Department of Civil Engineering National Institute of Technology Calicut

HARDNESS TESTS

GENERAL PRINCIPLE

Hardness is one of the important mechanical properties of material. Several arbitrary

definitions have been given to this property. It may be expressed in terms of the resistance to
permanent indentation, rebound under impact loads, resistance to scratching, abrasion, cutting
or drilling.

In material testing, the resistance of the material to permanent indentation by another

hard metal is commonly taken as the definition of hardness. The material tested so that the
indenture is not subjected to permanent plastic deformation under contact application of load.

There are three standard tests used in laboratories to determine the hardness of
materials, based on the above principle. They are:

1. Rockwell Hardness Test

2. Brinnel Hardness Test

3. Vickers Hardness Test

In all these tests there is an indenter which penetrates into the surface of the specimen
for a specified duration of time under a specified load. In Brinnel and Vickers tests, the
hardness is related to the quotient of the load to the surface area of indentation whereas the
Rockwell test is based on the depth of indentation.

It has been experimentally shown that there exists a relationship between the
indentation hardness number and the tensile strength of materials. Hardness tests are also used
for specification purposes, to check heat treating procedure, to check the effectiveness of
surface-hardening methods. For this reason indentation hardness tests are generally used as a
control test for materials used by the engineer.

Cutting and abrasion hardness are associated with machinability and wear phenomena
of materials.

Material Testing Lab Manual Page 24 of 71

Department of Civil Engineering National Institute of Technology Calicut

Moh’s scale is an arbitrary scale of material hardness, based on the resistance to

scratching. A hard material can make a scratch on a softer material.

MOH’S SCALE

Material Hardness

Talc 1
Gypsum 2
Calcite 3
Flourspar 4
Apatite 5
Felspar 6
Quartz 7
Topaz 8
Corundum 9
Diamond 10

Material Testing Lab Manual Page 25 of 71

Department of Civil Engineering National Institute of Technology Calicut

Material Testing Lab Manual Page 26 of 71

Department of Civil Engineering National Institute of Technology Calicut

4. ROCKWELL HARDNESS TEST

Exp.No……… Date:……………..

AIM
To find the Rockwell Hardness Number of the material of test specimen.

THEORY AND APPLICATION

Rockwell testing is the most widely used method of determining hardness owing to the
following reasons:

1. It is faster than other tests.

2. It has got a wide range of adaptability and can be used for the hardness testing of
finished parts.

3. It gives direct reading of hardness.

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 two types of indenters used in this test. A hardened steel ball of 1.6mm
diameter for Rockwell B test and small diamond cone having an apex angle of 1200 for
Rockwell C test. The diamond cone is used for testing hard materials whereas the steel ball is
used for testing softer materials.

There are two types of Rockwell tests:

1. Rockwell: The minor load is 10 kg, the major load is 60, 100, or 150 kg.
2. Superficial Rockwell: The minor load is 3 kg and major loads are 15, 30, or 45 kg.

In both tests, the indenter may be either a diamond cone or steel ball, depending upon the
characteristics of the material being tested.

Material Testing Lab Manual Page 27 of 71

Department of Civil Engineering National Institute of Technology Calicut

In the test, the indenter is made to penetrate into the test specimen under the action of
two consecutive applied loads – a preliminary load of 10 Kg and a total (preliminary and main
loads together ) of 100 or 150 Kg. The preliminary load is applied to make sure that there is a
uniform and perfect contact between the indenter and the test specimen. This eliminates the
errors that might arise as a result of differences in the surface finish of various test specimens.

The type of indenter and the final load to be applied are chosen from from the following
table.

Appropriate Rockwell Permissible

Brinnel Hardness Indenter Load in Kg Symbol scale range
Hardness scale

60-230 B Steel Ball 100 HRB 25-100

(soft materials)

230-700 C Diamond 150 HRC 20-67

(hard steel) cone

The criterion of material hardness is the difference in the penetration depths ( = h ) of

the imprint made under the initial and final loads. The Rockwell Hardness Number is defined
by the ratio

HR = K-h/0.002 where

K = 100 for C scale (Cone penetrator)

= 130 for B scale (Ball penetrator)

Generally the machine is so calibrated as to give the Rockwell Hardness number

directly, using C scale for cone indenter and B scale for ball indenter. One scale division of
the indicator dial corresponds to an indentation depth of 0.002 mm.

Material Testing Lab Manual Page 28 of 71

Department of Civil Engineering National Institute of Technology Calicut

The thickness of the specimen to be tested should not be less than ten times the
penetration depth = 0.002 (130-HRB ) or 0.002 (100-HRC) as the case may be. The distance
between the imprint centres and from centre to edge of the test specimen should be not less
than 2.5 mm for C scale and 4 mm for tests according to scale B.

EXPERIMENTAL INVESTIGATION

The Rockwell Hardness machine consists of a table to support the test piece. This table
can be raised or lowered by means of a hand wheel. The indenter is fixed to a spring support
to which the load can be applied through a hand lever. The initial load of 10kg is reached
when the indicator light will be put off. The final load is transmitted through a system of
weights and levers. The duration of the application of the final load is 5 to 10 seconds, after
which the hand lever is released. The Hardness number is then directly read on the indicator
dial.

Procedure

1. Study the operation of the machine.

2. The surface of the specimen should be flat and finished smooth and clean, removing all
oxide scales and other impurities.

3. Choose the proper indenter. Use diamond cone for testing hard steel specimens and steel
ball for softer material.

4. Switch on the machine when the lamps for the dial and the signal lamp flash up.

5. Press the button corresponding to the load to be applied, located on the side of the machine.

6. Turn the hand wheel until the specimen comes in contact with the clamping sleeve for the
indenter. Continue to turn the wheel until the signal lamp is extinguished. This corresponds to
the application of the initial load.

7. Apply the main load by pulling out the button and wait until the pointer of the dial stands
still. The hand lever on the right side of the machine moves up and comes to a stop after a
short while.

Material Testing Lab Manual Page 29 of 71

Department of Civil Engineering National Institute of Technology Calicut

8. Wait for 10 seconds and remove the main load by pushing the hand lever down smoothly
without jerking.

9. Take the reading from the dial indicator using C scale for cone indenter and B scale for ball
indenter.

OBSERVATIONS

Sl. No. Material Initial Final Indenter HRB HRC Average

load load

RESULTS

Rockwell Hardness numbers of the given materials are:

Rockwell Hardness number of steel =

Rockwell Hardness number of brass =

Material Testing Lab Manual Page 30 of 71

Department of Civil Engineering National Institute of Technology Calicut

QUESTIONS FOR REVIEW

1. Discuss the merits and demerits of the Rockwell Hardness Test.

2. Determine the average depths of indentation corresponding to the average values of HRC
obtained for (a) steel and (b) brass.

3. Suggest a method of correlating the Rockwell Hardness number with Brinnel Hardness
number.

4. Discuss the typical applications of Rockwell Hardness scale.

5. Discuss the importance of hardness test.

REFERENCES

1. Mechanical metallurgy – George E Dieter

2. Engineering materials science – C W Richard

3. IS 1586 : 2000 Method for Rockwell Hardness Test for Metallic Material (Scales A-B-
C-D-E-F-G-H-K 15N, 30N, 45N, 15T, 30T and 45T)

4. IS 3754 : 1988 Method for calibration of standardized blocks to be used for Rockwell
hardness testing machines(Scales A-B-C-D-E-F-G-H-K)

5. IS 3804 : 1988 Method for calibration of Rockwell hardness testing machines (Scales
A-B-C-D-E-F-G-H-K)

6. IS 5652 : Part 1 : 1993 /ISO 3738-1 : 1982 Hard metals - Rockwell Hardness Test
(Scale A) - Part 1 : Test Method

Material Testing Lab Manual Page 31 of 71

Department of Civil Engineering National Institute of Technology Calicut

Material Testing Lab Manual Page 32 of 71

Department of Civil Engineering National Institute of Technology Calicut

5. BRINNEL HARDNESS TEST

Exp.No……… Date:……………..

AIM
To find out the hardness of the material of the test specimen using Brinnel testing Machine

THEORY AND APPLICATION

As mentioned earlier a completed satisfactory general definition of hardness is not

available. The principle used in finding the Brinnel hardness number is based on the
resistance of the material to permanent indentation. A hardened steel ball with diameter
D(mm) is forced in to the surface under a specified load P for a duration of time ranging from
10 to 15 seconds. The hardness index is determined by the ratio of the load P(kg) to the
curved surface area (A) of the ball imprint ie BHS=P/A. If d is the diameter of the
impression in millimetre at the surface.

BHN or (HB) = P
D
π D − D2 − d 2 
2 

The unit of measurement viz. kg/mm2 is dropped and the brinnel hardness, designated by HB
or BHN ,is given as a number only. The diameter of ball imprint produced during test should
lie between 0.2D and 0.6D i.e . 0.2D,it is necessary to use a higher load P and conversely a
smaller load is to be used if ‘d’ is too large. While changing the load P and diameter of the
indenter D, it should be ensured that geometrical similarity in indentation is preserved. In
order to achieve this objective P/D2 should be maintained a constant for testing a particular
material.

If the impressions are similar for P1,D1, P2,D2 the total angle subtended at the centre of the
balls must be equal(refer Fig 1). This implies that

Material Testing Lab Manual Page 33 of 71

Department of Civil Engineering National Institute of Technology Calicut

It can be shown that the diameter, d of the indentation is related to the load, P by the
proportionality relationship . Since , geometrical similarity of indentation can
be maintained by keeping P/D2 a constant. This relation allows changes to be made in the ball
diameters so that smaller load could be used for thin sections while still making it possible to
compare hardness numbers so obtained for different values of load.

The following table gives the load, the diameter of the indenter and the duration of the
application of the load to be used for different materials and their thickness. Generally P =
30D2 for ferrous metals and P = 10D2 for non-ferrous metal.

The symbol HB denotes that the Brinnel hardness was determined under standard test
conditions, i.e. D = 10mm, P = 30kgf and time is 10 to 15 seconds. For special test conditions
the symbol HB is supplemented by an index, for example BH 5/750/20 indicates that D =
5mm, P = 750kgf and time of load application is 20 seconds.

Test
Thickness of Diameter
Interval Load in duration
Materials specimen in of Ball in P/D2
of BHN kg in
mm mm
seconds
Ferrous metals Below 6 10 3000
(cast iron and steel) 140-450 3-6 5 750 10 30
3 2.5 187.5
Ferrous metals Below 6 10 3000
140 6-3 5 750 10 30
3 2.5 187.5
Non Ferrous metals 6-3 10 1000
(copper, Brass, 32-130 4-2 5 250 30 10
Bronze, Magnesium) Below 2 205 62.5
Aluminium 8-35 6 19 250
Bearings alloy 6-3 5 62.5 60 2.5
3 2.5 15.6

Material Testing Lab Manual Page 34 of 71

Department of Civil Engineering National Institute of Technology Calicut

EXPERIMENTAL INVESTIGATION

It is already mentioned that in Brine test the hardness of metal is obtained from the
dimensions of the impression made by a steel ball after the ball has been pressed into the
metal under a known load. The determination of the hardness by ball indention can be carried
out using any type of press that is capable of loading the specimen accurately for the required
duration of time.

The standard testing machine consists of an anvil for supporting the specimen, an
elevating screw and a hand wheel for raising the specimen to the required height. The mandrel
with the ball is secured with the aid of a screw in the spindle sleeve. The upper end of the
spindle presses against the knife edge of a small lever. The operation of this lever is linked to
a loaded lever mechanism which is operated by an electric motor. The loading of the lever
mechanism and the duration of load application can be adjusted suitably by setting the
movable disc located on the right side of the machine.

The proper marking (a notch) on this disc (cup) corresponding to the diameter of ball
used and the duration of the load application is set against the approximate Brinnel hardness
number marked on the fixed outer disc. It should be remember that when testing ferrous
metal, the notch located on the housing should be used. When testing non ferrous metals and
alloys with a hardness of 35 to 130 units, the notches located on the right hand upper part of
the scale (of a red colour) on the housing and the red notch on the cup marked 30sec. should
be used. When the hardness of the material is being tested from 8 to 35 units, the notches
located on the lower right hand part of the scale on the housing and the notch marked 60 sec,
on the cup should be used.

When the machine switched on, the motor operates and gradually transfer the lever
load to spindle. The load remains for the present time and then gets automatically released
without any jerk. After the motor has stopped the table with the specimen ,is lowered by
rotating the hand wheel. The diameter of the impression is measured using a microscope for
determining the hardness number.

Material Testing Lab Manual Page 35 of 71

Department of Civil Engineering National Institute of Technology Calicut

Brinnel hardness testing machine

TESTING PROCEDURE

1. Study the operation of the machine.

2. Choose the diameter of the ball indenter depending on the thickness of the
specimen.(10mm diameter ball can be used for all thick(6mm)specimens.
3. Obtain the load to be applied using the relation P = 30D2 for ferrous materials and P =
10D2 for non ferrous materials. Find out the proper time interval from the table
4. Place the proper load on the rod suspended from the end of the lever. Set the proper
timing in the machine.
5. Keep the specimen with a smooth ,clean and flat surface on the table and bring it in
contact with the indenter for testing.

Material Testing Lab Manual Page 36 of 71

Department of Civil Engineering National Institute of Technology Calicut

6. Switch on the machine for loading . the load will remain for the specified duration and
afterwards will get disengaged automatically.
7. Repeat the test on the specimen three times displacing the point of indentation to
different places.

The distances from the imprint centre to the specimen edge should not be less than the
ball diameter and that to the centre of the neighbouring imprint should be equal to at
least two ball diameters. It should also be ensured that the specimen thickness should
be at least eight times the depth of the print.

8. Remove the specimen and measure the diameter of the indentation, taking at least two
reading of opposite diameter for each indentation.

OBSERVATIONS

Material Dia. of
Sl Dia. of Load in Duration Mean dia.
of impression: BHN
No: indenter Kg. in sec. in mm.
specimen d1 d2

RESULT

Brinnel Hardness Number of the materials are

Brass:

Steel:

Material Testing Lab Manual Page 37 of 71

Department of Civil Engineering National Institute of Technology Calicut

QUESTIONS FOR REVIEW

1) Give reasons for the following:

a) Brinnel test is not suitable for testing extremely hard materials and also for testing
thin specimens like razor blades
b) It is not suitable for testing case-hardened surfaces.
c) Finished surfaces get spoiled by Brine hardness test.
2) Why is the ratio P/D2 kept higher for ferrous metals compared to non ferrous metals?
3) What is the minimum thickness of specimen in hardness test?

REFERENCES

1) IS 4132 : 2005 (Method for Calibration of Standardized Blocks to be Used for Brinell
Hardness Testing Machines (Second Revision)
2) IS 1500 : 2005(Method for Brinell Hardness Test for Metallic Materials (Third
Revision))
3) IS 2281 : 2005(Method for Verification of Brinell Hardness Testing Machines (Third
Revision))

Material Testing Lab Manual Page 38 of 71