LABORATORY MANUAL

Material Science
4th Semester BE

Department of Mechanical Engineering

Jorhat Engineering College
Jorhat – 785007 (Assam)
 STUDENT PROFILE
NAME :

ROLL NUMBER :

SECTION :

SEMESTER : 4th Semester

YEAR :

PERFORMANCE RECORD
EXP. REMARKS /
TITLE OF EXPERIMENT
NO. GRADE

1 Rockwell Hardness Test.

2 Brinell Hardness Test.

3 Charpy Pendulum Impact Test.

4 Tension Test.

Course Outcomes: After completion of the course, the students will able to
CO1: Determine the hardness of metals
CO2: Determine the yield strength, ultimate tensile strength and ductility of metals
CO3: Determine the impact strength of metals

OFFICE USE

Checked By :

Overall Grade / Marks :

Signature of Teacher :
 Experiment No. 1

TITLE: Rockwell Hardness Test.

OBJECTIVE:
To determine hardness of a flat mild steel and high carbon steel specimen.

THEORY:
The hardness of a material is its resistance to
penetration under a localized pressure or resistance
to abrasion. Hardness test provides an accurate,
rapid and economical way of determining the
resistance of the material to deformation.

In Rockwell hardness test, the instrument

measures the depth of penetration made by a
particular indenter under a definite amount of load
and indicates it as a dimensionless hardness
number on a Dial Indicator.

Initial a Preliminary Test Force (Minor Load) is applied to the test piece and the
Indenter penetrates through a certain depth into the test piece. Since the surface of the
test piece may not be fully free from irregularities, hence this initial penetration
eliminates any effect of surface finish on the test results and sets the Zero Reference
Line for the test procedure.

Figure 1.1: Indentation under different test loads

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 Next, an Additional Test Force (Major Load) is applied and the Indenter
penetrates through the maximum depth possible. This load is kept in application for a
definite amount of time (dwell time) and then released to allow elastic recovery in the
test piece. There will remain some residual depth of penetration (Permanent Depth of
Penetration) on the test piece and this residual depth is converted into a dimensionless
Hardness Number as indicated on the Dial Indicator.

A variety of penetrators and standard loads can be used; giving a series of

different scales identified by capital letters A, B, C, D, E, F, G, H, K, N and T. Refer
Table 1.1 for all the details.

The Rockwell method is much faster than any other methods of hardness testing
and produces an indentation of the order of 0.005 inch. It is therefore suitable for thin
specimen.

PRECAUTIONS:
 The thickness of the test piece should be at least ten times the permanent indentation
depth for cone indenters and fifteen times the permanent indentation depth for ball
indenters.

 The test should be carried out at ambient temperature within the limits of 10℃ to
35℃. However, because temperature variations may affect the results, hence for
better results, the test can be carried under controlled environment.

 The test surface should be smooth and even, free from oxide scale, foreign matters
and, in particular, completely free from lubricants. Exceptions include reactive metals,
like titanium, which might adhere to the indenter. In such situations, a suitable
lubricant such as kerosene may be used. The use of a lubricant shall be reported on
the test report.

PROCEDURE:
1. Place the Test Piece on the Test Piece Bed.

2. Press the Handle download to unload the apparatus. i.e. the External Loads
(major load) are not in application.

3. Keep pressing the Handle download and raise the Bed by rotating the Hand Wheel in
clockwise direction. Continue raising the Bed even after the initial contact between
the Test Piece and Indenter is made, till the needle on the Small Dial is aligned with
the SET mark. This indicates that an initial load of 10 kg (Pre-load / minor load) has
been applied on the Test Piece.

4. Manually rotate the Large Dial to align the ZERO Mark with the large needle.

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 5. Now rotate the Handle on the other direction to apply the External Loads. Keep the
External Loads in application for at least 21 seconds (dwell time).

6. After 21 seconds, unload the apparatus, as done in step 2 and record the reading on
the Large Dial. This will be the Rockwell Hardness Number for the Test Piece.

7. Lower the Bed by rotating the Hand Wheel in anti-clockwise direction and collect the
Test Piece.

OBSERVATION TABLE – 1
Sl. No. Specimen Reading (HRB) Mean Hardness (HRB)

1
2 Flat Mild Steel Plate
3

OBSERVATION TABLE – 2
Sl. No. Specimen Reading (HRC) Mean Hardness (HRC)

1
Flat High Carbon
2
Steel Plate
3

RESULT:
1. The hardness of the mild steel test piece is found to be :

2. The hardness of the high carbon steel test piece is found to be :

Figure 1.2: Writing a particular Result after test [as per ISO 6508-1:2005(E)]

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 Table 1.1: Rockwell Scales and Indenters [as per ISO 6508-1:2005(E)]
Rockwell Preliminary Additional Total Test
Hardness Field of Application
Hardness Type of Indenter Test Force Test Force Force
Symbol (Rockwell Hardness Test)
Scale (𝑭𝟎 ) (𝑭𝟏 ) (𝑭)
A HRA 1200 Diamond cone 10 kgf 50 kgf 60 kgf 20 HRA to 88 HRA
B HRB 1/16 inch Ball 10 kgf 90 kgf 100 kgf 20 HRB to 100 HRB
C HRC 1200 Diamond cone 10 kgf 140 kgf 150 kgf 20 HRC to 70 HRC
D HRD 1200 Diamond cone 10 kgf 90 kgf 100 kgf 40 HRD to 77 HRD
E HRE 1/8 inch Ball 10 kgf 90 kgf 100 kgf 70 HRE to 100 HRE
F HRF 1/16 inch Ball 10 kgf 50 kgf 60 kgf 60 HRF to 100 HRF
G HRG 1/16 inch Ball 10 kgf 140 kgf 150 kgf 30 HRG to 94 HRG
H HRH 1/8 inch Ball 10 kgf 50 kgf 60 kgf 80 HRH to 100 HRH
K HRK 1/8 inch Ball 10 kgf 140 kgf 150 kgf 40 HRK to 100 HRK
15N HR15N 1200 Diamond cone 3 kgf 12 kgf 15 kgf 70 HR15N to 94 HR15N
30N HR30N 1200 Diamond cone 3 kgf 27 kgf 30 kgf 42 HR30N to 86 HR30N
45N HR45N 1200 Diamond cone 3 kgf 42 kgf 45 kgf 20 HR45N to 77 HR45N
15T HR15T 1/16 inch Ball 3 kgf 12 kgf 15 kgf 67 HR15T to 93 HR15T
30T HR30T 1/16 inch Ball 3 kgf 27 kgf 30 kgf 29 HR30T to 82 HR30T
45T HR45T 1/16 inch Ball 3 kgf 42 kgf 45 kgf 10 HR45T to 72 HR45T
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 Figure 1.3: Rockwell Hardness Apparatus

Figure 1.4: The Dial Indicator showing both Rockwell B & C Scales

Figure 1.5: Different types of Indenters

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REFERENCES

 ISO 6508-1:2005(E) document.

Title: To determine hardness of a flat mild steel and high carbon

Exp. No. 1
steel specimen
Name of Student:

Roll No.:

Date of Experiment:

Date of Submission:

Signature of Teacher SEAL

with Date of Check

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 Experiment No. 2

TITLE: Brinell Hardness Test.

OBJECTIVE:
To determine hardness of a mild steel and high carbon steel specimen.

APPARATUS REQUIRED:
1. Brinell Hardness Tester [fig. 2.2 (a, b, c)]
Manufactured by Zaklady Automatyki Przemyslowej,
Poland

2. External Weights: 3000 kg for hard material, 1500 kg for

intermediate material, and 500 kg for soft material. Refer
Table 2.1 for more details.

3. Steel Ball Indenter of 10 mm diameter [fig. 2.2 (c)]

4. Brinell Microscope [fig. 2.2 (d)]

Manufactured by PZO Warszawa, Poland

THEORY:
The hardness of a material is its resistance to penetration under a localized
pressure or resistance to abrasion. Hardness test provides an accurate, rapid and
economical way of determining the resistance of material to deformation.

In this test, a Tungsten Carbide steel ball indenter of diameter D is pressed

against the surface of the test piece by a gradually applied load P, and this force is
maintained for a definite amount of time. The impression on the test piece so obtained
is measured using an optical microscope and the required Brinell Hardness Number
(BHN) or Brinell Hardness (HB) is calculated using the following relation:

𝐀𝐩𝐩𝐥𝐢𝐞𝐝 𝐭𝐞𝐬𝐭 𝐟𝐨𝐫𝐜𝐞 𝐢𝐧 𝐤𝐠𝐟 𝑷

𝐁𝐇𝐍 𝐨𝐫 𝐇𝐁 = =
𝐀𝐫𝐞𝐚 𝐨𝐟 𝐢𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐨𝐧 𝐢𝐧 𝐦𝐦𝟐 𝑨

Where,

𝑃 = Applied Test Force in kgf.

⁄
𝐴 = Indented area = 𝜋(𝐷⁄2) 𝐷 − (𝐷 − 𝑑 )

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 𝐷 = Diameter of steel ball indenter = 10 mm

𝑑 = Diameter of impression on the test piece

The BHN is expressed in kg/mm2. For obtaining good results, the steel ball indenter
used in this test should be well polished and free from any surface defects.

PRECAUTIONS:
 The thickness of the test piece should be at least 8-10 times the depth of
indentation. Visible deformation at the back of the test piece can indicate that
the test piece is too thin.

 The test should be carried out at ambient temperature within the limits of 10℃
to 35℃. However, because temperature variations may affect the results, hence
for better results, the test can be carried under controlled environment.

 The test surface should be smooth and even, free from oxide scale, foreign
matters and, in particular, completely free from lubricants.

 Brinell Hardness test is not recommended for materials above 650 HBW
10/3000.

PROCEDURE:
1. Place the test piece on the test piece Bed of the apparatus.

2. Raise the Bed by rotating the Hand Wheel in clockwise direction till the initial
contact between the surface of the test piece and the indenter is made.

3. Place suitable External Weights on the Yoke and close the Release Valve. The
amount of external weights attached corresponds to the test force that would be
applied on the test piece.

4. Start pumping the hydraulic fluid by moving the Handle up-and-down to

gradually increase the test force on the test piece, till the fluid overflows
through the Overflow Valve. Overflow gives an indication that the maximum
amount of test force has been applied on the test piece.

5. Keep the test force in application for about 15 seconds (dwell time).

6. Now, open the release valve to release the test force.

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 7. Lower the Bed and collect the test piece.

8. Measure the diameter of the impression by using the Brinell Microscope.

Hence, calculate the area of impression and the required Brinell Hardness
Number (BHN).

OBSERVATION TABLE – 1

Diameter of Diameter of Area of

Sl. steel ball Impression Impression Average
Specimen BHN
No. Indenter (𝑫) (𝒅) (𝑨) BHN
(𝒎𝒎) (𝒎𝒎) (𝒎𝒎𝟐 )

1
Flat Mild Steel
2
Plate
3

OBSERVATION TABLE – 2

Diameter of Diameter of Area of

Sl. steel ball Impression Impression Average
Specimen BHN
No. Indenter (𝑫) (𝒅) (𝑨) BHN
(𝒎𝒎) (𝒎𝒎) (𝒎𝒎𝟐 )

1
Flat High
2 Carbon
Steel Plate
3

RESULT:
1. The hardness of the mild steel test piece is found to be :

2. The hardness of the high carbon steel test piece is found to be :

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 Figure 2.1: Writing a particular Result after test [as per ISO 6506-1:2014(E)]

Hardness symbol HBW should be used if a Tungsten Carbide Ball Indenter is

used, where W is the chemical symbol for Tungsten. Otherwise, if a Hardened Steel
Ball indenter is used, the hardness symbol HBS should be used, where S denotes
Hardened Steel.

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 (a) (b)

(c) (d)

Figure 2.2: (a, b, c) Different parts of the Brinell Hardness Testing apparatus ; (d) Brinell
Microscope

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 Table 2.1: Test Forces for different hardness conditions and hardness range
Ball
Test force Force-diameter Recommended
Hardness Diameter
value (F) index Hardness Range
Symbol (D)
(kgf) (F/D2) (HBW)
(mm)
HBW 10/3000 10 3000 30 95.5 to 650
HBW 10/1500 10 1500 15 47.7 to 327
HBW 10/1000 10 1000 10 31.8 to 218
HBW 10/500 10 500 5 15.9 to 109
HBW 10/250 10 250 2.5 7.96 to 54.5
HBW 10/125 10 125 1.25 3.98 to 27.2
HBW 10/100 10 100 1 3.18 to 21.8
HBW 5/750 5 750 30 95.5 to 650
HBW 5/250 5 250 10 31.8 to 218
HBW 5/125 5 125 5 15.9 to 109
HBW 5/62.5 5 62 2.5 7.96 to 54.5
HBW 5/31.25 5 31.25 1.25 3.98 to 27.2
HBW 5/25 5 25 1 3.18 to 21.8
HBW 2.5/187.5 2.5 188 30 95.5 to 650
HBW 2.5/62.5 2.5 62 10 31.8 to 218
HBW 2.5/31.25 2.5 31 5 15.9 to 109
HBW 2.5/15.625 2.5 16 2.5 7.96 to 54.5
HBW 2.5/7.8125 2.5 7.8125 1.25 3.98 to 27.2
HBW 2.5/6.25 2.5 6 1 3.18 to 21.8
HBW 1/30 1 30 30 95.5 to 650
HBW 1/10 1 10 10 31.8 to 218
HBW 1/5 1 5 5 15.9 to 109
HBW 1/2.5 1 3 2.5 7.96 to 54.5
HBW 1/1.25 1 1.25 1.25 3.98 to 27.2
HBW 1/1 1 1 1 3.18 to 21.8

REFERENCES:

 ISO 6506-1:2014(E) document.

 ASTM E10-15 and ASTM E10-01 document.

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 Title: To determine hardness of a mild steel and high carbon
Exp. No. 2
steel specimen.
Name of Student:

Roll No.:

Date of Experiment:

Date of Submission:

Signature of Teacher SEAL

with Date of Check

Jorhat Engineering College (13) Material Science Lab

 Experiment No. 3

TITLE: Charpy Pendulum Impact Test.

OBJECTIVE:
To determine impact resistance of an assigned specimen in
the form of a notched bar flexure specimen.

APPARATUS REQUIRED:
 Charpy Pendulum Impact test apparatus (Fig. 3.3)

 V-notched bar. (Fig. 3.2)

THEORY:
A notched bar of definite geometry is broken with the single blow from a
swinging pendulum, dropped from a definite height, and the energy absorbed during the
impact is determined. This absorbed energy during the impact is the impact resistance
of the test piece.

The pendulum of mass 𝑚 𝑘𝑔 is raise to a definite height ℎ and then dropped

freely to swing. The striker edge of the pendulum then hits the test piece at a point just
opposite to the notch, breaks it into two pieces, and swings freely to a height ℎ on the
other side. Energy absorbed during the process is the energy used in breaking the
specimen, and that is equal to 𝑚𝑔(ℎ − ℎ ).

PROCEDURE:
1. Place the specimen on the supports and against the anvils as shown in Fig. 3.1. The
notch should be on the side of the specimen away from the striking edge of the
pendulum and directly in line with it.

2. Raise the pendulum to a certain height ℎ and hold it. Record the first dial reading and
find the initial Potential Energy (𝑃𝐸 = 𝑚𝑔ℎ) stored in the pendulum at this height.
The dial reading directly gives the value of 𝑚ℎ. Multiply this value with 𝑔 to get the
value of 𝑃𝐸.

3. Then release the pendulum to fall freely and rapture the specimen. The pendulum will
then rise to a maximum height ℎ on the other side. Record the second dial reading
and find the final 𝑃𝐸 for the pendulum at that height.

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 4. Now calculate the energy lost during the impact. This is the required impact resistance
of the test specimen.

OBSERVATION:

Initial PE of Final PE of Energy absorbed

the Pendulum the Pendulum during impact Average
Specimen
at height at height (𝑿𝟏 − 𝑿𝟐 ) (Joule)
𝒉𝟏 = 𝑿𝟏 Joule 𝒉𝟐 = 𝑿𝟐 Joule (Joule)

Mild Steel Bar

RESULT:
The impact resistance of the given test specimen is found to be : ……………..… 𝑲𝑽𝟐

Here, 𝐾𝑉 is used to denote the impact resistance of the test piece. Letter 𝑽 is used for
V-notch and 𝑼 for U-notch; and the subscript 2 in 𝐾𝑉 denotes the striker radius in
𝑚𝑚.

Figure 3.1: Placement of the test piece on apparatus supports

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 Figure 3.2: Geometry of the V-notched bar [as per ISO 148-1:2009(E)]

Table 3.1: Tolerances on specified test piece dimensions [as per ISO 148-1:2009(E)]
Symbol Nominal Machining
Designation
used Dimension Tolerance

Length 𝑙 55 𝑚𝑚 ±0.60 𝑚𝑚
Height ℎ 10 𝑚𝑚 ±0.075 𝑚𝑚

Width
𝑤 10 𝑚𝑚 ±0.11 𝑚𝑚
(for standard test piece)

Angle of notch 𝜃 45° ±2°

Height below notch

𝑥 8 𝑚𝑚 ±0.075 𝑚𝑚
(height of test piece minus depth of notch)

Radius of curvature at base of notch 𝑅 0.25 𝑚𝑚 ±0.025 𝑚𝑚

Depth of notch 𝑧 2 𝑚𝑚 −

Distance of plane of symmetry of notch from ends of

𝑦 27.5 𝑚𝑚 ±0.42 𝑚𝑚
test piece
Angle between adjacent longitudinal faces of test
piece 𝛼 90° ±2°

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 Figure 3.3: Parts of the Charpy Impact Test apparatus
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REFERENCE:
 ISO 148-1:2009(E) document.

Exp. No. 3 Title: Charpy Pendulum Impact Test.

Name of Student:

Roll No.:

Date of Experiment:

Date of Submission:

Signature of Teacher SEAL

with Date of Check
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 Experiment No. 4

TITLE: Tension Test.

OBJECTIVE:
To determine the following parameters of
the given specimen:

1. Elongation
2. Maximum stress
3. Breaking stress
4. % age of reduction of Area

THEORY:
Refer to the following Stress – Strain diagram for ductile material.

APPARATUS:
1. Universal Testing Machine

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SPECIMEN:
Draw the dimensional sketch of the specimen.

OBSERVATION:
Length of
Length of the
Average Neck Breaking
the specimen Maximum
Sl. Diameter Diameter Diameter Load
specimen after Load (𝑷𝟏 )
No. (𝒎𝒎) (𝑫) (𝒅) (𝑷𝟐 )
(𝑳𝟏 ) elongation (𝒌𝑵)
(𝒎𝒎) (𝒎𝒎) (𝒌𝑵)
(𝒎𝒎) (𝑳𝟐 )
(𝒎𝒎)

𝐷 =

𝐷 =

𝐷 =

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RESULTS:
1. Elongation = 𝐿 − 𝐿 =

2. Maximum stress 𝑃 ⁄𝐷 =

3. Breaking stress = 𝑃 ⁄𝐷 =

Therefore, % Reduction of Area = (𝜋⁄4)(𝐷 − 𝑑 ) =

Exp. No. 6 Title: Tension Test.

Name of Student:

Roll No.:

Date of Experiment:

Date of Submission:

Signature of Teacher SEAL

with Date of Check

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