Unit IV

HARDNESS MEASUREMENTS

Dr. K. Devendranath Ramkumar

Hardness

The Metals Handbook defines hardness as "Resistance of metal to plastic deformation, usually by indentation Also referred to as Resistance to Scratching, abrasion and 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.

Hardness Its impact in the design of Mechanical Systems

Normally in design of mechanical members, the hardness value wont be taken into account. That doesnt mean that the hardness has no impact over the design. The value of hardness can be employed indirectly by means of tensile strength. Also it has its influence over the tensile and compressive properties of the metal or alloy.

Cont

Hardness can be correlated with wear resistance also. Hardness correlates with heat treatments. Based on the heat treatment, the hardness value can be changed. For example the hardening process followed by rapid quenching of 0.8% eutectoid steel produces martensite, which is having maximum hardness. So the influence of hardness comes in indirect mode of design.

Hardness tests
Elastic hardness Test or Rebound test Resistance to abrasion or scratching

Scratch Test File Test

Resistance to Indentation
Brinell hardness test Rockwell hardness test Vickers hardness test Knoop hardness test

Elastic Hardness Test / Rebound Test

Uses Sceleroscope which is a device measuring the height of rebound of a small diamond tipped hammer after it falls from the definite height by its own weight onto the surface of the specimen, creates an impression. The higher the rebound, the harder the work piece. This test is really a measure of resilience (Spring steels etc.)

Resistance to abrasion / scratching

Scratch Test

File Test
10 different Test piece is subjected to cutting action of a file of known hardness. Basically this test is carried out in quality and inspection areas for acceptance or rejection of lot. Normally this test is carried out for heat-treated specimens; because the heat-treated specimens shouldnt produce a visible cut when it is subjected to filing action

Scale consists minerals

of

Talc (No.1), Gypsum (No.2), Calcite (No.3), Flourite (No.4), Apatite (No.5), Orthoclase (No.6), Quartz (No.7), Topaz (No.8), Corundum (No.9) and Diamond (No.10).

The range of scale is arranged from lower to higher grade of hard minerals.
The test material is rubbed against any one of the minerals;

Whichever the mineral is producing scratches, the value of that particular mineral would be the hardness of the test material

Resistance to Indentation
Brinell Hardness Test

Brinell hardness test method consists of indenting the test material with a 10 mm diameter hardened steel or carbide ball subjected to a load of 3000 kg. Brinell tests are frequently done on large parts 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

Procedure

Cont

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 this country is 500 to 3000 kg with 5 or 10mm carbide balls A well structured Brinell hardness number reveals the test conditions, and looks like this, "75 HB 10/500/30 What do you mean by this??

PROS & CONS

Pros
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. A wide range of test forces and ball sizes to suit every application. Non-destructive, sample can normally be reused.

Cons
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. Slow Testing can take 30 seconds not counting the sample preparation time.

Rockwell Hardness Test

The Rockwell hardness test method consists of indenting the test material with a diamond cone or hardened steel ball indenter. The indenter is forced into the test material under a preliminary minor load F0(Fig. 1A) usually 10 kgf. When equilibrium has been reached, an indicating device, which follows the movements of the indenter and so responds to changes in depth of penetration of the indenter is set to a datum position. While the preliminary minor load is still applied an additional major load is applied with resulting increase in penetration (Fig. 1B). When equilibrium has again been reached, the additional major load is removed but the preliminary minor load is still maintained. Removal of the additional major load allows a partial recovery, so reducing the depth of penetration (Fig. 1C).

HR = E - e F0 = preliminary minor load in kgf, F1 = additional major load in kgf, F = total load in kgf, e = permanent increase in depth of penetration due to major load F1 measured in units of 0.002 mm, E = a constant depending on form of indenter: 100 units for diamond indenter, 130 units for steel ball indenter, HR = Rockwell hardness number, D = diameter of steel ball.

Cont

There are two types of Rockwell tests: Normal Rockwell: Minor load is 10 kgf, the major load is 60, 100, or 150 kgf. Superficial Rockwell: Minor load is 3 kgf and major loads are 15, 30, or 45 kgf. In both tests, the indenter may be either a diamond cone or steel ball, depending upon the characteristics of the material being tested

Typical Applications
Quality control for metal heat treatment Incoming material inspection Weld evaluations in steels and other alloys Grade verification for hard plastics Failure analysis

Vickers Hardness 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

ASTM E384 micro force ranges 10g to 1kg ASTM E92 macro force ranges - 1kg to 100kg ISO 6507-1,2,3 micro and macro ranges

Vickers Test Procedure

1. All Vickers ranges use a 136 pyramidal diamond indenter that forms a square indent. 2. The indenter is pressed into the sample by an accurately controlled test force. 3. The force is maintained for a specific dwell time, normally 10 15 seconds. 4. After the dwell time is complete, the indenter is removed leaving an indent in the sample that appears square shaped on the surface. 5. The size of the indent is determined optically by measuring the two diagonals of the square indent. 6. The Vickers hardness number is a function of the test force divided by the surface area of the indent.

Cont

The average of the two diagonals is used in the following formula to calculate the Vickers has HV = Constant x test force / indent diagonal squared HV = 1.854 F/d2 The constant is a function of the indenter geometry and the units of force and diagonal.

Knoop Hardness Test

Knoop (HK) hardness was developed by at the National Bureau of Standards (now NIST) in 1939. The indenter used is a rhombicbased pyramidal diamond that produces an elongated diamond shaped indent. Knoop tests are mainly done at test forces from 10g to 1000g, so a high powered microscope is necessary to measure the indent size. Because of this, Knoop tests have mainly been known as microhardness tests.

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 an elongated diamond shaped indent in the sample. The size of the indent is determined optically by measuring the longest diagonal of the diamond shaped indent. The Knoop hardness number is a function of the test force divided by the projected area of the indent.

Knoop Test Procedure

KHN = F/A = P/CL2

F = applied load in kgf A = the unrecovered projected area of the indentation in mm2 L = measured length of long diagonal of indentation in mm C = 0.07028 = Constant of indenter relating projected area of the indentation to the square of the length of the long diagonal.