Operating Instructions

Hardness Tester EQUOTIP and EQUTIP 2

Copyright 1978 by Proceq SA, Switzerland 10th edition

820 350 01E ver 05 2006

Standardized according to ASTM A 956-96.

Proceq SA Ringstrasse 2 CH-8603 Schwerzenbach Switzerland

Tel.: +41 (0)43 335 38 00 Fax: +41 (0)43 335 38 12 E-Mail: info@proceq.com Internet: www.proceq.com

Table of Contents
1 1.1 1.2 1.3 2 2.1 2.2 2.3 2.4 3 3.1 3.2 4 4.1 4.2 4.3 5 5.1 5.2 5.3 5.4 6 6.1 6.2 6.3 7 7.1 7.2 7.3 7.4 7.5 7.6 8 9 9.1 9.2 9.3 EQUOTlP/EQUOTlP 2 Electronic Indicating Device EQUOTlP-Units Types of Impact Devices EQUOTlP/EQUOTlP 2-Hardness Tester Measuring Method Examples of Application Measuring Range Technical Data Operating the Instruments Electronic Indicating Device Handling the Impact Devices Perfomance of Hardness Tests Preparations Hardness Test Evaluation Perfomance Check and Maintenance of the Instruments Performance Check Maintenance of the Impact Devices EQUOTIP Standard Test Blocks with PROCEQ-Calibration EQUOTIP Standard Test Blocks with MPA-Certificate Treatment of Samples Preparation of the Surface Supporting the Samples during Testing Samples with Curved Surfaces Conversion with other Hardness Numbers EQUOTIP Conversion-Tables Conversion Deviations Deviations from Conversion Values Setup of Plant-lnternal Conversion Curves Application of Individual Conversions Notation of Hardness Values Fault Diagnosis System Accessories Support Rings Automatic Hardness Tester EQUOmatic 2 Hardness Tester EQUOSTAT 4

11

19

20

23

26

31 32

1 EQUOTlP/EQUOTlP 2
1.1 Electronic Indicating Devices 9 1

2 10 7/8 6 5 4.1 3

>

4.2

1 2

Operating keypad Large LCD display for hardness values and representation of actual measurements 3 Input-socket 3-pole 4.1 Input-socket 2-pole 4.2 Input-socket 6-pole for EQUOSTAT Probe R5 4

5 6 7 8 9 10

Signal output RS 232 Ext. power supply 9 VDC Battery compartement Battery compartement cover Housing upper part Housing lower part

1.2 Units Electronic indicating device Impact device with cable 1.5 m Small support ring Sandard test block Cleaning brush Coupling paste 6 batteries 1.5 V type LR 6 Operating instructions *Optional with MPA certificate

Typ Typ Typ

D x D x D* D x x x

G x G x G* G x x

E x E x E* D x x x

DC x DC x D D x x x

C x C x D D x x x

D+15 x D+15 D D x x x

DL x DL D D x x x

1.3 Types of Impact Devices

DC

D+15

DL

7 1 2 3 4

6a

5 5 6 6a 7

Fig. 2

Loading tube Guide tube Coil with holder Release button

Connection cable 3-pole Large support ring Small support ring Impact body 5

Special Features of Impact Devices D Universal standard unit For the majority of hardness testing assignements Extremely short impact device Otherwise same specifications as for type D Application: - in very confined spaces - in holes, cylinders - internal measurements on assembled machines

DC

D+15 Particularly slim front section Application: - hardness measurements in grooves and on recessed surfaces DL Extremely slim front section Application: - in extremely confined spaces - at the base of grooves Reduced impact energy (approx. 1/4 of that for type D) Application: - on surface hardened components, coatings - min. Iayer thickness of 0.2 mm - on thin walled or impact sensitive components (small indentation) Synthetic diamond test tip (approx. 5000 HV) Application: - for measurements in the extremly high range - cold work tool steel with carbide inclusions - on rolls in the hardness range up to 1200 HV Increased impact energy (approx. 9 times that of type D) Application: - for measurements in the Brinell-range - on heavy castings and forgings - lower demands on measuring surface finish

Schematic Design of the Impact Devices Status at the moment of triggering the impact (impact spring stressed)

Fig. 3

1 2 3 4 5 6 6a 7 8 9 10 11 12

Loading tube* Guide tube Coil with holder Release button Connection cable 3-pole Large support ring Small support ring Impact body Spherical test tip Impact spring Loading spring Catch chuck Material to be tested

*The model DC ist not equipped with a loading tube; it is loaded by means of a separate stick. The devices should not be disassembled; otherwise misadjustements in the spring system and the transmitter will occur.

2 EQUOTlP/EQUOTIP 2 Hardness Tester

The hardness tester is designed for testing metallic materials, the hardness of which ranges from very low to very high values. Hardness testing can be performed directly on-site and in any position. Typical applications for the EQUOTIP instruments are large, heavy workpieces which are difficult to access. It is especially suitable for applications in which static hardness testing is either not feasible or not economical. 7

2.1 Measuring Method The hardness measurement carried out with the EQUOTIP hardness tester is a dynamic method predicated upon the principle of energy measurement; EQUO = Energy-QUOtient. During a hardness test, an impact body, equipped with a spherically shaped tungsten carbide test tip (with impact device E of synthetic diamond), impacts under spring force against the test surface from which it rebounds. Impact and rebound velocities are measured in a contactless manner at the precise moment, when the spherically test tip is located approx. 1 mm from the test surface. This is accomplished by a permanent magnet built into the impact body which, during the test impact, passes through a coil. During the forward and rebound movement, electrical voltages are induced which are proportional to the velocities. The measurement values derived from the impact and rebound velocities are processed into the hardness number L by the indicating device.

2.2 Examples of Application - Hardness tests on installed machines or steel-structures; e.g. on heavy and large workpieces or on permanently installed system parts. - Rapid testing of multiple measuring areas for examination of hardness variations over larger regions. - Control measurement for the rapid determination of a specific thermal treatment result; e.g. annealed or quenched and tempered conditions. - Testing of workpieces for which the indentation made by the hardness test must be as small as possible and may not leave sharp edges; e.g. on rolls or grinded surfaces of machine parts. - Automatic hardness tests of mass - produced parts during manufacturing operation.

2.3 Measuring Range The impact device D is the basic unit in the EQUOTIP measuring system. Compared to the other impact devices, the most universal applicability and the largest number of tables for converting to hardness of other measuring systems are available for this type.

Impact Device
Group of material Hardness testmethod

D/DC

D+15

DL

1 Steel and cast steel Vickers Brinell HV HB !1 !2 !3 Rockwell HRC HRB HRA Shore 2 Cold work tool steel Vickers Rockwell 3 Stainless steel and hightemperature resistant steel Vickers Brinell Rockwell HV HB HRC HRB 4 Cast iron, lamellar graphite GG Brinell Vickers Rockwell 5 Cast iron, nodular graphite GGG Brinell Vickers Rockwell 6 Cast aluminium alloys Brinell Rockwell 6.1 Alu-AN 40 Brinell 7 Brass (copper-zinc alloys) Brinell Rockwell copper-tin alloys) Brinell 9 Wrought copper alloys Brinell HB 45- 315 HB 60- 290 HB HRB 40-173 14- 95 HB 31- 176 HB HRB 19-164 24- 85 21- 167 2385 19-168 24- 86 23176 HB HV HRC 95-687 96-724 21- 61 127-364 HB HV HRC 90-664 90-698 21- 59 92-326 85-802 85-655 20- 62 47-102 87881949861 668 64 102 HV HRC 80-900 21- 67 80-937 20- 68 80-905 21- 67 98- 942 2067 82-1009 2370 HS 30-100 31- 99 31- 97 30- 102 81-955 81-654 81-952 81-643 80-950 81-646 80-1012 81- 694 90-646 84-1211 83- 686

Tensile strength N/mm2 271-2193 271-2193 271-2193 271-2193 271-2193 271-2193 619-1477 619-1477 619-1477 619-1477 619-1477 619-1477 451- 846 451- 846 451- 846 451- 846 451- 846 451- 846 20- 68 38-100 19- 68 21- 68 37-100 2070 48-100 6188 30- 103 2072

8 Bronze (copper-aluminium/

2.4 Technical Data Measuring Accuracy a) Measuring accuracy of EQUOTIP when using the hardness value L as the direct hardness number: - average measurement deviation of the L-value throughout the entire measuring range: 4L relative to L = 800 0.5 % b) When converting the hardness value L into other hardness numbers: - mean conversion deviation when converting into static indentation methods (HB, HV or HRC), depending on measuring range and method: 3% to 15% - mean conversion deviation when converting into Shore hardness, depending on measuring range: 1.5% to 4.5% Indicating Device Battery set Operating time of battery set at 20 C Admissible operating temperature Input-sockets impact devices (for EQUOTIP/EQUOTIP 2-indicating device) Input-socket, EQUOSTAT Sonde R5 (for EQUOTIP 2-indicating device) Input for external power supply Data-output Data-format Dimensions Weight
Technical Data of Impact Devices

6 single batt.1.5 V LR6 approx. 65 hours 0 C to + 50 C 2-pole / 3-pole 6-pole 9 V DC 0.2 A RS 232 / DB 9p 9600 baud, no parity 8 data-bits,1 stop-bit 175 x 180 x 80 mm 750 g batteries incl.

type

D/DC 940 HV

D+15 940 HV

DL 950 HV

C 1000 HV

G 650 HB 90 20 5 30 250

E 1200 HV 11 5.5 3 20 155 synth. diamond

Max. hardness of sample Impact energy Nmm Mass of impact body g Dia. test tip mm Dia. impact device mm Length impact device mm Material of test tip Admissible operating temperature

11 11 11 3 5.5 7.8 7.3 3.0 3 3 2,8 3 20 20 20 20 150/85 165 202 141 - Tungsten carbide approx.1500 HV -20 C bis + 65 C (temporarily max.120 C)

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3 Operating the Instruments

3.1 Electronic Indicating Device The indicating device represents a highly userfriendly P-controlled measurement acquisition system characterized by the following benefits: - digital display and graphic recording of the measured L-values - calculation of mean value, standard deviation and range - instant acquisition of limit values - conversion into other hardness numbers - data storage with output facility via RS 232 - multi-language facility - mains-independent Display Operating keypad

Fig. 4 Cursor control On / Off button clear last impact selection of different input possibilities starts preselected line at MENU level ends MENU input or terminates measuring series upwards

to the left downwards

to the right

11

Connecting the Instruments EQUOTIP EQUOTIP 2 Fig. 5

1 Connection external battery or power supply 9 V DC 0.2 A 2 Connection for external Data-transmission Interface RS 232 3 Input-socket, EQUOTIP: 2-pole

4 Input-socket, EQUOTIP 2: 6-pole for EQUOSTAT Probe R5 5 Input-socket, EQUOTIP/EQUOTIP 2: 3-pole*

*The indicating device has an recognition for devices with 3-pole plug. Note red marks on plug and socket!

Putting Instrument into Service Connect impact device or probe R5. Press the ON key. The serial No. of the unit and the installed software - version appear briefly on the display. If 2-pole impact devices are used, a manual selection of the type of impact device will appear before the standard selection (Fig. 7) is displayed. Display of Standard Selections
Batt. still 24 Hrs. Device = D Impact Direction = " Conversion HV 1: Steel/Cast Steel

Confirm by START Select by MENU

Fig. 6 Test o.k.: Automatic self-test of the indicating device o.k.

Fig. 7 Preselected parameters: - Impact device type D - Inpact direction downwards - Conversion into HV/1 (1: Steel and cast steel)

Other settings are to be made after pressing the MENU key. 12

Check displayed parameters and confirm with START before measuring values. Display after confirmation with START The indicating device is ready to operate.

Actual value L max Limit values L min Minimum value Maximal value Range Standard Deviation only by n " 5 Mean value

Measure Series No. Fig. 8 Conversion to Vickers HV (Steel) Average after 5 impacts Impact direction downwards Impact device type D

Display after 2x5 measurements

L max Limit values L min

Actual value Minimum value Maximal value Range Standard Deviation only by n " 5 Mean value Converted HV-value* Converted LE-value Impact No. Measure Series No.

Fig. 9

*The converted value can be scrolled by pressing " #. Individual Conversion to Vickers HV (see Sect. 7.5)

Parameter changes can be made by selecting MENU. 13

Preselections MENU

Selection of Date/Time

Fig. 10

Fig. 11

Preselected settings remain stored after the unit is switched off and are displayed on switching once again. Where several settings are being made, the next selection is to be made with MENU.

Selection of Impact Direction

Selection of Mean Value

Fig. 12 The displayed values are automatically corrected with preselection of impact directions other than vertical downwards. 14

Fig. 13 With preselection (n = 0), the measuring series has to be terminated by END.

Selection of Measure Series No.

Selection of Conversion

Fig. 14 The measure series No. can be preselected. lt is automatically incremented after each measuring serie. Selection of Display Range

Fig. 15 0: Conversion not activated LE: Conversion LD # LE LDL: Conversion LD # LDL

Selection of Limit Values

Fig. 16 Conversion in other scales for different groups of material. If the selection starts with the additional setting from Fig. 15, both conversion are displayed.

Fig. 17 The display range is: minimal 100 L maximal 950 L adjustable with increment 50 L

15

Selection of Sprache/Language

Selection of data Output

Fig. 18 The limit values must be within the display range. 0: Limit values not activated. Selection of data Output

Fig. 19 Select between menu languages.

Locking the Settings

Fig. 20 Capacity of memory: approx. 5000 values.

Fig. 21 Save Off: All menu options are accessible. Save On: All menu options exept Data output and Save are blocked. The instrument is saved from unintentional changes of the settings.

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$ Memory transfer with software EQUOLINK 2 The EQUOLINK 2 software is a program for transferring the memorised data from the indicating device to an IBM- or compatible personal computer (on WlNDOWS-level). Following items are required: - EQUOTIP indicating device - IBM-PC or compatible PC (W95/W98/NT4.0/W2000/XP) - Original EQUOLlNK-cable to RS 232 from serial No. 714-0001 to serial No. 898-2080 - Original transfer cable from serial No. 918-0001 - EQUOLINK 2-software disk Procedure for installation: - Go to operating level Program Manager at computer - Insert EQUOLINK 2-disk in disk drive A - Information to the program by A:\ lnstall.TXT
- Start program EQUOLINK 2 by A:\ Setup The program EQUOLINK 2 contains all further information on data transfer and requests the next step via a dialog. Remark: The memory at EQUOTIP indicating device contains approx. 5000 values. With memory fullfilled, previously stored data are overwritten. $ Clear Memory Memory is cleared by additional confirmation with START. $ Display Memory - Measured Series No., type of impact device, impact direction and type of preselected conversion. - Display of measured values consequently to the measurements. $ EQUOlink 2 - Enter the key code and press key END (Fig. 22 and Fig. 23). - The key code is depending of the SN No. of the electronic device.

Fig. 22

Fig. 23 17

3.2 Handling the Impact Devices

Fig. 24 Carrying out the charging Depress charging tube until contact is felt, then allow it to slowly return to the starting position. The device is now ready for carrying out the hardness test.

Fig. 25 Apply Impact Device Place impact device on test surface. The hand holding the device rests on the workpiece. Fig. 26 Triggering the Test Impact Trigger the impact by exerting light pressure on the release button. The device must be pressed exactly perpendicular to the test surface by means of the coil holder, i.e. the support ring must be flush against the surface of the workpiece. Fig. 27 Handling of Impact Device DC Place loading stick adjacent to test area. Plunge face of impact device (coil side) over stick and press down until it reaches the stop position. The device is now ready for operation and the subsequent procedures are identical to those described in Figs. 25/26. 18

4 Performance of Hardness Tests

4.1 Preparations a) Prepare surface of the workpiece according to the procedures outlined in Sect. 6.1 b) Observe the recommendations in Sect. 6.2 concerning supporting of the samples. c) Carry out the performance check discussed in Sect. 5.1 4.2 Hardness Tests a) Preselection at indicating device according to Sect. 3.1. b) Operate the impact device according to Sect. 3.2 c) Number of impacts per measuring area - Each measuring area should be tested by at least 3 to 5 impacts. - Do not impact the same point more than once. - Display on the indicating unit of mean value L, standard deviation s and range R. - If the range within the same measuring area exceeds R " 30 L, check whether the surface of the sample has been adequately ground or whether the sample yields or flexes during the test impact. d) Minimum spaces of the impact points

Impact Device Types D/DC, D+15, DL, E G C Fig. 28

s mm 3 4 2

a in mm 1/8 5 1/6 8 1/12 4

in
1/5 1/3 1/6

4.3 Evaluation a) Impact Direction - The impact device is calibrated for vertical impact direction. (Impact from top to bottom). - The impact direction is preselectable at the indicating device. - The indicating unit corrects the influence of different impact directions automatically. b) Hardness value L as direct hardness measurement - With regard to a certain group of materials, the hardness value L constitutes a direct hardness measure and can be used as such (see Sect. 2.4). - This allows optimum utilization of the high accuracy of the EQUOTIPmethod. 19

c) Conversion to hardness values of other methods - With a certain loss of accuracy (conversion deviation), the hardness value L can be converted into equivalent hardness values of other measuring methods such as Brinell, Vickers, Rockwell C, Shore etc. - These conversions are selectable at the indicating device. - At the end of each test-cycle the calculated mean value L is indicated as well as the hardness value of the other hardness method selected (scrolling possible). - By preselection on the indicating device the different methods and group of materials are to consider.

5 Performance Check and Maintenance of the Instruments

5.1 Performance Check The Performance Check controls the mechanical and electronic functions of the impact device and the indicating unit. It is accomplished by measuring the hardness value L of the standard test block applicable to the particular type of impact device (see Sect. 5.3/5.4). Carrying out the Performance Check: - Clean an impact device according to Sect. 5.2 - Perform impact tests on standard test block. As a rule, 3 to 5 impacts evenly distributed on the test area, are sufficient. The distance between impact location and outer edge of the standard test block should be according to Fig. 28. - Read off mean value L and compare with reference L-value. The instrument operates properly if the indicated mean L-value x falls within the reference range and the range R does not exceed 16 L-units. If the deviation of the mean value from the reference L-value exceeds 12 Lunits, the instrument should no longer be used and must be returned to the manufacturer for servicing. With smaller deviations, the L-value can be corrected, until the next service, according to the following formula: Lk Lk Lk L L ref L actual = = = = = = L. L example L k= 582 . 764 = 574 L L. ref Example: L k = 582 . 774 L actual corrected mean value 574 L read-off mean value during testing a sample 582 L reference value from standard test block 764 L actual value when carrying out measurement 774 L operation at the test block

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Frequency of Conducting Operational Tests a) Test instrument is used continuously: - at least once per day - the latest after 1000 impacts b) Test instrument is used periodically: - before and after conducting a test series 5.2 Maintenance of the Impact Devices The devices do not require any particular care other than periodic cleaning of the impact body and the guide tube after performing approximately 1000-2000 tests. During cleaning, the following procedures need to be observed: - Unscrew support ring and remove impact body from guide tube - Clean off any dirt and metallic dust from impact body and test tip - Clean guide tube with the special brush provided - Do not apply oil to any parts for the impact device 5.3 EQUOTIP Standard Test Blocks with PROCEQ-Calibration EQUOTIP standard test blocks are calibrated with standard devices according to the EQUOTIP calibration basis by PROCEQ SA, they are equipped by a calibration certificate. The EQUOTIP calibration basis corresponds to the standard of the Quality Management System ISO 9001 : 1994 / chapt. 11 and is permanently inspected. The strict observance of the values marked on the standard test block guarantees the correct functions of the impact device and the indicating unit throughout the entire measuring range. Type, identification and reference values engraved on the standard test blocks see examples below.

Standard Test Block Type D dia. 90 x 56 mm, dia 3.6 x 2.2 inches, weight 2.8 kg suitable for impact devices: D/DC, D+15, C, DL reference-values serial no.
(traceability) (nominal range)

Vickers
(conversion value)

D.1443.9755B LD=7666 (LD+15=7726 / LC=8276 / LDL=8336) HV100=61015

Standard Test Block Type G dia.120 x 70 mm, dia 4.75 x 2.75 inches, weight 6.2 kg suitable for impact devices: G, (D/DC) serial no. reference-values Brinell (F=30D2)
(traceability) (nominal range) (conversion value)

G.161.9645 A

LG=5796 (LD=6206 )

HB5/750=3508

21

The value in parantheses applies to impact devices D and DC, provided they are used only within the Brinell range. For checking these devices throughout their entire measuring range (up to L=900 or 950 HV), the standard test blocks type D must be used. 5.4 EQUOTIP Standard Test Blocks with MPA-Certificate Standard test blocks D/MPA, G/MPA and E/MPA are calibrated in accordance with the dynamic hardness value L by PROCEQ SA and to the static hardness value of Vickers (HV) or Brinell (HB) by the MPA-NRW Dortmund-FRG, Accredition No. DKD-K-06302. These standard test blocks are equipped by a certificate to the EQUOTlP-L-value (PROCEQ SA) as well as a certificate to Brinell or Vicker (MPA). Suitability, type, identification, reference values etc. engraved on the standard test blocks see examples below.

Standard Test Block Typ D/MPA dia. 90 x 56 mm, dia 3.6 x 2.2 inches, weight 2.8 kg suitable for impact device: D serial no. reference-value
(traceability) (nominal range)

Vickers/MPA
(calibrated value)

D.1450.98-06

LD=7646

HV100=61115

Standard test blocks D/MPA are also available with other hardness levels: low approx. LD=4966 HV100=22010
high approx. LD=8556 HV100=84020

Standard Test Block Type G/MPA dia.120 x 70 mm, dia 4.75 x 2.75 inches, weight 6.2 kg suitable for impact device: G reference-value Brinell/MPA serial no.
(traceability) (nominal range) (calibrated value)

G.160.98-09

LG=5786

HB5/750=3538

Standard Test Block Type E/MPA dia. 90 x 56 mm, dia 3.6 x 2.2 inches, weight 2.8 kg suitable for impact device: E reference-value serial no.
(traceability) (nominal range)

Vickers/MPA
(calibrated value)

E.1420.98-02

LE=8236

HV100=84820

Remark: Densely impacted standard test blocks cannot be restored by grinding. Reason: Through grinding, the original hardness is altered in an uneven and uncontrolled manner. Therefore the standard test blocks can neither be calibrated for a new mean value nor for an acceptable tolerance. 22

6 Treatment of Samples
6.1 Preparation of the Surface The samples must feature a metallic smooth, ground surface, in order to eliminate erroneous measurements brought about by coarse grinding or lathe scoring. The roughness of the finished surface should not exceed the following values: Impact devices Type D, DC, D+15, DL, E G C Roughness measure Ra = CLA = AA 2.0 m /180 in. N7 7.0 m /275 in.N9 0.4 m /116 in.N5

Rt

10.0 m / 400 in. 30.0 m /1200 in. 2.5 m /0100 in.

Rt = Roughness depth (DIN 4762) Ra = Average roughness value (Germany) CLA = Centre line-average value (Great Britain) AA = Arithmetical average (USA) N5, N7, N9 = Roughness classification according to ISO/R 1302 When preparing the surface, please observe that the condition of the material may be affected (e.g. due to heating or cold working). As a consequence, the hardness is also influenced. If the surface is inadequately prepared, the measuring results can be affected as follows: - Excessive surface roughness results in lower L-values (the true hardness is greater than indicated), and broad variations of individual measurements. - Cold-worked surfaces produce excessively large L-values (the actual hardness is less than measured). 6.2 Supporting the Samples during Testing Impact devices Type Classification of Samples medium-weight light-weight 2.0 - 5.0 kg 5.0 -15.0 kg 0.5 - 1.5 kg 0.05-2.0 kg 0.50-5.0 kg 0.02-0.5 kg

heavy

D/DC, D+15, DL, E more than 5.0 kg G C more than 15.0 kg more than 1.5 kg

When measuring hardness with EQUOTIP, the following has to be noticed: Despite the low mass of the impact body and low impact energy, a relatively large impact force of short duration is generated when the impact body hits the measuring surface. G C Impact devices, Type D/DC, D+15, DL, E 900 N $ 90 kgf 2500 N $ 250 kgf 500 N $ 50 kgf max. impact force 23

For heavy samples of compact shape, no particular precautions are necessary. Smaller and lighter samples or workpieces yield or flex under this force, producing L-values which are too small and of excessively large variation. Even with big or heavy workpieces it is possible for thin-wall regions or thinner protruding parts to yield upon impact. Depending on the frequency of the resilient yielding action, the measured L-value may be too small or too large. In many situations, potential problems can be checked in the following manner: a) Medium-weight samples and also heavier samples with protruding parts or thin walls should be placed on a solid support in such a manner that they do not move or flex during the test impact. b) Light-weight samples should be rigidly coupled with a non-yielding support such as a heavy base plate. Clamping in a vice is of no value, since the samples become exposed to stress and because complete rigidity is never attained. As a rule, the measured L-values would be too small and show excessive variations. For coupling purposes, a thin layer of coupling paste is to be applied to the contact surface of the sample. Subsequently, the sample should be firmly pressed against the surface of the base plate by moving it with a circular motion (mutual rubbing of the mating surfaces). The coupling process has been carried out properly, if there is still no metallic contact between the parts. During testing, the impact occurs so quickly that the thin layer does not have time to yield. The sample and the support behave as if they were absolutely rigidly interconnected. For the coupling operation, the following prerequisites must be fulfilled: - The contact surface of the sample and the surface of the base plate must be flat, plane parallel and ground. - The direction of the test impact must be perpendicular to the coupled surface. Impact devices, types D, DC, D+15, DL, E G C Minimum sample thickness for coupling 3 mm / 1/8 inch 10 mm / 1/2,5 inch 1 mm / 1/25 inch

24

Proper Coupling: Proper coupling requires a little experience. Insufficiently coupled samples produce large variations of individual measurements, L-values which are too low and the operation is characterized by a rattling noise upon impact of the test tip. Example for coupling a test piece with a base plate Fig. 29 Application of the coupling paste (as thin as possible)

Fig. 30 Mutual rubbing of both parts while firmly pressing the sample against the base plate

Fig. 31 A particular advantage of coupling is the possibility of obtaining a very uniform, rigid connection between the sample and the support, totally eliminating stresses at the sample surface. The resulting variation in measured values is very low.

25

6.3 Samples with Curved Surfaces Impact testers only work properly, if the impact body has a certain position in the guide tube at the moment of impacting the test surface. In the normal position, automatically present when testing flat and convexcylindrical samples (such as round samples), the spherical test tip is located exactly at the end of the guide tube. However, when testing spherically or cylindrically shaped concave surfaces, the impact body remains further within the guide tube or protrudes further therefrom. Thus, with such types of curved surfaces, it is to be observed that the radii of curvature do not drop below the values indicated in Fig. 32. Curved surfaces should always be tested with the small support ring. R

max. -0,5 mm max. +0,5 mm

Concave surface

Convex surface

Fig. 32

Impact device types D/DC, D+1 5, C and E Impact device type G

Rmin = 30 mm / 1.2 inch Rmin = 50 mm / 2.0 inch

For impact devices D, DC, D+15, C and E, special support rings are available to accommodate smaller radii on convex or concave surface (see Sect. 9.1).

7 Conversion with other Hardness Numbers

7.1 EQUOTIP Conversion-Tables In the indicating device a various number of different conversion tables between the dynamic hardness value L and hardness numbers of other procedures such as HV, HB, HRC, HRB are integrated. For the comparison between hardness value L and other hardness test procedures, measurements were carried out on a large number of testpieces. The measured values thus obtained were then further processed to create the EQUOTIP conversion tables with the aid of equalizing calculation (non-linear regression), see Sect. 2.3. 26

7.2 Conversion Deviations The conversion deviation is the variance resulting from the comparison of measuring values observed with different hardness testing methods. It includes 2 components. The major share is caused by the fact that there is no clear physical relationship between the various methods. The second component results from the circumstance that the comparison of hardness values (e.g. L-value and Brinell) also includes the measuring deviation of the method being compared to. Therefore, a conversion between hardness values contains inaccuracies from the outset. This applies not only to conversion of the L-value into static indentation hardness values, but also for converting from one static hardness measuring method to another. The conversion deviations ( HB, HV, etc.) indicated in the conversion tables represent standard deviations, i.e. 68% of all materials tested to date fell within the specified variance range. 7.3 Deviation from Conversion Values Deviations from the values in the conversion can occur with the following steel qualities: High-Alloyed Steels - In high-speed tool steels, hotwork steels, and ledeburite chromium steels (group of high-carbon cold-work steels), the hard materials embedded in the matrix (ledeburite tungsten carbide e.g. type M7C3 and M6C) cause a local increase of the E-modulus, resulting in L-values which are actually too low. A typical representative of this group is the tool steel for cold work X210Cr12 (Material No.1.2080) containing 2.1% C and 12% Cr (see special conversions for impact devices D, C, D+15 and E). Cold Work-Hardened Steels - Drawn and in part also rolled steels frequently lead to excessively high L-values due to the pronounced cold-worked regions near the surface which simulate higher than actual hardness. Such steels should always be tested over their entire cross-section. Magnetic Steels - When testing magnetic materials, the velocity transmitter in the impact body is briefly influenced by their magnetic field. Therefore, slight deviations of the measured L-values may occur. Surface-Hardened Steels - Surface-hardened steels and especially case-hardened steels produce L- values which are too low when case-hardening depth is small because of their soft core.

27

Impact devices, types D, DC, D+15, DL, E C

Min. Iayer thickness for surface hardening 0.8 mm / 1/30 inch 0.2 mm / 1/125 inch

7.4 Setup of Plant-lnternal Conversion Curves For the special situations mentioned in Sect. 7.3, or when testing materials for which no generally applicable conversions are available, the user can develop individual conversion tables. When developing conversion curves, the following points must be observed: - The sample surface must be prepared very carefully. - If possible, samples should be of a size which makes coupling to a support base unnecessary. - The correct readout of the EOUOTIP hardness tester is to be checked against the standard test block for each test series. - The function of the static hardness testing machines and the correct optical evaluation of the indentations is to be checked for each test series, with the aid of standard test blocks of corresponding measuring range. - Only such hardness values should be correlated which are directly derived from immediate proximity to the relevant measuring area. To obtain a pair of comparative values, always form a mean value from at least 10 to 15 L- values and 3 static indentation hardness values.

Example: 3 measurements Brinell 3 x 5 measurements EQUOTIP

=1 correlation pair

Fig. 33

7.5 Application of Individual Conversions Plant-lnternal conversion tables generally show a systematic parallel deviation from an existing EQUOTIP conversion table. Such individually adapted user-specific tables can be stored in indicating devices listed below. - EQUOTIP - EQUOTIP 2 28 from SN 898-0401 / Vers. 2.7 upwards from SN 918-0001 / Vers. 3.2 upwards

Procedure for storing Individual User-conversions: $ Connection of impact device to EQUOTIP / EQUOTIP 2 indicating device. Example: impact device type D - preselection menu Conversion Fig. 34 - preselection of hardness procedure HB - preselection of group of material: 6: Cast Alum. Alloys $ EQUOTlP-conversion: HB/6 - activation of menu Correction Fig. 35 by keys CLEAR START press keys simultaneously $ Individual User-conversion: HB/6.1 Fig. 36 - setting of correction value + 12 HB - setting of valid hardness range 470 LD 100

Fig. 34

Fig. 35

Fig. 36

Fig. 37 Indentification in the menu Conversion and in the status-line 29

In order to avoid confusion between EQUOTlP-conversion tables and Individual User conversions, these tables are identified with an individual number, e.g. HB/6.1, see Fig. 36 and 37. This identification, including correction value and field of application, is taken into account during data transfer and further processing by EQUOLlNK 2. For the application of Individual User conversions a total of 20 individual tables can be stored in the indicating device. Within the menu Corrections all the Individual User-conversions entered in the indicating device can be transferred and recorded to a printer connected by means of pressing the button START. The printed record contains the following information: - no. consecutive - type of impact device - designation / identification of Individual User-conversion - correction value in HV, HB, HRC, HRB, or HS - preselected hardness level in L 100 Example of Individual User -conversion HB/6.1 for impact device type D according to the settings above:

Fig. 38

7.6 Notation of Hardness Values To avoid confusion between: - L-values measured with different impact devices - Hardness values of other measuring methods converted from the L-value and those mesured directly by respective system, the following form of notation is recommmended: Example: LD: L-value for impact device type D : 612 LD HBLD: LD value converted into hardness Brinell : 339 HBLD HVLD: LD value converted into hardness Vickers : 350 HVLD HRCLD: LD value converted into hardness Rockwell C : 36.2 HRCLD 30

8 Fault Diagnosis
Indication No digital readout Cause - dead batteries - batteries improperly poled - no contact at negative battery pole - no battery in holder - indicating device too cold (temp. <0 C) - poor cable contact or cable broken - the tested material is extremely homogenous - impact body is not or improperly located in the impact device - impact body does not release or cannot be loaded - measuring area inadequately prepared - the tested material is extremely inhomogenous or porous - sample is insufficiently supported Possible Remedy

correct defect

warm up device plug in cable completely, or even possibly replace cable

Digital display does not move

No impact occurs

correct defect service the catch chuck or release mechanism prepare sample according to Section 6.1

Marked deviation of individual L-values or L-values constantly too low

support sample according to Section 6.2

- sample exhibits large local hardness differences, e.g. at the transition seam to the base material

31

Indication

Cause - impact direction has been changed between the individual impacts

Possible Remedy Please see corrections for other impact directions clean impact device according to Section 5.2 replace impact body

L-values at the standard test block constantly too low

- impact device contaminated - spherical test tip cracked (e.g. due to impact against tungsten carbide) - support ring does not have rubber pad

replace support ring replace impact body

L-values at the ring standard test block constantly too high

- spherical test tip flattened (impact against tungsten carbide, wear) - standard test block damaged or full of identations

replace standard test block

9 System Accessoires
9.1 Support Rings for: lmpact Devices D/DC/D+15/C/E Part designation and dimensions: D6

suitable for the following test surfaces plane cylindrical hollow-cylindrical spherical hollow-spherical plane cylindrical hollow-cylindrical spherical hollow-spherical

19.5x5.5 mm R " 60 mm 2.4 inch

D6a

13.5x5.5 mm R " 30 mm 1.2 inch

32

Part designation and dimensions D6b/D+15

suitable for the following test surfaces plane cylindrical hollow-cylindrical spherical hollow-spherical / 0.40-0.6 inch / 0.55-1.2 inch / 1.00-2.0 inch

13.5 x 10.8 x 5.5 mm R " 30 mm 1.2 inch

Z 10-15 Z 14.5-30 Z 25-50

20 x 20 x 7.5 mm 20 x 20 x 6.5 mm 20 x 20 x 6.5 mm

cylindrical R 10 mm - 15 mm R 14.5 mm - 30 mm R 25 mm - 50 mm

R < 10 mm / 0.40 inch / not possible R " 30 mm / 1.20 inch / D6/D6a HZ 11 -13 HZ 12.5-17 HZ 16.5-30 20 x 18 x 5 mm 20 x 20 x 5 mm 20 x 20 x 5 mm hollow-cylindrical R 11 mm - 13 mm / 0.43-0.51 inch R 12.5 mm - 17 mm / 0.50-0.67 inch R 16.5 mm - 30 mm / 0.65-1.20 inch R < 11 mm / 0.43 inch / not possible R " 30 mm / 1.20 inch / D6a K 10-15 K 14.5-30

20 x 7.7 mm 20 x 6.7 mm

spherical R 10 mm - 15 mm R 14.5 mm - 30 mm

/ 0.40-0.6 inch / 0.55-1.2 inch

R < 10 mm / 0.40 inch / not possible R " 30 mm / 1.20 inch / D6/D6a HK11-13 HK 12.5-17 HK 16.5-30
17

x 5 mm 18 x 5 mm 20 x 5 mm

hollow-spherical R 11 mm - 13 mm / 0.43-0.51 inch R 12.5 mm - 17 mm / 0.50-0.67 inch R 16.5 mm - 30 mm / 0.65-1.20 inch R < 11 mm / 0.43 inch / not possible R " 30 mm / 1.20 inch / D6a

UN

52 x 20 x 16 mm

33

Impact Device G Part designation and dimensions: G6

suitable for the following test surfaces plate cylindrical hollow-cylindrical spherical hollow-spherical plate cylindrical hollow-cylindrical spherical hollow-spherical

29.5 x 7 mm R "100 mm 4 inch

G6a

19.5 x 7 mm R " 50 mm 2 inch

9.2 Automatic Hardness Tester EQUOmatic 2 The core of EQUOmatic 2 with the impact device type E, (synthetic diamond test tip). The automatic hardness tester is designed as a compact, electromechanically driven integrable component suitable for installation in production or inspection lines. See leafet 2002 08 387 E

9.3 Hardness Tester EQUOSTAT The EQUOSTAT hardness tester is based on the static measuring principle Rockwell HRZ and is specially designed for hardness measurements on small test objects. Typical applications are thin or thinly coated parts, sheet metals, pins, tubes and cylindrical specimens. See leaflet 2001 10 503 E 34

Appendices for impact device S

Note The Following appendices refer to impact device S. The same conditions as for impact device D apply unless special appendices follow. Impact device S is also available as unit S. Delivery with standard test block S (also available with MPA-certificate) Test block D labeled with LS-values The testing ball is made of special material with 10 times better durability compared to the testing ball of impact device D. Max. hardness of sample 970 HV. Lenght of impact device 155 mm.

Measuring range
Group of material 1 Steel and cast steel Hartness test-method Impact device S Vickers Brinell HB Tensile strenght N/mm Rockwell Shore 2 Cold work tool steel 3 Stainless steel and hightemperature resistant steel Vikers Rockwell Vickers Brinell Rockwell 6 Cast aluminium alloys Brinell Vickers 1 2 3 HRC HRB HRA HS HV HRC HV HB HRC HRB HB HV 61-88 28-104 104-924 21-68 119-934 105-656 21-64 70-104 20-184 22-196 22-70 HV 101-964 101-640