BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

HARDNESS

TEST

INCLUDING :
1.VICKERS HARDNESS TEST
2.ROCKWELL HARDNESS TEST
3.KNOOP HARDNESS TEST
4.BENEFITS AND CHALLENGES OF
HARDNESS TEST

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 BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

Hardness tests are extensively used to characterize a

certain material and to identify if it is appropriate for its
intended purpose. All hardness tests involve the
utilization of a particularly shaped indenter that is
harder than the material under testing. The indenter is
pressed onto the test surface with the use of a certain
amount of force. The size of the depth of the indent is
measured in order to determine the hardness value.

Hardness tests are beneficial because:

• The hardness test is easy to conduct.

• Results can be obtained within 30 seconds.
• Tests are relatively cost effective.
• Finished components can be subjected to testing without
being damaged.
• Any shape and surface size can be subjected to testing.

The major applications of hardness tests are to verify the type

of heat treatment to be used on a part and to identify if a
material possesses the required properties for its intended use.
This makes hardness tests beneficial in industrial applications.

The five most common hardness scales are:

• Knoop
• Vickers
• Rockwell
• Brinell
• Shore

ROCKWELL HARDNESS TESTING

The Rockwell hardness test is a fast method, making it ideal for
quick hardness testing. We give a definition of the Rockwell
hardness test, as well as practical information of how to apply
it in practice.

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 BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

The Rockwell hardness test at a glance:

• Generally used for larger samples

• No optical readout
• Can be used for advanced tests

DEFINITION OF THE ROCKWELL HARDNESS TEST

METHOD
The Rockwell hardness test methods are described by a
number of scales, characterized by a standard, an indenter
type, and a load in this case on a weld.

Examples of Rockwell hardness test methods:

• HRE 1/8” diameter tungsten carbide ball indenter, 100 kgf

major load
• HR30N (Superficial Rockwell 30N-scale): Diamond cone
indenter, 30 kgf major load

APPLICATION OF THE ROCKWELL HARDNESS TEST

Surface preparation

Before application of the Rockwell hardness test, you must

prepare the surface of the material to be tested. The
required surface condition for the Rockwell hardness test
depends on the load used.

The Rockwell hardness test is used for macro hardness

tests, which are generally defined as tests that use
indentation loads below or equal to 1 kgf. Therefore, a
ground surface is usually sufficient, and sometimes no
preparation is required.

ROCKWELL HARDNESS TESTING MACHINES (HARDNESS

TESTERS)

Hardness testing is key in most quality control procedures.

That’s why we provide a complete range of accessories, from

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equipment for lab application of hardness testing up to heavy-

duty hardness testers for large-scale production sites.

All our Rockwell hardness testers are designed to deliver the

long-term performance .

Duramin-150: Entry-Level Rockwell Hardness Tester

Load range: 3 – 150 kg

Duramin-100: Fully Automatic Micro/Macro/Universal

Hardness Tester
Load ranges: 10 gf – 62.5 kg, 10 gf – 150 kg, 10 g – 250 kg

Duramin-160: High-End Rockwell Hardness Tester

Load range: 1 – 250 kg

Duramin-600: Semi-Automatic Universal Hardness

Tester
Load ranges: 1 – 250 kg, 3 – 750 kg, 5 – 3000 kg

KNOOP HARDNESS TESTING

The Knoop hardness test is an alternative to the Vickers test in
the micro hardness testing range.

The Knoop hardness test at a glance:

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 BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

• A micro hardness test used for brittle materials, such as

ceramics
• Suitable for small elongated areas, such as coatings
• The Knoop hardness test is an alternative to the Vickers
hardness test in the micro hardness testing range, and it
can be performed on the same universal or micro
hardness testing machine. It is mainly used to overcome
cracking in brittle materials, as well as to facilitate the
hardness testing of thin layers.

As in the Vickers hardness test, the indenter used in the

Knoop hardness test is a pyramidal diamond. However,
instead of being symmetrical, the pyramid is elongated.
Knoop Hardness (HK) is ascertained by measuring
optically along the long diagonal of the indent.

• Surface preparation
Before application of the Knoop hardness test, you must
prepare the surface of the material to be tested.

The Knoop hardness test is used for micro hardness

testing (loads below or equal to 1 kgf) and so the surface
of the sample material should be highly polished or
electropolished before it is introduced to the micro
hardness tester.

Loads
The Knoop micro hardness test should not be used if it
produces diagonal lengths less than 20 μm, as this will
result in measurement inaccuracy.

KNOOP MICRO HARDNESS TESTING MACHINES

(HARDNESS TESTERS)

Hardness testing is key in most quality control procedures.

That’s why we provide a complete range of hardness testing
machines.

All our Knoop micro hardness machines are designed to deliver

the long-term performance for which Struers is renowned.

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 BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

BRINELL HARDNESS TESTING

The Brinell hardness test is used for larger samples in materials
with a coarse or inhomogeneous grain structure.

The Brinell hardness test at a glance:

• For hardness testing of larger samples

• Optical reading required

DEFINITION OF THE BRINELL HARDNESS TEST

The Brinell hardness test was originally developed in the late
1800s by the Swedish engineer of the same name. He wanted
to find a method to control the quality/hardness of steel. His
solution was to press a railway wheel-bearing ball into the
material and then measure the size of the mark it left. The
method proved reliable and in 1900 the Brinell hardness test
was officially born.

Today, the Brinell test is performed using a Brinell hardness

test unit. The machine presses a tungsten carbide ball into the

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sample, and then optically measures the diameter of the

impression.

• Indenter sizes: 1, 2.5, 5 and 10 mm

• Loads: From 1 kgf to 3000 kgf
• Maximum hardness: 650 HBW

A hardness test for larger samples

As the Brinell hardness test (HBW) indentation leaves a
relatively large impression, the Brinell hardness test is better
suited to larger samples with a coarse or inhomogeneous grain
structure, such as castings and forgings.

DID YOU KNOW?

HBW stands for Hardness Brinell Wolfram carbide. Wolfram
carbide (= tungsten carbide) underlines that newer Brinell
standards call for the use of tungsten carbide balls, as opposed
to the (softer) steel balls previously used (HBS). Values will
differ at higher hardness.

Before performing the Brinell hardness test, you must prepare

the surface of the material to be tested.
Surface preparation
Before the sample material is placed in the Brinell hardness
test unit, it must be either:

• Machined
• Ground
• Lapped
• Polished

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 BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

THE MOST COMMON BRINELL HARDNESS TEST METHODS

There are a number of common Brinell hardness test methods,
with corresponding materials and hardness ranges. Most test
methods can be performed on any Brinell hardness testing
machine.

The Brinell methods are generally divided into four subgroups

(HB30, HB10, HB5, HB2.5), each suitable for a different group
of materials.

• Each subgroup has the same force/diameter ratio (F/D2)

• Measured Brinell hardnesses can only be compared within
individual subgroups

VICKERS HARDNESS TESTING

The Vickers hardness test is suitable for a wide range of
applications, including micro hardness testing.

The Vickers hardness test at a glance:

• Ideal for micro hardness testing

• Can be used for case hardness depth measurement,
Jominy testing and hardness testing of welds

DEFINITION OF THE VICKERS HARDNESS TEST

The Vickers hardness test is a versatile hardness test method,
used for both macro and micro hardness testing. It has a broad
load range, and is suitable for a wide range of applications and
materials.

The Vickers hardness test is often regarded as easier to use

than other hardness tests: The process can be performed on a
universal or micro hardness tester; the required calculations
are independent of the size of the indenter; and the same
indenter (a pyramidal diamond) can be used for all materials,
irrespective of hardness.

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THE VICKERS HARDNESS CALCULATION

The Vickers Hardness (HV) is calculated by optically measuring
the diagonal lengths of the impression left by the indenter. The
measurements are converted to HV using a table or formula.

• Load range: From 10 gf up to 100 kgf

HOW TO MEASURE VICKERS HARDNESS IN 7 STEPS

- using a Duramin-40 hardness testing machine

1. Place your sample on the stage.

2. Click and drag the mouse to move the sample into position.
3. Scroll to focus.
4. Select the test method and load.
5. Choose an objective and job name.
6. Use the overview camera to position the indenter.
7. Start the test.

SURFACE PREPARATION
Before placing the sample material in the micro hardness
testing machine, you should ensure it is correctly prepared.

The required surface condition for the Vickers hardness test

depends on the load used.

Macro hardness testing (loads higher than 1 kgf)

• Surface should be ground

Micro hardness testing (loads below or equal to 1 kgf)

• Surface should be mechanically polished or

electropolished

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 BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

INDENT SPACING
Regardless of the micro hardness tester you use, when you
perform a Vickers hardness test, your indentation will deform
the surrounding material and alter its properties. In order to
avoid misinterpretations of perceived hardness, the Vickers
hardness testing standards prescribe a certain distance
between multiple indentations.

Steel and copper

• At least 3 diagonal widths between indentations

Lead, zinc and aluminum

• At least 6 diagonal widths between indentations

DIAGONAL WIDTHS

To ensure accurate reading of the indents, the Vickers

hardness testing standards prescribe a minimum diagonal
width of 20 µm.

For instance, this implies that CHD (see below) measurements

using less than HV0.2 should generally be avoided, as they will
produce indents smaller

Hardness of a material is generally defined as Resistance to the

permanent indentation under static and dynamic load.
Hardness is the property of the material by which it offers
resistance to scratch or indentation. It is the most important
property, as the material is subjected to friction and scratch.
When a material is required to use under direct static or
dynamic loads, only indentation hardness test will be useful to
find out resistance to indentation. This test is an indentation
test used for smaller specimens and harder materials. In this
test indentor is forced into the surface of a test piece in two

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operations, measuring the permanent increase in depth of an

indentation from the depth increased from the depth reached
under a datum load due to an additional load. Measurement of
indentation is made after removing the additional load.
Indentor used is the cone having an angle of 120 degrees
made of black diamond. The principle of a hardness test has to
do with the application of a standard load (Based on the type of
material) through a standard indentor (cone or ball indentor)
for a standard duration of time. The hardness number is
directly obtained in the experiment.

(IV) Procedure:

a) Keep the loading and unloading lever at position “A”

which is unloading position.
b) Select suitable indentor & weights according to the
scale.
c) Place the specimen on testing table anvil.
d) Turn the hand wheel to raise a job until it makes contact

with indentor & continue turning till the longer pointer

at the dial gauge makes 2 ½ rotations. Then it stops at
zero continue turning slowly till the small pointer
reaches the red spot at 3‟, this is automatic zero setting
dial gauge.
e) Turn the lever position “A” to “B” i.e. from unloading to

the loading position. So that the total load will act.

f) When the longer pointer of the dial gauge reaches

steady position, take back the lever to the unloading

position “A”. [Avoid sudden release at the lever]
g) Now note down the reading in the last dial indicator by
notifying the large pointer
h) Turn back the hand wheel and remove the job.

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 BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

i) Similarly, repeat the step from ‘a-h’ for different trials

and for different metals.

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 BOILER MAKING QUALITY ASSUARANCE HARDNESS TEST

Factors that influence hardness testing

A number of factors influence hardness tests results. As a
general rule, the lower the load you use in the hardness test,
the more factors that need to be controlled to ensure an
accurate conclusion of the hardness test.

Here are a few of the most important factors to consider to

ensure an accurate conclusion from a hardness test.

• External factors such as light, dirt, vibrations,

temperature, and humidity should be controlled
• The tester and stage should be secured on a solid
horizontal table, and the sample should be clamped or
held in a holder or anvil
• The indenter should be perpendicular to the tested surface
• Illumination settings should be constant during the test
when using Vickers, Knoop, or Brinell
• The tester should be recalibrated/verified every time you
change the indenter or objective lens

Benefits of the hardness

test
• it is unaffected by the flat, uneven metal surface.
• Less sensitive is this hardness test.
• It is used to gauge the toughness of cast and powder-
metallurgical components.
• It can support a substantial load during testing.
• Under a microscope or eyepiece, the indentation formed
on the material can be observed and measured.

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Brinell Hardness Test

drawbacks:

• The main drawback of this test is that its big indentor

impression prevents it from being used for small-sized
objects.
• Testing hard objects results in a somewhat off
measurement of hardness due to the deformation of the
ball indentor.
• Due of the deep penetration, thin objects are not
recommended.
• Only flat surfaces can withstand this test's demands.
• The Brinell hardness test takes a long time since it is
sluggish.

Compiled by:
Jeffery Mukaro
Wellington Chimbwanda
Takudzwa Jani
Takudzwa Mavemwa
Rutendo Newengo
Joshua Tembure
Malvin Masakure
Trevor Jeke

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