Hardness Evaluation of Carbon Steel Using the Rockwell Test

Rhena Pamela A. De Guzman

1
School of Mechanical, Manufacturing, and Energy Engineering, Mapúa University, Manila
2
Other affiliations

Abstract

This study examines the hardness of mild and high-carbon steel using the Rockwell Hardness Test, which
measures material resistance to indentation. The study addresses the significance of choosing the correct
Rockwell scale and the effect of material composition and heat treatment on hardness. A steel ball
indenter was used for mild steel, yielding an HRB reading of 92, while a diamond cone indenter was used
for high-carbon steel, producing an HRC reading of 25. The results confirmed that high-carbon steel is
harder than mild steel and emphasized the importance of proper testing procedures in engineering
applications.

Keywords: Rockwell Hardness, Indentation, Steel, Load, Material Testing

1. Introduction

Hardness is a fundamental mechanical property that determines a material’s ability to

resist deformation, indentation, or scratching. This property is crucial in engineering
applications for material selection, quality control, and research and development of
structural components, machine parts, and other industrial applications. Various
methods are available to measure hardness, including the Brinell, Rockwell, Vickers,
Mohs, and Knoop Hardness Tests [1].

The Rockwell Hardness Test (RHT) is widely used due to its efficiency and accuracy in
determining material hardness by measuring the depth of indentation caused by an
applied load. This study aims to understand the working principle and significance of
the Rockwell Hardness Test. Also, to determine the Rockwell Hardness Number (RHN)
of mild and high-carbon steel and to observe and differentiate the effects of two
indenters the steel ball and diamond cone. And lastly to identify the advantages and
limitations of the test. Explore the industrial applications of the Rockwell Hardness Test.

A brief review of hardness testing methods highlights the importance of the Rockwell
test in industrial applications. Unlike the Brinell hardness test, which measures the
diameter of an indentation, the Rockwell method provides a direct reading based on
penetration depth, making it suitable for production environments where rapid testing
is required.
This study investigates the accuracy of Rockwell Hardness measurements and the
limitations affecting results, such as machine calibration, surface roughness, and
operator errors. The scope of this study is limited to testing a selected range of metals
using different Rockwell scales. Factors such as surface preparation and measurement
accuracy will also be considered. However, this study does not explore the
microhardness testing techniques or the effects of extreme environmental conditions on
test results.

2. Methodology

The Rockwell Hardness Test was conducted following a standardized procedure to

ensure the accuracy, consistency, and reliability of the results. The test was performed
on mild and high-carbon steel specimens, which were selected based on their flat and
smooth surfaces to avoid any inaccuracies caused by surface irregularities. The
methodology includes specimen preparation, scale selection, load application, and
hardness measurement.

2.1 Preparation of Specimen

The specimens were cleaned to remove rust and irregularities. The specimens'
thickness was also checked to ensure that it was sufficient to withstand the
applied load without undergoing significant deformation. This step is crucial
because excessively thin specimens could deform under the load, leading to
inaccurate results. To conduct the Rockwell Hardness Test we used Mild and
High-Carbon Steel specimens.

Figure 2.1. Preparation of Specimen

2.2. Setting Up the Machine

The test was carried out using a calibrated Rockwell Hardness Testing Machine,
which was carefully maintained to ensure its proper function. The machine’s
accuracy is vital for obtaining precise measurements, so it was verified that the
calibration was within the recommended tolerances before starting the test.

The indenter choice was based on the material being tested: a steel ball indenter
was used for the mild steel specimens (HRB scale), while a diamond cone
indenter was selected for the high-carbon steel specimens (HRC scale). The steel
ball indenter is suitable for testing softer materials, while the diamond cone
indenter is ideal for harder materials like high-carbon steel, as it creates a more
defined and consistent indentation.

Figure 2.2.1. Rockwell Hardness Scale

Once the specimen was properly prepared, it was placed on the anvil of the
Rockwell testing machine. The anvil was adjusted to ensure that the specimen
was positioned correctly and securely, preventing any shifting during the test
that could affect the results. The height of the specimen was adjusted so that the
indenter made proper contact with the material, ensuring an accurate reading of
the indentation depth. After positioning, the dial indicator on the machine was
reset to zero to establish a baseline for the test.
 Figure 2.2.2. 1/16-inch Steel Ball Indenter

Figure 2.2.3 Diamond Cone Indenter

2.3. Conducting the Test

The procedure began by applying a minor load to the specimen. This initial load,
typically around 10 kg, was used to eliminate surface irregularities and establish
a consistent starting point for the test. It helped flatten any microscopic
imperfections on the specimen's surface, ensuring that only the true hardness of
the material was measured. Once this was completed, the major load—100 kg for
mild steel and 150 kg for high-carbon steel—was applied, which was sufficient to
cause an indentation in the material.
 Figure 2.3.1. Rockwell Hardness Test (HRB)

Figure 2.3.2. Rockwell Hardness Test (HRC)

2.4. Recording and Analyzing Results

The Rockwell Hardness Test measures the depth of the indentation caused by the
major load. The greater the depth, the softer the material, and the smaller the
depth, the harder the material. As the indenter penetrated the material, the
testing machine measured this depth and displayed it on the dial indicator. The
corresponding Rockwell Hardness Number (RHN) was read directly from the
machine's dial. For the HRB scale (mild steel), the measurement was taken under
a 100 kg load, and for the HRC scale (high-carbon steel), the 150 kg load was
used. Each test was repeated three times to ensure consistency in the results, with
each measurement providing an average value for better accuracy.
 Figure 2.4. Final Result (After Three Trials)

Throughout the testing process, special attention was given to maintaining the
integrity of the testing environment. The machine's calibration was rechecked
between each test to minimize the possibility of drift in the measurements. The
specimens were handled carefully to avoid any contamination or damage
between tests. Additionally, the indentation depth was closely monitored to
ensure that the indenter did not penetrate too deep, which could distort the
results and affect the precision of the hardness readings.
3. Results & Discussion

Table 3.1 Data Result from the Experiment

The Rockwell Hardness Test shows for mild steel, the test yielded a Rockwell hardness
value of HRB 92 with an indentation depth of 0.016 mm. This indicates that mild steel
has moderate hardness, which aligns with its known mechanical properties [1]. It is
commonly used in applications where good machinability and ductility are required,
such as in structural components and automotive parts [2].
For high-carbon steel, the test resulted in an HRC value of 25 with an indentation depth
of 0.25 mm. This hardness value classifies the material as relatively soft for high-carbon
steel, suggesting that it has not undergone heat treatment. Typically, hardened
high-carbon steels exhibit HRC values above 50 [3]. The larger indentation depth
indicates a greater degree of deformation under load, which is characteristic of
untreated or annealed high-carbon steel [4].

The test results confirmed that high-carbon steel is significantly harder than mild steel.
However, the use of different indenters and loads means that the hardness values
obtained cannot be directly compared. The HRB scale, which uses a steel ball, is more
suitable for softer materials, while the HRC scale, using a diamond cone, is intended for
harder metals [5].

Figure 3.1. Rockwell Hardness Scale

For mild steel, the HRB 92 value falls within the expected range for cold-rolled or
work-hardened steels. This level of hardness suggests moderate strength, making it
ideal for structural and manufacturing applications. If further hardness enhancement is
needed, processes such as cold working or heat treatment could be employed [1].
The HRC 25 value for high-carbon steel indicates that the material has not been
significantly hardened. In practice, high-carbon steel is often heat-treated to increase its
hardness and wear resistance, making it suitable for tools and high-stress applications.
If subjected to quenching and tempering, its hardness could increase significantly,
reaching values above HRC 50 [3].

Several factors could influence the accuracy of these measurements. Machine calibration
plays a crucial role, as deviations can lead to inconsistent readings [4]. Surface
roughness also affects the indentation depth, making proper specimen preparation
essential [2]. Operator errors, such as misalignment or incorrect readings, can further
introduce variability in results. Finally, material properties, including internal grain
structure and impurities, can impact the hardness values recorded [3].

The findings align with theoretical expectations, emphasizing the importance of

selecting the correct Rockwell scale and indenter for different materials. These results
also highlight the significance of heat treatment in improving the hardness and
mechanical properties of steel materials.

4. Conclusion

This study successfully determined the hardness of a material using the Rockwell
hardness test. The results demonstrated the effectiveness of the method in evaluating
the hardness of various materials based on indentation depth. Compared to other
hardness testing techniques, the Rockwell method provided quick and reliable results
suitable for industrial applications.

The findings confirmed that different indenters and load applications significantly
impact the hardness values. The study's limitations include potential measurement
errors due to surface irregularities and material inconsistencies. Future research could
explore the influence of environmental factors such as temperature and humidity on
Rockwell hardness readings, as well as a comparative analysis with other hardness
testing methods like Vickers or Knoop. This study underscores the importance of
accurate hardness testing in ensuring material quality and performance in engineering
applications.
5. References

[1] Smith, W.F., & Hashemi, J. (2019). Foundations of Materials Science and Engineering.
McGraw-Hill Education.

[2] ASTM E18-23, "Standard Test Methods for Rockwell Hardness and Rockwell
Superficial Hardness of Metallic Materials," ASTM International, 2023.

[3] B. R. Bhadeshia, "The heat treatment of high-carbon steel," Materials Science and
Technology, vol. 7, no. 12, pp. 1153-1161, Dec. 1991.

[4] Dieter, G.E. (2018). Mechanical Metallurgy. McGraw-Hill Education.

[5] Davis, J.R. (2002). Surface Hardening of Steels: Understanding the Basics. ASM
International.
Grading Sheet
Name:​De Guzman Rhena Pamela A.​ ​ ​ ​ Total Score:
Experiment 3: Hardness Test

You will be graded for the lab report using this rubric. Print and use it as the
front page of your submission.

Criterion Maximum Score Score

Correctness of content 20

Completeness and conciseness of the report 20

Clarity and coherence of discussion 20

Thoroughness of discussion 20

Adherence to format 10

Preliminary data sheet 10

TOTAL 100