Why Rockwell hardness test is better than Brinell?

Material hardness is a crucial property that determines its resistance to deformation, wear, and penetration. To accurately measure hardness, various testing methods are employed, each with its advantages and limitations. Among these methods, the Rockwell hardness test has emerged as a preferred choice over the Brinell hardness test.

However, in this article, we will help you explore the reasons why the Rockwell hardness test is better than the Brinell test in terms of accuracy, versatility, and efficiency.

So, here we go:

Reasons Rockwell hardness test is better than Brinell.

Let’s have a look at the key reasons why the Rockwell hardness test is better than the Brinell:

1. Accuracy of hardness test

The Rockwell test offers higher accuracy compared to the Brinell test. The Rockwell method measures hardness based on the depth of penetration of an indenter, while the Brinell method relies on the surface area of an indentation. The ability of the Rockwell test to measure smaller indentations accurately results in more precise hardness measurements.

2. Versatility of Rockwell hardness test  

The Rockwell hardness tester is typically more versatile than the Brinell test. The Rockwell method offers a range of scales that cater to different materials and test conditions.

This versatility of the Rockwell hardness test allows for the testing of various materials, including metals, polymers, and composites, with different hardness levels. In contrast, the Brinell test is limited to testing non-homogeneous materials such as castings.

3. Test Efficiency of Rockwell test

The Rockwell hardness tester is usually more efficient than the Brinell test. The Rockwell hardness test method requires minimal preparation and setup time. Therefore, it is considered an ideal for high-volume production environments.

Additionally, the Rockwell test provides faster results due to its simplified testing procedure. On the other hand, the Brinell test involves time-consuming steps, such as preparing a polished surface, applying a specified load, and measuring the diameter of the indentation.

4. Applicability to Thin and Small Components

The Rockwell hardness test is more suitable for testing thin or small components than the Brinell hardness test. These thin materials include foils or thin sheets, where the Brinell test may not be feasible due to the large indentation size.

The smaller indentation size of the Rockwell test minimizes the risk of damaging or deforming thin materials during testing.

The Brinell test requires a minimum thickness to accommodate the large indenter used. It ultimately allows for accurate hardness measurements without compromising the integrity of the sample.

On the other hand, the Rockwell test can be performed on thin materials or small components. In addition to that, you can apply the Rockwell hardness test to thin and small components without compromising accuracy.

5. Non-destructive Testing

The Rockwell test can be performed as a non-destructive test. It means it does not cause significant damage to the material being tested.

It makes Rockwell hardness test particularly beneficial when you need to test valuable or delicate components.

6. Ease of Use

The Rockwell test is relatively easy to perform and does not require specialized equipment or extensive training. The results can be read directly from the testing machine, eliminating the need for additional calculations or measurements.

7. Load Application

In the Rockwell test, a preload is applied to establish a zero position before the main load is applied. The main load is then removed, leaving only the preload, and the distance traveled is measured by the Rockwell testing machine.

On the other hand, the Brinell test applies a relatively high load to the material using a tungsten carbide ball, and the diameter of the resulting indentation is measured.

8. Readability

The Rockwell test provides easy-to-read hardness values directly on the testing device. This practice helps eliminate the need for additional calculations or conversions. This immediate readability makes the Rockwell test convenient and user-friendly.

9. Size and Portability

The Rockwell test equipment is generally smaller and more portable compared to the Brinell test equipment. It makes it easier to transport and use in various locations, including on-site inspections or in remote areas where mobility is essential. The compact nature of Rockwell testers allows for greater convenience and flexibility in hardness testing.

10. Depth of Indentation

The Rockwell test measures the depth of the indentation, whereas the Brinell test measures the diameter of the indentation. The depth measurement used in the Rockwell test provides a more accurate and reliable hardness value, as surface irregularities and variations less influence it. It makes the Rockwell test particularly useful when dealing with materials with heterogeneous microstructures or surface coatings.

Final Thoughts

While both the Rockwell and Brinell hardness tests have their merits, the Rockwell test proves to be a superior method due to its increased accuracy, versatility, efficiency, and applicability to thin and small components. Industries that require precise and efficient hardness measurements, alongside a wide material range, can benefit from adopting the Rockwell hardness test. The Rockwell method's ability to deliver accurate and reliable hardness data contributes to the overall quality control and performance of materials in various industries.