Metallurgical Replication

Metallurgical replication is a non-destructive technique used to obtain topographical or microstructural information from a surface that cannot be removed from service.

Light polishing and etching is performed on metallic surfaces using our portable, battery powered site equipment which allows exact replicas of the microstructure to be obtained for detailed optical microscopy analysis. The results achieved are directly comparable to laboratory prepared metallographic specimens, however, the replica can be obtained non-destructively and eliminates the need to remove equipment from service.

Replication is commonly used for:

  • Material identification
  • Creep and thermal degradation
  • Crack or corrosion mechanisms
  • Grain size analysis
  • Eta and sigma phase formation
Metallurgical Replication Micro


A second form of replication can be carried out using Microset polymer, this allows features such as indents, corrosion pits, cracks and rolling contact fatigue damage to be assessed using detailed, high magnification techniques such as White Light Interferometry and Scanning Electron Microscopy. This technique can also be used on polymers and ceramics.

The major advantage of these techniques is the ability to avoid removing or destroying components and preventing costly downtime and replacement whilst enabling detailed examination of a material condition. Examples of the use of replication includes:

  • Boiler tubes
  • Pipelines
  • Heritage structures
  • Bridge parapets
  • Vessels
  • Pump casings
  • Engine casings
  • Gearboxes
  • Turbines

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