Load, kgf Recommended hardness range, HB

3000 96–600

1500 48–300

500 16–100

frequently to avoid errors.

Between 100 and 130, the extreme tip of the ball is used. Because of the blunt shape of the ball at this location, the
sensitivity of most scales is poor. It should be realized that as the diameter of the ball is increased the sensitivity of the
test decreases. Therefore, it is recommended that the smallest diameter ball should always be used. On the other hand, if
Rockwell B readings are below 50, the indenter may be sinking too deeply for accurate readings, and the load should be
decreased or the size of the indenter should be increased. This also applies to the Rockwell E and F scales.

Specimen Thickness

The material immediately surrounding indentations is cold worked due to the flow of the material caused by the indenting
process. The extent of this cold-work area depends on the material and any previous work hardening of the test specimen.
The depth of material affected also extends down below the indentation. Studies and experiments indicate that the
affected zone is approximately 10 times the indentation depth. Therefore, as a rule it is recommended that the thickness of
the specimen be at least 10 times the depth of indentation with diamond indenters and 15 times with ball indenters. There
should not be any deformation or mark visible on the opposite side of the test specimen after testing, although not all such
markings are indicative of a bad test. Any bulging or marking on the underside of the specimen is commonly referred to
as “anvil effect,” (see the section “Anvil Effect” in this article).

Depth of the Brinell indentation can be calculated from:

where F is the force (in kgf), D is the ball diameter (in mm), and (HB) is the Brinell hardness number. Table 2 is a
summary of minimum thickness requirements for Brinell tests done at 500, 1500, and 3000 kgf with a 10 mm (0.4 in.)
ball; other forces and ball sizes can be calculated using the above formula.

Table 2 Minimum thickness requirements for Brinell hardness tests using a 10 mm (0.4 in.) ball
indenter

Minimum thickness of Minimum hardness for which the

specimen Brinell test may safely be made at

indicated load

mm in. 3000 kgf 1500 kgf 500 kgf

1.6 602 301 100

Minimum thickness of Minimum hardness for which the

specimen Brinell test may safely be made at

indicated load

mm in. 3000 kgf 1500 kgf 500 kgf

3.2 ⅛ 301 150 50

4.8 201 100 33

6.4 ¼ 150 75 25

8.0 120 60 20

9.6 ⅜ 100 50 17

Microindentation hardness tests are routinely done on thin sheet metals and other small parts of 0.025 mm
(0.001 in.) or less thickness. The Vickers indenter makes an indentation with a depth of one-seventh of the length of the
mean diagonals. The Knoop indenter makes an indentation depth of one-thirtieth of the long diagonal. Generally, the
same ratio (10:1) of depth of indent to thickness follows the same criteria as the other tests. The following examples show
this calculation.

Because the depth of the Vickers test is one-seventh of the diagonal length, the depth calculation is simply as follows:

For example, if the Vickers indentation mean diagonal is measured at 0.074 mm, then the corresponding depth would be
0.0106 mm = 0.074 mm/7. The minimum thickness of the specimen thus should be 0.106 mm = 0.0106 mm × 10.

The depth of the Knoop indenter is one-thirtieth the longitudinal diagonal, and depth is calculated as follows: if the long
diagonal of a Knoop indentation is measured at 136.4 μm, then the indentation depth is 4.55 μm = 136.4 μm/30. The
minimum thickness of the specimen thus should be at minimum 46 μm = 4.55 μm × 10.

Depth of the Rockwell Test Indentations. When using the C, A, or D scales, the Rockwell number is subtracted
from 100 and the result is multiplied by 0.002 mm. Therefore, a reading of 60 HRC indicates an indentation increase in
depth from preliminary to total force:

Depth = (100 - 60) × 0.002 mm = 0.08 mm

When the 1.59 mm ( in.) ball indenter with the B, F, or G scale is used, the hardness number is subtracted from 130;
therefore, for a reading of 80 HRB the depth is determined by:
 Depth = (130 - 80) × 0.002 mm = 0.10 mm

In Rockwell superficial testing, regardless of the type of indenter used, one number represents an indentation of 0.001 mm
(0.00004 in.). Therefore, a reading of 80 HR30N indicates an increase in depth of indentation from preliminary to total
force of:

Depth = (100 - 80) × 0.001 = 0.02 mm

Generally, depth computation is not necessary because minimum thickness values have been calculated (Table 3). These
minimum thickness values follow the 10-to-1 ratio for scales using the diamond indenter and 15-to-1 using the ball
indenters. It should also be noted that the initial indentation from the preliminary force is not included in these
calculations.

Table 3 Minimum work metal hardness values for testing various thicknesses of metals with
standard and superficial Rockwell hardness testers

Metal Minimum hardness for standard testers at indicated Minimum hardness for superficial testers at
thickness scale and load (in kgf) indicated scale and load (in. kgf)

Diamond indenter Ball indenter (1.59 mm, Diamond indenter Ball indenter (1.59 mm,
or

or in., diam)
in., diam)

mm in. A D C F B G 15N 30N 45N 15T 30T 45T

(60) (100) (150) (60) (100) (150) (15) (30) (45) (15) (30) (45)

0.152 0.006 92 … … … … … 92 … … … … …

0.203 0.008 90 … … … … … 90 … … … … …

0.254 0.010 … … … … … … 88 … … 91 … …

0.305 0.012 … … … … … … 83 82 77 86 … …

0.356 0.014 … … … … … … 76 78.5 74 81 80 …

0.406 0.016 86 … … … … … 68 74 72 75 72 71

0.457 0.018 84 … … … … … … 66 68 68 64 62
Metal Minimum hardness for standard testers at indicated Minimum hardness for superficial testers at
thickness scale and load (in kgf) indicated scale and load (in. kgf)

Diamond indenter Ball indenter (1.59 mm, Diamond indenter Ball indenter (1.59 mm,
or

or in., diam)
in., diam)

mm in. A D C F B G 15N 30N 45N 15T 30T 45T

(60) (100) (150) (60) (100) (150) (15) (30) (45) (15) (30) (45)

0.508 0.020 82 77 … 100 … … … 57 63 … 55 53

0.559 0.022 78 75 69 … … … … 47 58 … 45 43

0.610 0.024 76 72 67 98 94 94 … … 51 … 34 31

(a) (a)
0.660 0.026 71 68 65 91 87 87 … … … 18

0.711 0.028 67 63 62 85 … 76 … … … … … 4

0.762 0.030 60 58 57 77 71 68 … … 26 … … …

0.813 0.032 … 51 52 69 62 59 … … 20 … … …

(a) (a)
0.864 0.034 43 45 … 52 50 … … … 43 …

0.914 0.036 … … 37 … 40 42 … … … … 40 …

0.965 0.038 … … 28 … 28 31 … … … … 36 …

1.016 0.040 … … … … … 22 … … … … 33 …

1.066 0.042 … … … … … … … … … … 29 …

(a)
1.116 0.044 … … … … … … … … … … …

1.166 0.046 … … … … … … … … … … … …

1.216 0.048 … … … … … … … … … … … …
Metal Minimum hardness for standard testers at indicated Minimum hardness for superficial testers at
thickness scale and load (in kgf) indicated scale and load (in. kgf)

Diamond indenter Ball indenter (1.59 mm, Diamond indenter Ball indenter (1.59 mm,
or

or in., diam)
in., diam)

mm in. A D C F B G 15N 30N 45N 15T 30T 45T

(60) (100) (150) (60) (100) (150) (15) (30) (45) (15) (30) (45)

1.270 0.050 … … … … … … … … … … … …

(a)
1.321 0.052 … … … … … … … … … … …

1.372 0.054 … … … … … … … … … … … …

1.422 0.056 … … … … … … … … … … … …

1.473 0.058 … … … … … … … … … … … …

1.524 0.060 … … … … … … … … … … … …

(a)
1.575 0.062 … … … … … … … … … … …

1.626 0.064 … … … … … … … … … … … …

(a)
1.676 0.066 … … … … … … … … … … …

1.727 0.068 … … … … … … … … … … … …

1.778 0.070 … … … … … … … … … … … …

1.829 0.072 … … … … … … … … … … … …

1.880 0.074 … … … … … … … … … … … …

1.930 0.076 … … … … … … … … … … … …

1.981 0.078 … … … … … … … … … … … …
Metal Minimum hardness for standard testers at indicated Minimum hardness for superficial testers at
thickness scale and load (in kgf) indicated scale and load (in. kgf)

Diamond indenter Ball indenter (1.59 mm, Diamond indenter Ball indenter (1.59 mm,
or

or in., diam)
in., diam)

mm in. A D C F B G 15N 30N 45N 15T 30T 45T

(60) (100) (150) (60) (100) (150) (15) (30) (45) (15) (30) (45)

2.032 0.080 … … … … … … … … … … … …

2.083 0.082 … … … … … … … … … … … …

2.134 0.084 … … … … … … … … … … … …

2.184 0.086 … … … … … … … … … … … …

2.235 0.088 … … … … … … … … … … … …

2.286 0.090 … … … … … … … … … … … …

2.337 0.092 … … … … … … … … … … … …

2.388 0.094 … … … … … … … … … … … …

2.438 0.096 … … … … … … … … … … … …

2.489 0.098 … … … … … … … … … … … …

2.540 0.100 … … … … … … … … … … … …

Note: These values are approximate only and are intended primarily as a guide. Material thinner than shown should be
tested with a microindentation hardness tester. The thickness of the workpiece should be at least 1.5 times the diagonal of
the indentation when using a Vickers indenter, and at least 0.5 times the long diagonal when using a Knoop indenter.
(a) No minimum hardness for metal of equal or greater thickness

Example: Scale Selection for Thin Steel Strip. Consider a requirement to check the hardness of 0.36 mm
(0.014 in.) thick steel strip with a suspected hardness of 63 HRC. According to Table 3, material in this hardness range
must be approximately 0.71 mm (0.028 in.) thick for an accurate Rockwell C test. Therefore, 63 HRC must be converted
to an approximate equivalent hardness on other Rockwell scales. These hardness values taken from a conversion table are
82.8 HRA, 73 HRD, 69.9 HR45N, 80.1 HR30N, and 91.4 HR15N. (See the article “Hardness Conversions for Steels” in
this Volume.)
Referring to Table 3, only three Rockwell scales—45N, 30N, and 15N—are appropriate for testing this hardened 0.36
mm (0.014 in.) thick material. The 45N scale is unsuitable because the material should be at least 72 HR45N. The 30N
scale requires the material to be 64 HR30N; on the 15N scale, the material must be at least 70 HR15N. Therefore, either
the 30N or 15N scale should be used.

If a choice remains after all the criteria have been applied, then the scale applying the heaviest force should be used. A
heavier force produces a larger indentation covering a greater portion of the material and a better representation of the
material as a whole. In addition, the heavier the force, the greater the sensitivity of the scale. In this example, a conversion
chart indicates that, in the hard steel range, a difference in hardness of one Rockwell number in the 30N scale represents
just one-half of a point on the 15N scale. Therefore, smaller differences can be detected when using the 30N scale. This
approach also applies when selecting a scale to accurately measure hardness when approximate case depth and hardness
are known.

Anvil Effect. Minimum thickness charts and the 10-to-1 ratio serve only as guides. After determining which Rockwell
scale should be used based on minimum thickness values, an actual test should be performed, and the specimen side
opposite the indentation should be examined for any marking, bulging, or disturbed material; these indicate that the
material is not thick enough for the applied force. This condition is known as “anvil effect.” When anvil effect or material
flow restriction is encountered, the Rockwell value may not be correct and should be considered an invalid test. The
Rockwell scale applying the lower force should be used.

Use of several specimens or stacking is not recommended. Slippage between the contact surfaces of the specimens makes
a valid test impossible to obtain. The only exception is when testing plastics. The use of several thicknesses for
elastomeric materials when anvil effect is present is considered in ASTM D 785 (Ref 2). Testing performed on soft
plastics does not have an adverse effect when the test specimen is composed of a stack of several pieces of the same
thickness, provided that the surfaces are in total contact and not held apart by sink marks, burrs from saw cuts, or any
protrusions that would permit an air gap between the pieces.

When testing specimens from which the anvil effect results, the condition of the supporting surface of the anvil should be
inspected. After several tests, this surface can become marred or indented. Either condition will have adverse results with
Rockwell testing, because under the total force, the test material will sink into the indentation in the anvil and a lower
reading will result. If the anvil surface shows any damage it should be replaced or relapped.

When using a ball indenter and a superficial scale of 15 kgf on a specimen in which anvil effect or material flow is
present, a diamond spot anvil is used in place of the hardened steel anvil. Under these conditions, the diamond surface is
not likely to be damaged when testing thin materials. Furthermore, with materials that flow under load, the hard polished
diamond surface provides a more uniform frictional condition with the underside of the specimen, which improves
repeatability of readings. These results should be used in a comparative manner inasmuch as they may not be the same as
those obtained with a steel anvil.

Workpiece Size and Shape

Specimen size and configuration may require modification in the test setup for some indentation-type testing. For
example, large specimens and thin-wall rings or tubing may need additional support equipment as well as correction
factors for curved surfaces. A few examples and illustrations are provided here.

Workpiece Size. For large workpieces that are not easily transported to the stationary testers, the logical procedure is
to take the testers to the workpiece. Portable machines often are used for onsite testing of workpieces that are too large
and/or unwieldy to transport to the tester. In many applications where on-site testing is required, the Scleroscope can be a
great advantage. Likewise, ultrasonic instruments can be used for on-site testing. When using either Scleroscope or
ultrasonic testing, however, surface condition is critical to obtaining accurate results. Neither method is well suited for
testing cast irons.

Many specially designed Rockwell hardness testers also have been developed to accommodate the testing of unusually
large specimens, such as railroad car wheels and large turbine blades that cannot be conveniently brought to or placed in a
bench-type tester. Figure 2 shows an example of a Rockwell tester for large parts. For large and heavy workpieces or
workpieces of peculiar shape, a large support table may be required.