Hardness Testing

Lesson 3: Surface Preparation

For information regarding this presentation, please contact Dan Emelander (Metallurgist) 713-939-2672

The Importance of Surface Preparation

Poor surface preparation is one of the most common sources of incorrect hardness values Poor surface preparation may result in hardness readings that are too high or too low

Important Points
Grinding a flat is not necessarily enough preparation Machined surfaces are not always adequate for hardness testing
Machining lines can introduce error should be touched up with a flapper wheel

Use a sanding disc NOT a grinding wheel for rough preparation

If a grinding stone is used, it must be followed with a sanding disc and flapper wheel to avoid cold work on the test surface

Final prep should include using a flapper wheel or similar device to smooth out the surface The lighter the load, or smaller the indenter, the better the surface prep needs to be!

Surface Preparation vs. Test Method

When doing hardness tests using low-load methods (such as Rockwell A-scale)
A PERFECT surface finish is required Must be completely flat, with the tester perpendicular to the part

Rockwell B and C Scale

Very smooth, a thorough job with the flapper wheel is adequate Surface must be completely flat, with the tester perpendicular to the part

Brinell
Surface finish must be adequate to obtain accurate reading using the Brinell scope or Optical scanner (flapper wheel works) Surface must be completely flat, with the tester perpendicular to the part

Typical Surface Preparation Equipment

Sanding Disc
Used for rough grinding

Flapper Wheel

Works well to provide adequate surface finish for most testing methods

De-Carb
De-Carb is a term used for the reduction in carbon on the surface of a part. This occurs at high temperatures (during forging or in a heat treat oven). It is important to grind below the de-carb layer, because this layer will give you a false, soft result.
32 HRC

Image
Showing De-carb 35 HRC 35HRC Example

Grinding Depths*
Material Type
Low Alloy Steels (such as A487, 4130, 2 Chrome, etc)

Condition
Cast or forged and heat treated

Recommended Grinding Depth

1/8 3/16 (3.3 4.8mm)

Martensitic Stainless Steels (410, CA15, etc) and 17-4

Low Alloy, Martensitic Stainless Steel, 17-4PH Austenitic Stainless Steels, Nickel Based Alloys (316, 625, 725, etc) Low Alloy Steel All Materials

Cast or forged and heat treated

Rough machined and heat treated Cast or forged and heat treated Pipe / Tube in the heat treated condition Finish Machined Surfaces

1/8 3/16 (3.3 4.8mm)

1/16 1/8 (1.5 3.3mm) As required to obtain surface finish To 1/16 - Do not violate minimum wall thickness As required to obtain surface finish and remove any cold work

Grinding Depths
Previous table recommended depths to prepare the surface to
DO NOT grind to this depth if it will violate dimensional tolerances

Grind an area large enough for the Brinell scope (or optical scanner) to rest flat on the surface If scope or scanner rocks or wobbles on the surface, this is an indication the surface is not flat, and it must be re-prepared

Curved Surfaces
Brinell
ASTM allows testing on surfaces with a diameter 2.5 times the diameter of the indenter
This means any surface with a curvature greater than 1 is allowed in ASTM

Rockwell ASTM states that when testing the surface of small diameter parts, a correction factor should be used
For HRC, it is when the diameter is <1.5 For HRB, it is when the diameter is <1.0

This is NOT ALLOWED for Cameron testing Testing directly on a curved surface is only permitted when absolutely necessary. A flat should always be prepared whenever possible

The table of correction factors can be found in E18

Curved Surfaces
When testing curved surfaces, it is REQUIRED you test at the exact apex of the surface
If you are off the centerline, you WILL get inaccurate result!

Surface Examples

Not Acceptable
Machining marks, embedded rust may introduce error

Acceptable
Using a flapper wheel ensures a more accurate reading

Surface Examples

Not Acceptable -Too Rough, Rusted-

Acceptable

When in Doubtcall Metallurgy