Hardness Testing

Hardness Testing Equipment Part 1: The King Portable

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

The King Portable

The King portable hardness tester is one of the most commonly used testers in our facilities. As with any portable type tester, setup requires much more attention to detail than fixed models The standard that governs King portable testing is ASTM E110

King Portable
Test head
Produces a 3000kg force
Only for a brief time, as the pop-off valve relieves the pressure This is why it is necessary to pump 2-3 additional times once 3000kg is reached

10mm Tungsten Carbide Ball Used in conjunction with an adapter (Chain or Clamp)

King Portable Clamp Adapter

Clamp Adapter
Used to clamp many different surfaces Can be moved from location to location easily Uses different anvils for different geometries Adjustable for various thicknesses

Anvils
Dome Anvil* clamping on the ID of a tube or similar shaped part Flat Anvil Clamping on a flat surface V-Anvil Clamping on the OD of a tube, bar, or similar shaped part

Dome Anvils

Flat Anvil

V- Anvil

*Note: Using the dome anvil when clamping on large diameter tube-shaped material, has been found to produce false, soft results. This has been found on parts with diameters in the 20 range. The flat anvil, or modified chain adapter, was found to give a more accurate result. This will be discussed again later.

Chain Adapter

Standard model Not stable tester moves considerably Gives soft readings due to movement Unacceptable for use on large OD parts

Modified Design Very Stable tester remains firmly attached to the part Values are much more reliable, and closer to actual part hardness Modification is simple and inexpensive

Using the King Portable

Check the machine on a calibration block a minimum of once a day Once the surface has been properly prepared, place the tester on the part Tighten the clamp (or chain) down as tight as possible Close the valve Pump the pressure up to 3000kg using controlled strokes
Pump 2-3 additional times ONLY!
Do not hold for 15 seconds Do not pump 15 times once 3000kg is reached

Re-open the valve and remove the tester Read the impression

Reason for Restriction on Number of Pumps

ASTM E110 states 2-3 additional pumps, once reaching 3000kg, is equivalent to a standard Brinell test for Steel Although other methods may work, this is the standard! It is important everyone does the test the same way in order for results to be comparable This is the correct method, consult ASTM E110 if there is any disagreement

Verification
Prior to testing the part:
Make about 3 punches on a scrap piece to warm-up the tester (after period of non-use / beginning of each day) Make 2 punches on a calibrated, traceable test-block. These values must be within 3% of the actual value
197 HBW test block: 6 HB points 237 HBW test block: 7 HB points 321 HBW test block: 9 HB points NOTE: Although 3% is the limit, it is preferred that the machine be closer to the actual value.

Keep a log of the calibration block readings, so any developing trends can be caught

Using the Clamp Adapter

Install the correct anvil for the part you will be testing Crank the throat of the adapter down to approximately the same thickness of the part to be tested. Place the tester on the part, and crank the clamp closed tight
It is important to tighten this down as much as possible to avoid twisting of the tester

Perform the test Read the impression

Effects of Improper Setup

If the clamp is not tightened enough, the tester may twist during the test
This can cause false, soft values Oval indentations may also occur

Repeated twisting will damage the equipment NOTE: This only occurs when clamping on curved surfaces, and can be prevented.
Avoid clamping on curved surfaces (if possible) Avoid using the Dome Anvil

Modified Chain Tester

1.) Drill Holes Advantages No movement (other than uniform lifting) Easier setup Less room for operator error or variance

2.) Fabricate Blocks

3.) Bolt Together

(Modified Chain tester was developed at Cameron Singapore)

Using the Chain Adapter

Lower the test head as much as possible Place the tester on the part
Tester should be perpendicular to the part The 3 feet should be in contact with the surface The ball should be slightly above, or barely in contact with the surface

Wrap the chain around the part, and place on the tightest link possible

Using the Chain Adapter

(Continued)

Tighten the wheel on the tester as much as possible While tightening, adjust feet so they still remain in contact and do not roll over Feet should be in contact with the part when fully tightened.
If they are not, less links must be used in the chain

Using the Chain Adapter

(continued)

Once tightened, close the valve and perform the test The 3-feet on the test head should lift uniformly If they do not lift uniformly, it indicates that the tester was not perpendicular to the part. The tester will need to be repositioned, made perpendicular, and a re-test performed.

Limitations of the King Portable

Large load and indenter size This limits how thin of an area you are able to test
Particularly on small wall thickness (less than ) pipe, a squeezing effect may occur

Large amount of error associated with reading the impression (to be covered in detail later) Variability in number of pumps after 3000kg is reached Movement of the tester gives false, soft results
Especially using the dome anvil in large diameter cylinders Due to improper setup on the part

Advantages of the King Portable

Its portable can use in the field or on large parts Can provide very consistent, accurate results when used properly Durable Uses the same principles of a Brinell hardness test, measuring bulk properties

When in Doubtcall Metallurgy