Brinell Hardness Test

Dr. J. A. Brinell invented the Brinell test in Sweden in 1900. The oldest of the hardness test methods in common use today, the Brinell test is frequently used to determine the hardness of forgings and castings that have a grain structure too course for Rockwell or Vickers testing. Therefore, Brinell tests are frequently done on large parts. By varying the test force and ball size, nearly all metals can be tested using a Brinell test. Brinell values are considered test force independent as long as the ball size/test force relationship is the same. In the USA, 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 3000kg with 5 or 10mm carbide balls. In Europe Brinell testing is done using a much wider range of forces and ball sizes. It's common in Europe to perform Brinell tests on small parts using a 1mm carbide ball and a test force as low as 1kg. These low load tests are commonly referred to as baby Brinell tests.

Standards
Brinell Test methods are defined in the following standards: y y ASTM E10 ISO 6506

Brinell Test Method

All Brinell tests use a carbide ball indenter. The test procedure is as follows: y y y y y 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. The Brinell hardness number is a function of the test force divided by the curved surface area of the indent. The indentation is considered to be spherical with a radius equal to half the diameter of the ball. The average of the two diagonals is used in the following formula to calculate the Brinell hardness.

The Brinell number, which normally ranges from HB 50 to HB 750 for metals, will increase as the sample gets harder. Tables

are available to make the calculation simple. A typical Brinell hardness is specified as follows: 356HBW Where 356 is the calculated hardness and the W indicates that a carbide ball was used. Note- Previous standards allowed a steel ball and had an S designation. Steel balls are no longer allowed.

Applications
Because of the wide test force range the Brinell test can be used on almost any metallic material. The part size is only limited by the testing instrument's capacity. Strengths 1. 2. 3. 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. Nondestructive, sample can normally be reused.

Weaknesses 1. 2. 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.

Another common hardness test type, the Brinell test, consists of applying a constant load or force, usually between 500 and 3000 Kgf, for a specified time (from 10 - 30 seconds) using a 5 or 10 mm diameter tungsten carbide ball. The load time period is required to ensure that plastic flow of the metal has ceased. Lower forces and smaller diameter balls are sometimes used in specific applications. Similar to Knoop and Vickers testing, the Brinell test applies only a single test force. After removal of the load, the resultant recovered round impression is measured across diagonals at right angles and is usually recorded millimeters using a low-power microscope or an automatic measuring device. The actual Brinell hardness (BHN) is calculated by factoring the indent size and the test force however it is not necessary to make the actual calculation for each test. Calculations have already been made and are available in tabular form for various combinations of diameters of impressions and load. In addition various forms of automatic Brinell reading devices are available to perform these tasks. Brinell testing is typically used in testing aluminum and copper alloys (at lower forces) and steels and cast irons at the higher force ranges. Highly hardened steel or other materials are usually not tested by the Brinell method, but the Brinell test is particularly useful in certain material finishes as it is more tolerant of surface conditions due to the indenter size and heavy applied force. Brinell testers are often manufactured to accommodate large parts such as engine castings and large diameter piping.

Stanley P. Rockwell invented the Rockwell hardness test. He was a metallurgist for a large ball bearing company and he wanted a fast non-destructive way to determine if the heat treatment process they were doing on the bearing races was successful. The only hardness tests he had available at time were Vickers, Brinell and Scleroscope. The Vickers test was too time consuming, Brinell indents were too big for his parts and the Scleroscope was difficult to use, especially on his small parts.

To satisfy his needs he invented the Rockwell test method. This simple sequence of test force application proved to be a major advance in the world of hardness testing. It enabled the user to perform an accurate hardness test on a variety of sized parts in just a few seconds. Rockwell test methods are defined in the following standards: y y y ASTM E18 Metals ISO 6508 Metals ASTM D785 Plastics

Types of the Rockwell Test

There are two types of Rockwell tests: 1. Rockwell: the minor load is 10 kgf, the major load is 60, 100, or 150 kgf. 2. Superficial Rockwell: the 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.

Rockwell Scales
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 30 different scales. The majority of applications are covered by the Rockwell C and B scales for testing steel, brass, and other metals. However, the increasing use of materials other than steel and brass as well as thin materials necessitates a basic knowledge of the factors that must be considered in choosing the correct scale to ensure an accurate Rockwell test. The choice is not only between the regular hardness test and superficial hardness test, with three different major loads for each, but also between the diamond indenter and the 1/16, 1/8, 1/4 and 1/2 in. diameter steel ball indenters. If no specification exists or there is doubt about the suitability of the specified scale, an analysis should be made of the following factors that control scale selection: y y y y Type of material Specimen thickness Test location Scale limitations

Principal of the Rockwell Test

1. Select image to enlargeThe indenter moves down into position on the part surface 2. A minor load is applied and a zero reference position is established 3. The major load is applied for a specified time period (dwell time) beyond zero 4. The major load is released leaving the minor load applied

The resulting Rockwell number represents the difference in depth from the zero reference position as a result of the application of the major load. With the two test ranges available, the Rockwell test can be used on almost any metal sample as well as some hard plastics. The test can normally be performed in less than 10 seconds and the indent is usually small enough to allow the part to be used. Some parts with a critical hardness specification are tested 100%.

Strengths
1. Rapid test, usually less than 10 seconds 2. Direct readout, no questionable optical measurements required. 3. Non-destructive, part normally can be used.

Weaknesses
1. Multiple test scales (30) needed to cover the full range of metal hardness. 2. Conversions between scales can be material dependant. 3. Samples must be clean and have a smooth test point to get good results.