Practical No.

03:
Hardness Testing on Brinell Hardness Tester of given Sample Material.

I. Practical Significance
The hardness tests can provide information from which many important mechanical
properties can be derived. Since the hardness test can be conducted easily and quickly, they
are very popular in industry. These are used to control processing and for inspection and
acceptance of materials and components. The practical significance of the Brinell Hardness
Test method lies in its ability to provide critical information about material properties,
ensuring quality, reliability, and cost-efficiency in various applications across multiple
industries.
II. Industry/Employer Expected Outcome (s)
This practical is expected to develop the following skills for the industry/Employer.
1. State Operation of Hardness Testing Equipment.
2. Applying hardness testing in evaluating components that must withstand high stress and
wear, ensuring safety and reliability in critical applications.
3. Developing expertise in testing metals and alloys, understanding their properties, and
improving material formulations
III. Minimum Theoretical Background with diagram (if required)
The method of hardness testing was introduced by J.A. Brinell in 1900. The Brinell Hardness
Test involves pressing a hard spherical indenter into a material under a specified load and
measuring the resulting indentation. The Brinell Hardness Number (BHN) is calculated
based on the applied load and the indentation diameter. This test is essential for assessing
material properties such as strength and wears resistance and is widely used in quality control
and material selection processes. In this test, a standard hardened steel ball is indented into
the surface of the specimen by a gradually applied load which is maintained on the specimen
for a time (usually 10 or 15 sec). Ball of 10 mm, 5 mm, and 2.5 mm are generally used. The
diameter of the impression or indentation is measured by microscope and the Brinell
hardness number (B.H.N.) is found out by following formula.

Brinell Hardness Number (B.H.N.) = Total load/ surface area of indentation

2𝑃
BHN=
𝜋𝐷(𝐷−√𝐷2 −𝑑 2
Where:
P is the applied load (in kgf).
D is the diameter of the indenter (in mm).
d is the diameter of the indentation (in mm).

and h= depth of indentation = ( D-√𝐷2 − 𝑑 2 )/2

This Brinell Hardness Test is used to determine the hardness number of hard,
moderately hard, and soft material E.g. Brass, Bronze, Aluminum, Gold,
Copper, etc. Very hard material and brittle material cannot be tested by Brinell
hardness tester.

Fig. 3.1 Indentation image

 Fig.3.2 Indentation Parameters
IV. Experimental setup (Model)-

Fig. 3.3 Brinell hardness Tester

 Fig.3.4 Hardness Tester

V. Required Resources /Apparatus/Equipment with specification

S. Name of Suggested Broad Specification Quantit

No Resource y
.
1 Digital Brinell 1) Test loads - 500 to 3000 Kgf. in steps of 2
hardness Tester 250 Kg. 2)Magnification of objective - 14
X 3) Maximum test height - 380 mm. 4)
Least count -0.001 mm. 5) Throat depth -
200 mm.
2 Set of standard Mild steel, Brass, Bronze, Each
specimen Copper, One
Aluminium
VI. Precautions to be Followed
● Ensure the test surface is smooth, clean, and free from scale, rust, or other contaminants
that could affect the indentation.
● The sample should be thick enough to prevent deformation on the opposite side. A general
rule is that the thickness should be at least 10 times the depth of the indentation.
● The surface should be flat to ensure the indenter contacts uniformly across the test area.
● Use the correct indenter size (usually 2.5 mm, 5 mm, or 10 mm diameter) as specified for
the material and the standards being followed
 ● Apply the appropriate load (e.g., 500 kgf to 3000 kgf) based on the material type and
thickness. Incorrect loads can lead to erroneous hardness values.
● Ensure the Brinell hardness tester is properly calibrated before use. Regular calibration
checks are necessary to maintain accuracy.
● Apply the load smoothly and avoid jerks or sudden impacts. Maintain the load for the
standard dwell time (usually 10 to 30 seconds) as specified by the testing standard.
● Conduct the test in a stable environment. Avoid vibrations or temperature fluctuations that
could affect the machine's performance.
● Measure the indentation diameter accurately using a microscope or calibrated optical
system. Measure at least two diameters perpendicular to each other and use the average.
● Ensure the indentation is not too close to the edges of the sample or to other indentations,
which can affect the accuracy of the measurement. The distance from the edge should be
at least 2.5 times the indentation diameter.
● Wear appropriate PPE, such as safety glasses and gloves, to protect against potential
hazards.
● Handle the indenter carefully to avoid damaging its surface, as imperfections can affect the
test results.
VII. Procedure
1. The face of the specimen is lightly grind and rubbed with fine emery paper if required.
2. Ensure the surface of the material is smooth, clean, and free from any scale, rust, or
contaminants.
3. Select the proper test table based on the size and shape of the specimen and place it on
main screw or elevating screw.
4. Verify that the sample thickness is sufficient to avoid deformation on the opposite side,
typically at least 10 times the depth of the intended indentation.
5. Ensure the test surface is flat to ensure uniform contact with the indenter
6. Verify that the Brinell hardness tester is properly calibrated according to the
manufacturer's specifications and industry standards
7. Choose the appropriate indenter size (usually 2.5 mm, 5 mm, or 10 mm diameter) based
on the material and standard requirements.
8. Select the correct load (e.g., 500 kgf, 1500 kgf, or 3000 kgf) according to the type of
material being tested.
9. Check and keep the operating level in horizontal position.
10. Securely place the sample on the anvil or testing platform of the Brinell hardness
tester.
11. Align the sample so that the indenter will contact the test surface perpendicularly.
12. Lower the indenter until it makes initial contact with the sample surface.
13. Gradually apply the selected load without causing shock or vibration. Maintain the
load for the specified dwell time (usually 10 to 30 seconds) to allow for proper
indentation.
14. Carefully remove the load and lift the indenter from the sample, remove the
specimen.
 15. Use a microscope or calibrated optical system to measure the diameter of the
indentation. Measure the diameter in at least two perpendicular directions and record
the average diameter.
16. Find the Brinell hardness number using formula.
17. Perform multiple tests (usually at least three) on different areas of the sample to
ensure the accuracy and repeatability of the results.
18. Ensure the results are consistent and within the acceptable range of variation.
VIII. Observations and calculations -

Room temperature -

Diameter of Brinell
Test Dia. of Applied indentation Average
Hardness
S.N. specimen indenter load Kgf diameter
mm Number
material D mm (F) (d)mm
1 2 3 (BHN)

Sample calculations:

Brinell Hardness Number (B.H.N.) = Total load/ surface area of indentation

2𝑃
BHN=
𝜋𝐷(𝐷−√𝐷2 −𝑑 2
IX. Results
The Brinell hardness number of the given sample is as follows:-
S.N. Test specimen material Brinell Hardness Number (BHN)
1
2
3
4
5

X. Interpretation of Results
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XI. Conclusions and Recommendation
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XII. Practical Related Questions
Note: Below given are few sample questions for reference. Teachers must design more such
questions so as to ensure the achievement of identified CO.
1. State the difference between Hardness & Hardenability.
2. Explain the surface conditions necessary for Brinell hardness testing.
3. Very hard materials cannot be tested in Brinell hardness testing machine. State the reason
4. List the different types of indenters used in hardness testing.
5. Thickness of the test piece must not be less than 8 times the depth of impression. Justify
6. List the materials which cannot be tested by Brinell hardness tester
7. Can cylindrical samples be tested on Brinell hardness tester.
8. State the reason for using ball indenters of different diameter for Brinell hardness testing
9. Can the sample after testing be used for the desired application. Justify
10. Explain the principle behind the Brinell hardness testing method. How does it measure the
hardness of a material.
11. Explain the factors that can affect the accuracy of Brinell hardness test results. How can
these factors be controlled or minimized to ensure reliable measurements.
12. In what situations or applications would you choose to use a Brinell hardness tester instead
of other hardness testing methods? Provide examples to support your answer.
13. Explain the significance of determining the hardness of a material in engineering
applications. Provide examples of situations where knowledge of material hardness is
crucial.