in) | 0.059 | 0.078 | 0.078 | 0.100 |
| Max Speed (RPM) | 4500 | 3800 | 3200 | 3800 | |
| MAX-I | Thickness (in) | 0.059 | 0.078 | 0.078 | 0.100 |
| Max Speed (RPM) | 4500 | 3800 | 3200 | 3800 | |
| MAX-VHS | Thickness (in) | 0.075 | 0.078 | 0.098 | 0.100 |
| Max Speed (RPM) | 3055 | 2500 | 2220 | 1925 | |
| DMAX | Thickness (in) | 0.059 | 0.060 | 0.060 | 0.075 |
| Max Speed (RPM) | 6100 | 5000 | 4350 | 3800 |
Lubrication and swarf removal during abrasive cutting are required to minimize damage to the specimen. The ideal cutting fluid removes cutting swarf and degraded abrasive blade material, and should have a relatively high flash point because of the sparks produced during abrasive sectioning. For some older abrasive cutters, the proper cutting fluid can also have the added benefit of coating cast iron bases and fixtures to reduce or eliminate corrosion.
TIP: Most abrasive cutters have a hood, which can produce a corrosive humidity chamber when not in use. To reduce these corrosive effects, keep the hood open when not in use.
| Description | Quantity | Part No. | Product |
|---|---|---|---|
| MAXCUT Cutting Fluid (32 oz) | 32 oz | MAXCUT-1000-32 |
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| MAXCUT Cutting Fluid (1/2 gallon) | 1/2 gallon | MAXCUT-1000-64 |
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| MAXCUT Cutting Fluid (1 gallon) | 1 gallon | MAXCUT-1000-128 |
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| MAXCUT Cutting Fluid (5 gallons) | 5 gallons | MAXCUT-1000-5G |
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| Description | Quantity | Part No. | Product |
|---|---|---|---|
| MAXCUT 2 Cutting Fluid (with corrosion inhibitor) (32 oz) | 32 oz | MAXCUT2-1000-32 |
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| MAXCUT 2 Cutting Fluid (with corrosion inhibitor) (1/2 gallon) | 1/2 gallon | MAXCUT2-1000-64 |
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| MAXCUT 2 Cutting Fluid (with corrosion inhibitor) (1 gallon) | 1 gallon | MAXCUT2-1000-128 |
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| MAXCUT 2 Cutting Fluid (with corrosion inhibitor) (5 gallons) | 5 gallons | MAXCUT2-1000-5G |
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| Description | Quantity | Part No. | Product |
|---|---|---|---|
| MAXCUT OL1000 Water Soluble Emulsion Cutting Fluid (32 oz) | 32 oz | MAXCUT-OL-1000-32 |
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| MAXCUT OL1000 Water Soluble Emulsion Cutting Fluid (1/2 gallon) | 1/2 gallon | MAXCUT-OL-1000-64 |
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| MAXCUT OL1000 Water Soluble Emulsion Cutting Fluid (1 gallon) | 1 gallon | MAXCUT-OL-1000-128 |
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| MAXCUT OL1000 Water Soluble Emulsion Cutting Fluid (5 gallons) | 5 gallons | MAXCUT-OL-1000-5G |
|
Abrasive sectioning is ideal for cutting ductile materials like metals, composites, plastics, and rubbers. Success depends on understanding the relationship between abrasive type, bonding, specimen properties, and proper cutting technique.
Modern blades use alumina (best for ferrous metals) or silicon carbide (ideal for nonferrous metals). The bonding material should break down at the same rate as the abrasive dulls to maintain cutting efficiency. The right resin system depends on the sample's hardness and wear characteristics.
Variable speed saws enhance control by matching cutting speed to material hardness. Softer metals require slower speeds to minimize burrs, while harder materials benefit from higher speeds to expose sharp abrasives. For hardened steels, use 50% of the blade's maximum speed to avoid overheating.
| Symptom | Cause | Action |
|---|---|---|
| Chipped or broken blade | Secure sample properly Reduce cutting force | Secure sample properly Reduce cutting force |
| Bluish burnt color on specimen | Incorrect cutting fluid Improper blade or excessive force | Use proper cutting fluid Consult applications guideline or use a blade with a softer resin |
Our MEGA manual abrasive cutters provide precision cutting for metallographic sample preparation. Available in multiple sizes (10" to 16" blade capacity) with features like variable speed control, coolant systems, and robust construction for reliable operation.
MEGA automated abrasive cutters offer programmable cutting cycles, automatic feed control, and advanced safety features. Perfect for high-volume labs requiring consistent, repeatable cuts with minimal operator intervention.
Common questions about abrasive cutting and blade selection
Blade selection depends on your material's hardness and composition. For soft non-ferrous materials like aluminum and brass, use harder bonding materials. For harder materials like steel and ceramics, use softer bonding to allow for self-sharpening. Refer to our blade selection guide on this page for detailed recommendations by material type, or contact our applications team for personalized assistance.
Blade life is influenced by several factors: proper blade selection for the material, appropriate cutting speed and feed rate, adequate coolant flow, correct specimen clamping, and blade storage conditions. Using too much force, incorrect coolant, or cutting at excessive speeds can significantly reduce blade life. Follow our recommended procedures section for optimal cutting parameters.
The choice of coolant depends on your material and application. Soluble oils provide good cooling and lubrication for most metals. For materials sensitive to water, use petroleum-based fluids. For non-ferrous metals prone to staining, specialized coolants may be required. Our cutting fluids section provides detailed recommendations. Proper coolant flow is essential to prevent heat buildup and blade wear.
Cutting parameters vary by material and blade size. As a general rule, harder materials require slower speeds and lighter feed rates, while softer materials can handle higher speeds. Never exceed the maximum operating speed marked on the blade. Start with conservative parameters and adjust based on cut quality and blade wear. Our recommended procedures section provides specific guidelines for common materials.
Edge retention and minimal damage require proper technique. Always secure specimens firmly to prevent movement. Use adequate coolant to minimize heat generation. Select the appropriate blade for your material. Apply consistent, moderate cutting pressure rather than forcing the cut. For critical edge retention, consider using precision wafering blades with finer abrasives and resin-bonded construction.
Burning or discoloration indicates excessive heat, typically from inadequate coolant flow, incorrect blade selection, or too much cutting force. Check coolant levels and flow rate first. Verify you're using the correct blade for your material. Reduce feed rate and cutting force. For persistent issues, consult our troubleshooting guide on this page or contact our technical support team for assistance.