HARDNESS TEST

YEDTEPE UNIVERSITY DEPARTMENT OF MECHANICAL ENGINEERING

YEDITEPE UNIVERSITY ENGINEERING FACULTY MECHANICAL ENGINEERING LABORATORY

Hardness Test
1. Objective: The objective of this lab is to introduce the students to the topic of the indentation hardness of metals using the common hardness tests and scales (e.g. Rockwell, Brinell, and Vickers). These sets of tests on metals of widely different hardness (e.g. soft and hard steel, aluminum and brass) show: 1. The empirical interrelationship between the various hardness scales. 2. The relationship for a given scale (e.g. Vickers) as a function of applied load. 3. The relationship between hardness and tensile properties.

2. Equipment: Buehler Micromet 5114 micro indentation testing machine. Wolpert Dia-Tester 751 for Brinell and Vickers tests. Three annealed steels varying in carbon content from 0.18 to 0.90% C. 2024-T351 aluminum, 7075-T351 aluminum, and 60-40 brass supplied as cold formed. 3. Theory:

The Metals Handbook defines hardness as "Resistance of metal to plastic deformation, usually by indentation. However, the term may also refer to stiffness or temper, or to resistance to scratching, abrasion, or cutting. It is the property of a metal, which gives it the ability to resist being permanently, deformed (bent, broken, or have its shape changed), when a load is applied. The greater the hardness of the metal, the greater resistance it has to deformation. In mineralogy the property of matter commonly described as the resistance of a substance to being scratched by another substance is hardness. The dictionary of Metallurgy defines the indentation hardness as the resistance of a material to indentation. This is the usual type of hardness test, in which a pointed or rounded indenter is pressed into a surface under a substantially static load.

3.1 Brinell Hardness Test Dr. J. A. Brinell invented the Brinell test in Sweden in 1900. The oldest of the hardness test methods in common use today. Brinell tests are frequently done on large parts. By varying the test force and ball size, nearly all metals can be tested using a Brinell test. Brinell values are considered test force independent as long as the ball size/test force relationship is the same. In the USA, Brinell testing is typically done on iron and steel castings using a 3000Kg test force and a 10mm diameter carbide ball. Aluminum and other softer alloys are frequently tested using a 500Kg test force and a 10 or 5mm carbide ball. Therefore the typical range of Brinell testing in the USA is 500 to 3000kg with 5 or 10mm carbide balls. In Europe Brinell testing is done using a much wider range of forces and ball sizes. Its common in Europe to perform Brinell tests on small parts using a 1mm carbide ball and a test force as low as 1kg. These low load tests are commonly referred to as baby Brinell tests. 3.1.1 Applications Because of the wide test force range the Brinell test can be used on almost any metallic material. The part size is only limited by the testing instruments capacity. 3.1.2 Strengths 1. The Brinell test is frequently used to determine the hardness of forgings and castings that have a grain structure too course for Rockwell or Vickers testing. 2. One scale covers the entire hardness range, although comparable results can only be obtained if the ball size and test force relationship is the same. 3. A wide range of test forces and ball sizes to suit every application. 4. Nondestructive, sample can normally be reused. 3.1.3 Weaknesses 1. The main drawback of the Brinell test is the need to optically measure the indent size. This requires that the test point be finished well enough to make an accurate measurement. 2. Slow. Testing can take 30 seconds not counting the sample preparation time. 3.2 Vickers Test The Vickers (HV) test was developed in England is 1925 and was formally known as the Diamond Pyramid Hardness (DPH) test. The Vickers test has two distinct force ranges, micro (10g to 1000g) and macro (1kg to 100kg), to cover all testing requirements. The indenter is the same for both ranges therefore Vickers hardness values are continuous over the total range of hardness for metals (typically HV100 to HV1000). With the exception of test forces below 200g, Vickers values are generally considered test force independent. In other words, if the material tested is uniform, the Vickers values will be the same if tested using a 500g force or a 50kg force. Below 200g, caution must be used when trying to compare results.

3.2.1 Applications Because of the wide test force range, the Vickers test can be used on almost any metallic material. The part size is only limited by the testing instruments capacity. 3.2.2 Strengths 1. One scale covers the entire hardness range. 2. A wide range of test forces to suit every application. 3. Nondestructive, sample can normally be used. 3.2.3 Weaknesses 1. The main drawback of the Vickers test is the need to optically measure the indent size. This requires that the test point be highly finished to be able to see the indent well enough to make an accurate measurement. 2. Slow. Testing can take 30 seconds not counting the sample preparation time. 3.3 Rockwell Hardness Test Stanley P. Rockwell invented the Rockwell hardness test. He was a metallurgist for a large ball bearing company and he wanted a fast non-destructive way to determine if the heat treatment process they were doing on the bearing races was successful. The only hardness tests he had available at time were Vickers, Brinell and Scleroscope. The Vickers test was too time consuming, Brinell indents were too big for his parts and the Scleroscope was difficult to use, especially on small parts. To satisfy his needs he invented the Rockwell test method. This simple sequence of test force application proved to be a major advance in the world of hardness testing. It enabled the user to perform an accurate hardness test on a variety of sized parts in just a few seconds. 3.3.1 Principle An accurately shaped indenter is used to make an indent in the sample to be tested. This indenter is either a spheroconical diamond (120 cone with a 0.2mm radius tip) or a hard metal ball (1/16, 1/8, 1/4, or 1/2 inch diameter). The instrument is designed to position the centerline of the indenter perpendicular to the test surface and has a depth-indicating device that can measure the vertical movement of the indenter into the sample. The indenter is first pressed into the sample a small amount by a relatively low preliminary force of 10KG (HRC scale). After the preliminary force has been fully applied, the depth-indicating device is set to a zero indication. Then, a much larger additional test force of 140KG is applied to the indenter for a total force on the sample of 150KG. This large total force causes the indenter to penetrate the sample much farther. After the total force is fully applied, it is maintained for a short time to make sure that all penetration has stopped. Then, the additional force (140KG) is removed while still maintaining the preliminary 10KG force. After the preliminary force has been removed, the depth indicating devise indicates the difference of penetration of the indenter as a result of the additional force. This depth is converted into the Rockwell number by subtracting the value from 100 (HRC scale). This will

result in a harder material giving a higher number than a softer material. In the HRC scale the formula is setup to have one Rockwell point be equal to 0.002mm. 3.3.2 Applications With the two test ranges available, the Rockwell test can be used on almost any metal sample as well as some hard plastics. The test can normally be performed in less than 10 seconds and the indent is usually small enough to allow the part to be used. Some parts with a critical hardness specification are tested 100%. 3.3.3 Types of Test 1. Rockwell: the minor load is 10 kgf; the major load is 60, 100, or 150 kgf. 2. Superficial Rockwell: the minor load is 3 kgf and major loads are 15, 30, or 45 kgf. 3.3.4 Weaknesses 1. Multiple test scales (30) needed to cover the full range of metal hardness. 2. Conversions between scales can be material dependant. 3. Samples must be clean and have a smooth test point to get good results. 3.3.5 Rockwell Scales Rockwell hardness values are expressed as a combination of a hardness number and a scale symbol representing the indenter and the minor and major loads. The hardness number is expressed by the symbol HR and the scale designation. There are 30 different scales. The majority of applications are covered by the Rockwell C and B scales for testing steel, brass, and other metals. However, the increasing use of materials other than steel and brass as well as thin materials necessitates a basic knowledge of the factors that must be considered in choosing the correct scale to ensure an accurate Rockwell test. The choice is not only between the regular hardness test and superficial hardness test, with three different major loads for each, but also between the diamond indenter and the 1/16, 1/8, 1/4 and 1/2 in. diameter steel ball indenters. The scale is chosen depending upon the following factors: 1. 2. 3. 4. Type of material Specimen thickness Test location Scale limitations

4. Procedure: Students will use the three carbon steels as well as aluminum, and brass (60-40). Hardness testing will be done on tensile specimens PART 1: For macro-sized specimens determine hardness using Brinell (use 3000kg for steels and 500kg for softer materials), macro-Vickers (at appropriate loads such that the indentation fills from 1/3 to the viewing window), and Rockwell (HRC for the harder steel, HRB for the softer steels, brass and aluminum). 4.1 Brinell Test All Brinell tests use a carbide ball indenter. The test procedure is as follows: 1. 2. 3. The indenter is pressed into the sample by an accurately controlled test force. The force is maintained for a specific dwell time, normally 10 15 seconds. After the dwell time is complete, the indenter is removed leaving a round indent in the sample. The size of the indent is determined optically by measuring two diagonals of the round indent using either a portable microscope or one that is integrated with the load application device.

4.

4.2 Vickers Test All Vickers ranges use a 136 pyramidal diamond indenter that forms a square indent. 1. The indenter is pressed into the sample by an accurately controlled test force. 2. The force is maintained for a specific dwell time, normally 10 15 seconds. 3. After the dwell time is complete, the indenter is removed leaving an indent in the sample that appears square shaped on the surface.

Figure 1

4. The size of the indent is determined optically by measuring the two diagonals of the square indent. 4.3 Rockwell Test 1. An appropriate scale is chosen to be used. 2. The indenter moves down into position on the part surface 3. A minor load is applied and a zero reference position is established

4. The major load is applied for a specified time period (dwell time) beyond zero 5. The major load is released leaving the minor load applied 6. The measurement is taken.

Figure 2 PART 2: For the low carbon steel use progressive indents of the 5 and/or 2.5 mm ball, D, (Wolpert) in the same location making measurements of indent diameter after each impression. Loads can be varied from 1kg to 250 kg so that a table of Meyers hardness (Pm) an indentation diameter (d) versus load (F) can be obtained. Plot the load (y-axis) versus indentation diameter both linearly and as log-log. The slope of the linear portion of the log-log plot gives n, the Meyers index which can be related to the strain hardening exponent (n) by the expression n = n + 2. PART 3: For mounted specimens (used in the laboratory on optical microscopy and metallography) determine micro hardness (Buehler micro hardness tester) with Vickers indenters as a function of load. At least 4 loads should be used for each material and a table prepared giving loads versus indentation length for each material and set of loads. Determine the effect of indentation load on hardness value for both indenter types for all materials. 5. Data Analysis: 5.1 Brinell Test The Brinell hardness number is a function of the test force divided by the curved surface area of the indent. The indentation is considered to be spherical with a radius equal to half the diameter of the ball. The average of the two diagonals is used in the following formula to calculate the Brinell hardness. The Brinell number, which normally ranges from HB 50 to HB 750 for metals, will increase as the sample gets harder. Tables are available to make the calculation simple. A typical Brinell hardness is specified as follows: 356HBW Figure 3 Where 356 is the calculated hardness and the W indicates that a carbide ball was used. Note- Previous standards allowed a steel ball and had an S designation. Steel balls are no longer allowed.

5.2 Vickers Test The Vickers hardness number is a function of the test force divided by the surface area of the indent. The average of the two diagonals is used in the following formula to calculate the Vickers hardness.
HV = C*F d2

Where C is a function of the indenter geometry, F is the force and d is the indent diagonal. The Vickers number, which normally ranges from HV 100 to HV1000 for metals, will increase as the sample gets harder. Tables are available to make the calculation simple, while all digital test instruments do it automatically. A typical Vickers hardness is specified as follows: 356HV0.5 Where 356 is the calculated hardness and 0.5 is the test force in kg.

6. Results and Conclusions:

1. Tables for all materials and all hardness tests appropriately labeled (units, etc). These tables should be prepared on a spreadsheet to permit analysis of the data in the text section of the report. A table should also be supplied for the results of calibration block hardness on all machines used in this laboratory. 2. Graphs of the relationships between hardness scales should be included in your results (HV vs. BHN, HRC, HRB). 3. Record your measurements for the strain hardening exponent, n.