Hardness Testing

Lesson 5: Evaluating the results of Hardness tests

For information regarding this presentation, please contact Dan Emelander (Metallurgist) 713-939-2672

Evaluating test values

It is important to be able to recognize an inaccurate hardness test Any readings that differ more than about 7% from the other values should be suspected of being a bad punch
This is 15 HBW points in the 197-237 HBW range 20 HBW points in the 300 HBW range

Always expect the hardness to be in the required range

In other words, if the hardness is out of the required range, suspect that it could be a bad punch, and re-test the same area.

Be careful with hardness values which are on the edge of the specification!

Uniformity of Hardness Values

The hardness values on large forgings often vary from one side to the other This should not be a large variance, and again all values should be within a range of 7% of the HBW value
This is not an accept or reject requirement, simply a guideline to alert the inspector there may be a problem

Certain materials are more susceptible to this variance

The more Hardenable the material, the more uniform it should be

Material Influence
Certain materials are expected to have more uniform hardness values
Some typical alloys in order of uniformity (the first having the most uniformity expected)
410 Stainless should be very uniform throughout the entire part 2 Chrome should also be quite uniform 4140 should be uniform, but some variance is expected 4130 may have significant variance due to its low hardenability 1040 may have significant variance as well

As Heat-Treated vs. after Machining

As discussed in previous lessons, different alloys have different hardenability properties.
This means as you machine away sections, the hardness may be different 2 down from the original surface, depending on the alloy

4130 is very susceptible to this

If there is a large part of 4130, and it was originally tested at 223 HBW, once only 1 is machined off, it would not be uncommon to find a hardness of only 197 HBW

While 4130 is not the only alloy to show this behavior, it is one of the worst

Example - 4130
Which one of these readings would you suspect as being a inaccurate value?
(The material is 4130, in the as heat treated condition) 223 HBW 217 HBW 20 HBW points less than any other value 217 HBW 197HBW

Example 4130 Machined

Which one of these readings would you suspect as being a inaccurate value?
(The material is 4130, machined AFTER heat treat)
(original size)

223 HBW 197 HBW

On 4130, or any quench and tempered steel, material will not get harder after machining away a few inches

229 HBW 223HBW

Example 410 Stainless

Which one of these readings would you suspect as being an inaccurate value?
(The material is 410 Stainless Steel, in the as heat treated condition) 223 HBW 16 HBW points less than any other value, typically 410 Stainless will be more uniform 223 HBW

207 HBW

223HBW

Example 410 Machined

Which one of these readings would you suspect as being a inaccurate value?
(The material is 410 Stainless Steel, machined AFTER heat treat)
(original size)

237 HBW 217 HBW 410 Stainless is very uniform because of its high hardenability. This variation could indicate a bad punch 212HBW

212 HBW

Previous Examples
While the previous examples demonstrate when some values may be suspect, it does not indicate if they are truly inaccurate To determine if the value obtained is the true hardness, there are two different approaches you can take
Re-punch using the same method Re-punch using another, more accurate method
If you used Brinell originally, re-test using a Rockwell

Comparing to the MTR or MS

If the MS the material was ordered to specified a hardness range, and the part is outside this range, double check the test If the test result is actually out of range, and the vendor had reported it being in range, the causes for the discrepancy are usually:
Testing in different locations Using different test methods Vendor or inspector did not perform the test properly

Re-testing HRC
NACE states you can re-test a part if it is less than 2 HRC points above the maximum A NACE re-test consists of making several (3 or more) indentations in the same area, and averaging the value of all tests
Note: There is no limit as to the number of tests you may do when averaging the results; NACE only states that several shall be taken.

If a test obviously provides a false value, then just simply testing the same area again may be the solution
For example, if all values on a part are 237 HBW, and then one is a 286 HBW, chances are something went wrong during that test.

Re-testing HBW
NACE has no requirements when re-testing a Brinell hardness test. If a test obviously provides a false value, then just simply testing the same area again may be the solution
For example, if all values on a part are 237 HBW, and then one is a 286 HBW, chances are something went wrong during that test.

If a value is only slightly above the specification (10 HBW for steel, 15 HBW for Nickel alloys), than a more detailed approach must be used
Perform 2 or more tests in the same area Average all results to obtain the true hardness. Note, this is a Cameron requirement, and may be waived by Metallurgy.

It is always best, if possible, to double check using another method. (such as Rockwell)

Remember
Hardness testing is susceptible to many types of errors that can produce false results If a value is obtained, that is not what would be expected, always double check by re-testing in the same area

When in Doubtcall Metallurgy