METALLURGY PRACTICUM MODULE

HARDNESS TEST
Objectives
1. To know the ability of materials to withstand localized plastic deformation such as indentation
or scratch through hardness test.
2. To know the processes, methods, and other important factors that must be considered in
conducting a hardness test.
3. To know the advantages and limitations of each method that is used in a hardness test.
4. To know the relationship between hardness and strength of materials.

Scope of the Problem

1. The conducted tests are Brinell, Rockwell C, and Vickers hardness test
2. The conducted tests are based on JIS Z 2243
3. Testing apparatuses are considered to have been set up correctly and properly.
4. The specimens used in the conducted test are aluminium plate, bolt head, and chisel.
5. The test surface of the specimens are considered to have been prepared correctly and properly
6. The ambient temperature of the testing room or area is 25 degrees Celsius.

Apparatuses and Workpieces Used in Testing

1. Wolpert Hardness Testing Machine
2. Indenter
a. Hardened Steel ball (d = 2,5 mm) for Brinell method
b. Diamond Pyramid (tip’s angle = 136 degrees) for Vickers method
c. Diamond Cone for Rockwell method
3. Aluminium plate
4. Chisel
5. Bolt head (SS 316L)
6. Loupe

Testing Steps
1. Specimen’s surface is cleaned
2. The specimen is placed on the machine’s circular baseplate.
3. The indenter is mounted on the machine’s indenter holder
4. The load is placed onto the machine (62,5 kgf for Brinell, 30 kgf for Vickers, and 150 kgf for
Rockwell)
5. The machine’s circular baseplate is raised by turning the handwheel until the small scale needle
is pointing to the number 3, and then wait for 10 seconds. At this point of time, an initial load of
10 kgf is placed on the specimen.
 6. Side handle is touched lightly so that it start to move. This will start full loading and indentation
process. Let the movement of side handle happened naturally, unforced, and unobstructed, so
that the loading happened slowly enough to simulate static loading.
7. The handle is turned to its initial position after it stopped moving for about 10 seconds.
8. The machine’s circular baseplate is lowered by turning the handwheel
9. The specimen is repositioned so that the indenter would be located on a place roughly 1,5 times
of the length of first indentation’s longest diameter/diagonal.
10. Repeat step 4 to 9 to do the second and third indentation.
11. Brinell and Vickers resulting indentation’s impressions (diameter for Brinell, diagonal for Vickers)
is measured using loupe. Rockwell’s resulting indentation is not needed to be measured, because
the hardness number is showed directly on the machine’s scale.

Reference Keywords to Research the Underlying Theory of the Practicum

1. Hardness definition
2. The definition, specification, and importance of hardness testing and knowing a material’s
hardness number
3. How to get hardness number from hardness testing
4. The specifics of each Brinell hardness test, Vickers hardness test. and Rockwell Hardness Test, and
each of their advantages and limitations.
5. Hardness scale conversion
6. Sinking (sink-in) and ridging (pile-up) phenomenon on indentation
7. Theoretical mechanical properties (especially hardness) of aluminum plate, bolt head, and chisel,
based on its function.
 IMPACT TEST

Objectives

1. To know the ability of materials to absorb impact energy

2. To know how temperature affects the ability of materials to absorb impact energy

Scope of the problem

1. The conducted tests are based on JIS Z 2242

2. The conducted tests used the Charpy method.
3. The specimens used in the conducted tests are based on ASTM A131
4. Testing variables that are used on the conducted tests are temperature valued at -20 degrees
Celsius, 25 degrees Celsius (ambient temperature), and 100 degrees Celsius.
5. Testing apparatuses are considered to have been set up correctly and properly.

Apparatuses and Workpieces Used in Testing

1. Frank 580 M Machine
2. 3 specimens
3. Calipers
4. Ruler
5. Hacksaw
6. Water
7. Dry Ice
8. Water Heater
9. Thermocouple

Testing Steps

1. Each of the specimen’s dimension (length, width, thickness) is measured three times and then
averaged.
2. Specimen is placed and conditioned in an environment filled with dry ice (preferably an
insulated box), and other one of the specimen is placed and conditioned in a pot filled with
boiling water. Both of which are rested in their respective environment for about 5 to 10
minutes.
3. The pendulum is raised and placed on a +-30 degrees angle by turning the handwheel, after
that, the lever to unlock the peg that connects the pendulum to the handwheel’s arm is pulled,
so that the pendulum would fall and move freely.
4. Immediately after the peg is unlocked, the handwheel is turned again indefinitely but just
enough so that the arm would go further up and would not obstruct the pendulum movement.
 5. Let the pendulum do 50 revolutions of movement and note the time required for it to do so,
then push the brake lever until the pendulum stop moving.
6. The handwheel’s arm is lowered by turning the handwheel, positioned the peg on the arm and
the key slot on the pendulum correctly, and the lever is pulled to safely lock both of the
mechanism together. After that, placed the pendulum on its initial and neutral position by
turning the handwheel.
7. The needle is repositioned on the machine’s scale so that it is pointing 0.
8. The pendulum is raised and placed using the handwheel to secure just enough area to place the
specimen on the impact area. Do not let go the handwheel while the specimen is being placed.
Manually support the raised pendulum if necessary for safety reason.
9. The specimen is placed properly using charpy method
10. Made sure that the testing area is safe
11. Made sure that the needle on the machine’s scale is pointing 0
12. The pendulum is further raised by turning the handwheel so that it is placed on a 156 degrees
angle, and then the peg is unlocked by pulling the lever so that the pendulum would fall and
move freely.
13. The brake lever is pushed at least 2-3 seconds after impact.
14. The handwheel’s arm is lowered by turning the handwheel, positioned the peg on the arm and
the key slot on the pendulum correctly, and the lever is pulled to safely lock both of the
mechanism together. After that, placed the pendulum on its initial and neutral position by
turning the handwheel.
15. The impact energy and after impact angle of the pendulum is noted from the machine’s scale
16. The needle is repositioned on the machine’s scale so that it is pointing 0.
17. Step 8 to 16 is repeated to get second and third specimen’s test data.
18. The fracture’s pattern is drawn, and the leftover thickness of the three fractured specimen is
measured (if there was any).

Reference Keywords to Research the Underlying Theory of the Practicum

1. Toughness definition
2. Impact Test definition, specification, and importance
3. Charpy and Izod
4. Notches
5. Notch toughness
6. Ductile to brittle transition
 TENSILE TEST

Objectives

1. To know the ability of material to withstand tensile loading

2. To know the processes, methods, and other important factors that must be considered in
conducting a tensile test
3. To know and understand mechanical properties that can be obtained from tensile test
4. To know the relationship between loading-elongation curve and stress-strain curve
5. To know the relationship between engineering stress-strain curve and true stress-strain curve

Scope of the Problem

1. Testing apparatuses are considered to have been set up correctly and properly.
2. The conducted tests are based on JIS Z 2241
3. The specimens used in the conducted tests are based on JIS Z 2201
4. The process of testing and on-site loading value observation is carried out by experience
operator.

Apparatuses and Workpieces Used in Testing

1. Reinforced steel rod (rebar rod)
2. Steel rod
3. Wolpert Tensile-Bending Machine, Maximum Capacity 300 kg
4. Calipers
5. Ruler
6. Graph paper (Millimeter Block)
7. Marker

Testing Steps

1. The dimensions of both specimens are measured three times and then averaged
2. The ends of both specimens are given an appropriate grip
3. One of the specimen is mounted on the machine’s holder
4. The loading scale is set.
5. Graph paper and marker are fixed on the testing machine.
6. The testing machine is turned on and load is given to the specimen
7. The yield loading, maximum loading, and fracture loading are observed and noted by the help of
machine operator. Meanwhile, the marker should automatically drew a loading-elongation
curve related to the testing and specimen’s condition on the graph paper.
 8. The fractured specimen is unmounted from the machine’s holder
9. Remove the graph paper from the testing machine
10. Label the graph paper so that it would not be confused with the next test’s curve
11. The fractured specimen is manually reconnected and its dimensions are measured and noted
12. Step 3 to 11 is repeated to get the test data of second specimen
13. Both specimen curves is processed and calculated to know the loading value per one of its
ordinate and abscissa scale

Reference Keywords to Research the Underlying Theory of the Practicum

1. Mechanical properties, a few of them are:

a. Strength (tensile)
b. Toughness
c. Ductility
d. Brittleness
e. Stiffness
f. Hardness
g. Creep
h. Fatigue
i. Resilience
j. Plasticity
k. Elasticity
2. Tensile test definition, specification, and importance
3. Tensile properties
4. Engineering stress-strain & True stress-strain
5. Elastic recovery
 RELATED FORMULAS

Hardness

2𝑃
𝐻𝐵 =
𝜋𝐷(𝐷 − √𝐷2 − 𝑑 2 )

𝛼
(2) 1,854𝑃
𝐻𝑉 = 2𝑃 sin =
𝑑2 𝑑2

Tensile Strength (MPa) = 3,45 × HB

Tensile Strength (psi) = 500 × HB

Impact

𝑙
𝑇50 = 2𝜋√
𝑔

𝑤. 𝑙(cos 𝛽 − cos 𝛼)
𝐼𝑆 =
𝐴
Tensile

𝜌𝑠𝑡𝑒𝑒𝑙 = 7,85 𝑔𝑟/𝑐𝑚

𝑚 𝑚 4𝑚
𝜌= = =
𝑉 1 𝜋𝐷2 𝐿 𝜋𝐷2 𝐿
4

4𝑚 4𝐵
𝐷𝑒 = √ =√ 𝑜𝑟 𝐷𝑒 = 12,736√𝐵 (𝑚𝑚)
𝜋𝜌𝐿 𝜋𝜌

𝑚 𝑔𝑟
𝐵= ( ) 𝑤ℎ𝑒𝑟𝑒 𝐿 𝑖𝑠 𝑡ℎ𝑒 𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠𝑝𝑒𝑐𝑖𝑚𝑒𝑛
𝐿 𝑚𝑚

𝑃𝑚𝑎𝑥
𝑉𝑎𝑙𝑢𝑒 𝑝𝑒𝑟 𝑜𝑛𝑒 𝑜𝑟𝑑𝑖𝑛𝑎𝑡𝑒 𝑠𝑐𝑎𝑙𝑒 (𝑦 𝑠𝑐𝑎𝑙𝑒) =
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑏𝑜𝑥𝑒𝑠 𝑢𝑛𝑡𝑖𝑙 𝑐𝑢𝑟𝑣𝑒 ′ 𝑠 ℎ𝑖𝑔ℎ𝑒𝑠𝑡 𝑝𝑜𝑖𝑛𝑡

∆𝐿 𝑎𝑓𝑡𝑒𝑟 𝑓𝑟𝑎𝑐𝑡𝑢𝑟𝑒𝑑
𝑉𝑎𝑙𝑢𝑒 𝑝𝑒𝑟 𝑜𝑛𝑒 𝑎𝑏𝑠𝑐𝑖𝑠𝑠𝑎 𝑠𝑐𝑎𝑙𝑒 (𝑥 𝑠𝑐𝑎𝑙𝑒) =
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑏𝑜𝑥𝑒𝑠 𝑢𝑛𝑡𝑖𝑙 𝑐𝑢𝑟𝑣𝑒′𝑠 𝑙𝑜𝑛𝑔𝑒𝑠𝑡 𝑝𝑜𝑖𝑛𝑡
∆L(𝑥) = 𝑥 × 𝑉𝑎𝑙𝑢𝑒 𝑝𝑒𝑟 𝑜𝑛𝑒 𝑎𝑏𝑠𝑐𝑖𝑠𝑠𝑎 𝑠𝑐𝑎𝑙𝑒
𝑃(𝑦) = 𝑦 × 𝑉𝑎𝑙𝑢𝑒 𝑝𝑒𝑟 𝑜𝑛𝑒 𝑜𝑟𝑑𝑖𝑛𝑎𝑡𝑒 𝑠𝑐𝑎𝑙𝑒
∆𝐿
𝜀𝑒𝑛𝑔𝑖𝑛𝑒𝑒𝑟 =
𝐿𝑜
𝑃
𝜎𝑒𝑛𝑔𝑖𝑛𝑒𝑒𝑟 =
𝐴0
𝐿𝑡𝑟𝑢𝑒 = 𝐿𝑜 + 𝛥𝑙
𝐿𝑜 × 𝐴𝑜
𝐴𝑡𝑟𝑢𝑒 =
𝐿𝑠
𝜀𝑡𝑟𝑢𝑒 = 𝑙𝑛 (1 + 𝜀 𝑡𝑒𝑘𝑛𝑖𝑘)

𝜎𝑡𝑟𝑢𝑒 = 𝜎𝑡 (1 + 𝜀𝑡 )
l1 − l0
ε (%) atau EL (%) = × 100%
l0
A1 − A0
φ (%) atau RA (%) = × 100%
A0
Py
σy =
A0
εf
Ut = ∫ σ dε
0

or
Ut = Total area under stress − strain curve
 1 σy 2
Ur = σ ε or Ur =
2 y y 2E
σ
E=
ε
*σ & ε on E is a specific value of ordinate and abscissa of a random point that is located on
stress-strain curve proportional area. And so on, and so forth…