4.1 These test methods cover procedures for estimating and rules for expressing the average grain size of all metals consisting entirely, or principally, of a single phase. The test methods may also be used for any structures having appearances similar to those of the metallic structures shown in the comparison charts. The three basic procedures for grain size estimation are:

4.1.1 Comparison Procedure-The comparison procedure does not require counting of either grains, intercepts, or intersections but, as the name suggests, involves comparison of the grain structure to a series of graded images, either in the form of a wall chart, clear plastic overlays, or an eyepiece reticle. There appears to be a general bias in that comparison grain size ratings claim that the grain size is somewhat coarser (¹/₂ to 1 G number lower) than it actually is (see X1.3.5). Repeatability and reproducibility of comparison chart ratings are generally ±1 grain size number.

4.1.2 Planimetric Procedure-The planimetric method involves an actual count of the number of grains within a known area. The number of grains per unit area, N_A , is used to determine the ASTM grain size number, G. The precision of the method is a function of the number of grains counted. A precision of ±0.25 grain size units can be attained with a reasonable amount of effort. Results are free of bias and repeatability and reproducibility are less than ±0.5 grain size units. An accurate count does require marking off of the grains as they are counted.

4.1.3 Intercept Procedure-The intercept method involves an actual count of the number of grains intercepted by a test line or the number of grain boundary intersections with a test line, per unit length of test line, used to calculate the mean lineal intercept length, ℓ. ℓ is used to determine the ASTM grain size number, G. The precision of the method is a function of the number of intercepts or intersections counted. A precision of better than ±0.25 grain size units can be attained with a reasonable amount of effort. Results are free of bias; repeatability and reproducibility are less than ±0.5 grain size units. Because an accurate count can be made without need of marking off intercepts or intersections, the intercept method is faster than the planimetric method for the same level of precision.

4.2 For specimens consisting of equiaxed grains, the method of comparing the specimen with a standard chart is most convenient and is sufficiently accurate for most commercial purposes. For higher degrees of accuracy in determining average grain size, the intercept or planimetric procedures may be used. The intercept procedure is particularly useful for structures consisting of elongated grains.

4.3 In case of dispute, the intercept procedure shall be the referee procedure in all cases.

4.4 No attempt should be made to estimate the average grain size of heavily cold-worked material. Partially recrystallized wrought alloys and lightly to moderately cold-worked material may be considered as consisting of non-equiaxed grains, if a grain size measurement is necessary.

4.5 Individual grain measurements should not be made based on the standard comparison charts. These charts were constructed to reflect the typical log-normal distribution of grain sizes that result when a plane is passed through a three-dimensional array of grains. Because they show a distribution of grain dimensions, ranging from very small to very large, depending on the relationship of the planar section and the three-dimensional array of grains, the charts are not applicable to measurement of individual grains.