NEW TECHNOLOGY!!! Case Depth Results less than 1 Minutes with NO Sample Prep!

King Tester_Brinell Tester_Rockwell Tester_Metal Hardness Testing_CaseRock
King Tester_Brinell Tester_Rockwell Tester_Metal Hardness Testing_CaseRock

Case depth can now be measured quickly and accurately in less than a minute without time-consuming sample preparation using continuous-acquisition testing.

 

Case hardness matters in so many applications, from aerospace to automotive to machine tools and military to name a few. However, measurement of case depth is limited by current testing because testers used today require a time-consuming process of cutting, mounting and sample polishing to be able to perform sequential microhardness tests that describe the case depth of the sample. The elapsed time from start to finish is measured in hours.

These limitations are eliminated by the CaseRock® HTD (tester), which offers significant innovations in case-depth testing measurement. It uses a Rockwell-type approach with continuous-acquisition testing to determine the hardness of the metal throughout the case and provide effective case-depth results in under a minute. The tester eliminates the need for cutting, mounting, polishing and sequential tests. It uses full-load testing with force up to 4,000 kg (8,820 pounds). The benefits of continuous-acquisition testing are evident in the time savings and opportunities for rapid process-control feedback.

The benefits of CaseRock HTD’s continuous-acquisition testing include:

  • Faster results
  • Reduce sample preparation time by eliminating cutting, mounting and polishing
  • Reduce testing time from hours to minutes
  • Improve process control with real-time information

 

How it Works


Fig. 4. Hardness and force data from continuous-acquisition testing

The CaseRock HTD is designed to test the effective case depth of surface-hardened layers with only one indentation and without damaging the integrity of the part. The tester uses a conical indenter of 120 degrees and a tip radius of 0.2 mm, a penetrator shroud to reference the penetration depth and a transducer for measuring the penetrator displacement with respect to the shroud.

The tester applies a constantly increasing load up to 4,000 kg and acquires hardness data. The data is displayed as specific hardness at multiple levels of force (Fig. 4). A proprietary, patented algorithm processes the information from force and depth obtained to deliver the value of the effective case depth and the schematic curve (Fig. 5) of the hardened surface layer. The absolute hardness values are then converted into Vickers hardness numbers according to standard conversion tables. 

 

Test Results


Fig. 5. Case-depth results and analysis

The tester uses the information acquired from the continuous application of the load to generate a load-penetration curve (not a single value) from each single test. Figure 4 provides an example of the test results. The vertical axis is hardness, and the horizontal axis is the load applied. The downward curve in this example illustrates that hardness declines as force (Kgf) is applied.

The data acquired is then used in the algorithm to calculate the effective case depth (Fig. 5). In this instance, the effective case depth is 2.95 mm (Vickers 513 corresponds to a hardness of Rockwell C 50). The results of these tests are referenceable to all applicable standards.

p>Figure 6 shows a different example of test results, this time on the computer screen. In this example, the case depth is 0.37 mm.

 

Implications

This type of testing allows users to achieve test results and analysis much faster with savings of manpower, time and money. The process-control opportunities are profound because information is available so much faster than with previous testing machines. Users can choose to tighten their process controls and increase their quality sampling.

The test results reduce uncertainty and provide for improved supplier/customer communication while reducing waste and improving throughput. Cost savings are achieved through both reduction in sample preparation and testing time as well as reduction in product rejects.

With increasing emphasis in all industries on quality, tightening of standards and process control, the CaseRock HTD is a logical value-added measurement and analysis tool for commercial and captive heat treaters. It provides an opportunity to demonstrate case-depth consistency and decrease uncertainty while reducing the cost and time involved in case-depth measurement.

Authored by Jim Knight for Industrial Heating Magazine.

 


So you think your sac is leaking
And there is fluid on your ball 
Don’t do anything drastic 
Just remember who to call
When your ram gets too extended
Yea, its maybe not your fault
Your pump handle just sheared off
We can probably fix it 
Even if your screws are bending
It’s time to have yours services
And to use the one we’re sending

–  Bill Daley, King Tester Renaissance Man 


King Tester, A Poem

Posted on 23Aug

 

Don’t hurt your back
Leave the steel on the rack
Just slide it an inch
And let the King take a pinch
You’ll work smarter, not harder
And beat the rest to the door
You can test on a bench
Or right off the floor
Just clamp on the tester
In any direction
The mark that it makes
Will help your selection
Next check the wall chart
And then you will know
If the steel that you have
Is ready to go
So get the right tool for the job
One you know you can trust
You’ll be finished in minutes
And your back, you won’t bust
King: We got your back

– Bill Daley, King Tester Renaissance Man


KingScopeKingScope 100KingScan IVe
Brinell Hardness Testing Reader: Manual or Automatic

Posted on 31Jul

Reading Brinell Impressions

The first thing to consider when choosing a Brinell reading device is: how accurate a Brinell Reading you need and then consider if you want to read the impression manually or automatically?   Is a reading to the nearest tenth of a mm sufficient or do you need greater accuracy in your readings?

Manual reading is easy and straightforward.  You look through the lenses, focus the optics, position in the lens on the impression and read the result in mm.  The result in mm is then converted to HBW (Hardness Brinell) by looking up the mm measurement and the table provides the hardness.

Automatic reading uses a digital camera which shoot the image and does the calculations for you and tells you the diameter of the impression in mm and also the HBW (Hardness Brinell) number.  Automatic readers reduce the opportunity for human error and provide greater precision in the readings with readings measured to the .01mm. They also eliminate the need for the Brinell table lookup because the automatic reader does the calculation for you and provides you the Brinell hardness level.

Manual is easier and less expensive up front.  However, the other consideration is the potential for human error and the reproduce-ability of results.  The human eye and interpretation play a much larger role in handheld results than in automatic results and the time savings may justify the purchase of an automated reading device.  Additional considerations come from the ASTM E10 specification which defines two types of devices; type A and type B. 

ASTM E10 Considerations

KingScope Brinell Hardness Testing
KingScope
kingscope100 Brinell Hardness Testing
KingScope 100

 

Automatic Microscope for Brinell Hardness Testing
KingScan

Measurement Device

The measurement device used for the measurement of the diameter of Brinell indentations may be an integral part of the hardness machine or a separate stand-alone instrument. The allowable measurement devices are classified into two types.

Type A 

The Type A device includes microscopes having movable measuring lines with some type of indicator or computerized measuring system, or an image analysis system.

Type B 

The Type B device is a hand-held microscope with fixed measuring lines. Type B devices shall not be used for measuring indentations made with 2.5 mm and 1 mm ball indenters.

Note the limitations on the use of handheld scopes as it pertains to smaller indentations.

King Tester Readers 

King offers both handheld and automatic reading systems.  We have two Type A devices; the KingScan which is computerized and fully automatic and the KingScope 100 which is handheld.  For Type B handheld we offer the KingScope which has been and continues to be the industry preference for a handheld reader.


Back to Top >