Department of Mechanical & Manufacturing Engineering Faculty of Engineering, University of Putra Malaysia

HARDNESS TEST
Introduction
Hardness is the resistance of a material to localized deformation. Hardness measurements are widely used for the quality control of materials because they are quick and considered to be nondestructive tests when the marks or indentations produced by the test are in low stress areas. This manual contains some fundamental theory for understanding the experiment, description of the apparatus and experimental procedure for hardness test.

Objective
The objectives of this experiment are 1. To determine the hardness of various engineering materials using Rockwell hardness test. 2. To develop an understanding of suitable scale for hardness test specimens.

Theory
1. General Hardness is a measure of the resistance of a metal to permanent (plastic) deformation. The hardness of the metal is measured by loading an indenter into its surface. The indenter material which is usually a ball, pyramid, or cone, is made of a material much harder than the material being tested. For most standard hardness tests a known load is applied slowly by pressing the indenter at 90 degrees into the metal surface being tested. After the indentation has been made, the indenter is withdrawn from the surface. An empirical hardness number is then calculated or read off a dial (or digital display), which is based on the cross-sectional area of depth of the indentation. The most common type of tests that widely used and adopted in engineering practices are the Brinell, Vickers and Rockwell methods. D 2. Brinell Hardness Test With the Brinell test, a hardened steel ball or tungsten carbide ball is pressed for a time of 10 to 15 seconds into the surface of specimen by a standard load F [kgf] (Figure 1). After the load and the ball have been removed, the diameter of the indentation d [mm] is measured. The Brinell hardness number HB, is obtained by dividing the size of the load applied by the surface area of the spherical indentation A [mm2].
Side view

d
Top view

d Fig. 1 Shape of indentation in Brinell hardness test

D HB = F / A = F / Dh = F / [ D 2

(D

d 2 )

(1)

where h [mm] is the depth of indentation, D [mm] is the diameter of the ball. The Brinell test cannot be used with very soft or very hard materials. This test is limited to materials with hardnesses up to 450 HB with a hardened steel ball and 600 HB with a tungsten carbide ball. 3. Vickers Hardness Test The Vickers test involves a diamond indenter, in the form of a square-based pyramid with an apex angle of 136, being pressed under load for 10 to 15 seconds into the surface of the specimen under test. The result is a square-shaped indentation. After the load and indenter are removed the diagonals of the indentation d [mm] are measured. The Vickers hardness number HV is obtained by dividing the size of the load F [kgf], applied by the surface area A [mm2], of the indentation (Figure 2). Thus the HV is given by

HV = F /(d 2 / sin 68) = F /(d 2 / 1.854 ) = 1.854 F / d 2

(2)

Department of Mechanical & Manufacturing Engineering Faculty of Engineering, University of Putra Malaysia

Typically a load of 30 kg is used for steels and cast irons, 10 kg for copper alloys, 5 kg for pure copper and aluminium alloys, 2.5 kg for pure aluminium and 1 kg for lead, tin and tin alloys. Up to a hardness value of about 300 HV, the hardness value number given by the Vickers test is the same as that given by the Brinell test. 4. Rockwell Hardness Test The Rockwell test differs from the Brinell and Vickers tests in not obtaining a value for the hardness in terms of an indentation but using the depth of indentation, this depth being directly indicated by a pointer on a calibrated scale. The test uses either a diamond cone or a hardened steel ball as the indenter. The procedure for applying load to specimen is illustrated in Figure 3. A minor load of 10 kg is applied to press the indenter into contact with the surface. A major (additional) load is then applied and causes the indenter to penetrate into the specimen. The major load is then removed and there is some reduction in the depth of the indenter due to the deformation of the specimen not being entirely plastic. The difference in the final depth of the indenter and the initial depth, before the major load was applied, is determined. This is the permanent increase in penetration e due to the major load. The Rockwell hardness number HR is then given by. h1

136
Side view

d
Top view

Fig. 2 Shape of indentation in Vickers hardness test

W1

h2

W2

h3

W1 h4

Reference line representing zero hardness

W1 Minor load W2 Total load (Major load + W1) h1 Depth of penetration under test load before application of major load h2 Increase in depth of penetration under major load h3 Permanent increase in depth of penetration under preliminary test load after removal of major load (e) h4 Rockwell hardness HB = E e

HR = E e

(3)

where E is the arbitrary constant which is dependent on the type of indenter. For the diamond cone indenter E is 100, for the steel ball 130. There are a number of Rockwell scales (Table 1), the scales being determined by the indenter and the major load used. A variation of the Rockwell test has to be used for thin sheet, this test being referred to as the Rockwell Superficial Hardness Test. Similar loads are used and the depth of indentation which is correspondingly smaller is measured with a more sensitive device. The number of Rockwell Superficial scales also is given in Table 1.

Fig. 3 Load application in the Rockwell hardness test

Table 1 Rockwell hardness and Rockwell Superficial hardness test scales Total Load [kgf] Diamond Cone 15 30 45 60 100 150 15N 30N 45N A D C Indenter Steel Ball 1/8 15H 30H 45H H E K

Method Rockwell Superficial Rockwell

1/16 15T 30T 45T F B G

1/4 15X 30X 45X L M P

1/2 15Y 30Y 45Y R S V

Department of Mechanical & Manufacturing Engineering Faculty of Engineering, University of Putra Malaysia

Description of Rockwell Hardness Tester

The Rockwell Hardness Testing Machine (Figure 4) is one of the more accurate ways to determining hardness of metals. It conforms to ASTM E18, ISO 6508 and JIS Z 2245 standards, while meeting and exceeding standard requirements for Rockwell testing as well as Rockwell Superficial testing. The Superficial hardness test uses the same principle as a Rockwell hardness test, but at small loads to determine the hardness of either thin samples or very soft specimens. It can also be use to determine case and coating hardness. Side panel The hardness testing machine consists of side panel with calibration switch and total load sequence switch to select Front panel auto/manual measurement. The desired method of Rockwell Selector or Rockwell Superficial method can be selected from the ring selector ring. The selector knob is used to fix the total load for the hardness testing. The specimen is mounted on the anvil, Indenter and the elevating handle rotates to enable anvil shifts until tip Anvil of the indenter touches the test specimen. The diamond and 3 steel ball indenters (Figure 5) are provided together as Selector accessories with this machine, as well as calibration blocks. The knob machine also consists of a digital indicator in front panel which reduces test duration and increases ease of use (Figure 6). The Elevating hardness value is displayed directly on the hardness indicator. handle (a) (b) Switch start

Fig. 5 (a) Diamond and (b) steel ball indenters

Fig. 4 Mitutoyo ATK-600 Rockwell / Rockwell Superficial Type Hardness Testing Machine Loading lamp

Loading navigator OK/NG lamp

Overloading lamp

Upper limit setting lamp Lower limit setting lamp Offset setting lamp Indenter selection lamp Test a method setting lamp Rockwell Superficial Hardness test selection lamp Rockwell Hardness test selection lamp
OK NG
HIGH LOW OFFSET INDENTER METHOD METHOD
ROCKWELL SUPERFICIAL ROCKWELL TEST FORCE PRE. TOTAL 3 (S) 10 (R) 15 30 45 60 100 150

O VE R

L O A D I N G

PRELOAD

Hardness indicator UPDOWN switch

SELECT

SELECT switch Diamond indenter lamp

DIA.
15N 30N 45N A D C

1/16 15T 30T 45T F B G

BALL

1/8 15H 30H 45H H E K

1/4 15X 30X 45X L M P

1/2 15Y 30Y 45Y R S V

Ball indenter lamp Scale table

Fig. 6 Front panel of ATK-600 hardness testing machine

Department of Mechanical & Manufacturing Engineering Faculty of Engineering, University of Putra Malaysia

Specimen and Equipments

1. 2. 3. 4. Rockwell hardness tester Mitutoyo ATK-600 Ball and diamond indenters Calibration block Hardness specimens: steel, brass, aluminium

Procedures
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Turn ON the power switch. Set the total load sequence switch to the AUTO position in the side panel. Set the minor load from selector ring to S (Rockwell Superficial) or R (Rockwell). For selecting a desired indenter, refer to Table 1. Fix the indenter. Place the specimen on the anvil. Set the total load value by turning the selector knob. Preparation complete: Loading navigator rapidly flashing (from outer to inner) Indicator 100 (diamond indenter); 130 (ball indenter) Apply the minor load by raising the anvil by rotating clockwise the elevating handle slowly until the tip of the indenter touches the specimen. During minor load application: Loading navigator slowly flashing (from outer to inner) When the hardness indicator displays as below. Stop the handle operation. Indicator 620 to 640 (Rockwell Superficial); 360 to 370 (Rockwell) After appropriate minor load is applied, minor load application is complete. Loading navigator 4 LEDs light up Press the START switch. The measurement process is automatically performed from step 1417. Presetting: Loading navigator 4 LEDs light up Loading lamp lights up Indicator 100 (diamond indenter); 130 (ball indenter) During total load application: Loading navigator flashing (from outer to inner) Loading lamp lights up Indicator rapid to slow count-down (duration time: 3 to 60 seconds) During total load removal: Loading navigator flashing (from inner to outer) Loading lamp lights up Indicator rapid count-up Measurement complete: Indicator hardness value displayed OK/NG lamps OK lights up Read and record the hardness value from the hardness indicator. Turn the elevating handle in the reverse direction to lower the anvil and remove the specimen. Repeat step 3 to 19 for specimens of other methods and specimens. Take three readings on each test specimen and method (Refer Table 2).

15.

16.

17. 18. 19. 20. 21.

Precautions i. Ensure that both surfaces of the specimens are flat and positioned securely on the anvil. ii. Rotate the elevating handle gently during elevation of the anvil. Otherwise due to abrupt strike of the indenter tip with the specimen, the indenter may be destroyed. iii. If the minor load application is in overload condition: Loading navigator 4 LEDs light up; Indicator AAAA; Overloading lamp Lights up

Department of Mechanical & Manufacturing Engineering Faculty of Engineering, University of Putra Malaysia

Results
Show all the hardness measurements of the specimens in Table 2. Table 2 Experimental results Scale Specimen Reading 2 Average

Discussion
1. Discuss on the obtained results for each tested specimens. 2. Discuss on the suitable scale for each tested specimen. 3. Compare and discuss on the hardness values of tested specimens with values from reference sources or manufacturers data. 4. Give a critical discussion on why hardness test needs to perform in engineering practice.

Conclusion
1. Give an overall conclusion based on the obtained experimental results. 2. Conclude on the applications of the experiment.

References
1. Philip, M. and Bolton, B. Technology of Engineering Materials. Butterworth-Heinemann. 2002. 2. Callister, W.D. Materials Science and Engineering An Introduction. Sixth Edition. John Wiley and Sons, Inc. 2002. 3. Benham, P.P., Crawford, R.J. and Armstrong, C.G. Mechanics of Engineering Materials. Second Edition. Longman. 1996. 4. Mitutoyo. Instruction Manual for Digital Hardness Testing Machine (Twin Type). Model: ATK-600, 601. Mitutoyo. 2000.