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I. Measurement requirements from the customer: Measurement of the chrome plating hardness on battery electrode rolling rolls.
By using the Motorized Ultrasonic Hardness Tester SU-300M with the electric probe and a dedicated support bracket for rolling rolls, the following measurement parameters can be achieved:
Material quality assessment: Hardness measurement can help evaluate the material quality of the rolling rolls. Higher hardness usually indicates harder material with better wear resistance and durability.
Rolling performance evaluation: By measuring the hardness of the rolling rolls, their performance characteristics can be evaluated, such as their ability to withstand high pressure and heavy loads. Higher hardness generally means the rolling rolls can withstand greater pressure and loads.
Chrome plating quality inspection: Chrome plating is a common protective coating that provides wear resistance and corrosion protection to the surface of the rolling rolls. By measuring the hardness of the chrome plating layer, its quality and thickness can be evaluated to ensure sufficient protective performance.
Quality control: Hardness measurement is an important aspect of quality control and can be used to ensure consistency and standardization in the manufacturing process of rolling rolls. By regularly measuring hardness, any non-conforming rolling rolls can be detected, and appropriate measures can be taken for repair or replacement.
II. Challenges faced by the customer
Rockwell, Brinell, and Vickers Hardness Testers are not suitable for direct measurement of large-sized products. It requires cutting the product for measurement, resulting in low efficiency. After testing, the products can only be scrapped. This testing method is not suitable for batch testing in practical work.
Portable Leeb Hardness Testers, which use the Leeb impact principle to measure hardness, have high requirements for the size and weight of the measured workpiece. They can only measure large and medium-sized workpieces (theoretical requirement of 5 kg) and cannot measure irregularly shaped or smaller workpieces, thin workpieces (including electroplated coatings, spray coatings, nitrided surfaces, etc.). Therefore, Leeb Hardness Testers cannot be used to measure the chrome plating Hardness of rolling rolls. The head of the customer's quality department is facing the challenge of lacking testing equipment to control the hardness of the chrome plating on rolling rolls. They hope to find an efficient and non-destructive hardness measurement solution.
Based on the challenges faced by the customer, we have decided to use an Motorized Ultrasonic Hardness Tester for the measurement of the samples. The Motorized Ultrasonic Hardness Tester can measure hardness within approximately 4 seconds per measurement, which is more than 17 times faster than the efficiency of a tabletop Rockwell Hardness Tester and more than 40 times faster than the efficiency of a tabletop Vickers Hardness Tester. The indentation diameter after measurement with the Motorized Ultrasonic Hardness Tester is 0.026 mm, while the indentation diameter after measurement with the Rockwell Hardness Tester is 0.484 mm (see indentation in Figure 2). The use of the Ultrasonic Hardness Tester for measurement does not affect the subsequent assembly and use of the product by the customer. Middle One Precision's Motorized Ultrasonic Hardness Tester applies a small load, which allows for batch measurement of the chrome plating hardness on battery electrode rolling rolls without damaging the workpiece, effectively ensuring the production quality of the product.
Figure 2. Observation of the indentation and measurement of the indentation diameter at 412 times magnification using Sinowon VM-500 high-definition microscope.
IV. Test Results
|Statistics and analysis of the data obtained from measuring rolling roll samples using the Motorized Ultrasonic Hardness Tester|
|Test||1||2||3||4||5||Average (HRC)||Reproducibility (HRC)|
Note: The values highlighted in red represent the maximum and minimum values obtained from six measurements on the same sample.
V. Test Images
VI. Test Conclusion
Based on the data analysis, the following conclusions can be drawn:
The Motorized Ultrasonic Hardness Tester offers simple operation, high stability, and precise Hardness measurement. It only requires the preparation of surface-treated sample blocks made of the same material as the tested product to achieve accurate hardness measurements.
The Motorized Ultrasonic Hardness Tester has the advantages of speed, portability, and high accuracy. It can be used to test irregular, large-sized workpieces that cannot be tested with traditional hardness testers such as Rockwell, Brinell, and Vickers. It is suitable for on-site hardness inspection of large quantities of finished workpieces, without the risk of product scrap caused by hardness testing.
The Motorized Ultrasonic Hardness Tester applies a small test force, allowing measurement of thinner workpieces that cannot be measured by a Rockwell Hardness Tester, such as thin plates, thin-walled pipes, electroplated coatings, spray coatings, nitrided surfaces, and carburized surfaces. After testing, no visible indentation is left on the surface of the workpiece, making it ideal for high-end users who require non-destructive hardness measurement without damaging the finished product.
When paired with SPC data processing software, the Motorized Ultrasonic Hardness Tester supports real-time data collection and statistical analysis, providing visualized measurement data with intuitive graphical displays. It allows the setting of upper and lower limits, highlighting anomalies, and supports report saving and export. The test data can be traced and tracked.
In conclusion, Sinowon's SU-300 series Motorized Ultrasonic Hardness Tester provides an efficient on-site hardness testing solution for modern industrial production. It enhances the quality control of enterprises, reduces losses, and increases profitability.
I. Suitable Users: Customers who require efficient, non-destructive hardness measurement for large workpieces that cannot be measured using a Rockwell Hardness Tester.
Customers who require efficient, non-destructive hardness measurement for large workpieces that cannot be measured using a Rockwell Hardness Tester. These types of users typically need a hardness measurement device that is efficient, non-destructive, and suitable for large workpieces. Compared to traditional hardness testers, the Motorized Ultrasonic Hardness Tester offers a more convenient, accurate, and comprehensive hardness measurement solution.
By using the Motorized Ultrasonic Hardness Tester, users can benefit from:
Efficiency: The Motorized Ultrasonic Hardness Tester allows for rapid measurements, enabling users to obtain accurate hardness data in a short period of time. This is particularly advantageous for users who require frequent hardness measurements.
Non-destructiveness: Unlike traditional hardness testing methods, the Motorized Ultrasonic Hardness Tester does not damage or impact the material's integrity. Therefore, users can obtain precise hardness values without compromising the integrity of the workpiece, which is crucial for applications that demand high material integrity.
Adaptability to large workpieces: Traditional Rockwell Hardness Testers may not be suitable for measuring large workpieces, but the Motorized Ultrasonic Hardness Tester can overcome this limitation. With a wider measurement range and adaptability to different sizes and shapes of large workpieces, users can perform hardness measurements with ease.
In summary, the Motorized Ultrasonic Hardness Tester is efficient, non-destructive, and suitable for large workpieces. It is ideal for users who have high requirements for equipment performance, especially those who need to accurately measure the hardness of large workpieces in a short period of time.
Measuring the Hardness of samples with electroplated coatings, such as chrome-plated, copper-plated, carburized, and nitrided layers, as well as applications in the field of rolling rolls, screws, wind power, etc.
III. Features of the Motorized Ultrasonic Hardness Tester
High accuracy: The testing accuracy can reach HV: ±3% HV, HR: ±1.5 HR, HB: ±3% HB.
Small indentation: The indentation is not visible to the naked eye and requires a high-magnification metallographic microscope to observe.
Fast speed: Test results can be obtained within 6 seconds, which is 20 times faster than a microhardness tester.
Large screen: The 3.2" color screen directly displays the current measurement value, maximum value, minimum value, average value, and hardness conversion value.
Easy operation: Results can be quickly obtained with a simple one-key operation.
Wireless printing: Supports wireless Bluetooth printing and data transmission.
▲ Click on the image to view product details
▲ Equipped with an electric probe dedicated support for rolling rolls
Contact us to learn more about hardness testers. We are committed to providing you with technical support and excellent after-sales service.
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