DEPARTMENT OF MECHANICAL ENGINEERING

TECHNOLOGY
Faculty of Engineering and Built Environment

UNIVERSITY OF JOHANNESBURG
Doornfontein Campus

Title: Experiment 2: The Rockwell Hardness Testing

By

Mpho Matheta
223084928

A Semester 2 Report submitted

in partial fulfilment of the requirements for the module

STRENGTH OF MATERIALS [STRMIB1]

B. ENG TECH (BENG(TECH))
Engineering: Mechanical

LECTURER: Mr. OJ. Kaelo

Date: 19/09/2023
 PLAGIARISM DECLARATION

1. I am aware that plagiarism involves using someone else's thoughts, words,

creations, or other works as one's own. I am aware that plagiarism encompasses
both verbatim copying and the extensive use of someone else's ideas without
appropriate attribution (including the appropriate use of quotation marks). I am
aware that using information obtained from printed sources or the Internet in this
manner constitutes plagiarism.

2. I am aware of the moral wrongness of plagiarism.

3. I am aware that I need to correctly cite my research. I abided by the guidelines for
reference, citation, and the usage of quote marks as outlined in the departmental
guide.

4. Paraphrased or summarized information from other sources has been properly

cited and referenced.

5. Any data, figures, or tables taken from external sources have been appropriately
acknowledged and referenced.

6. My sole effort is this assignment. I understand that it's improper to duplicate an

assignment entirely or partially from another person and that submitting the same
work to many people will be considered plagiarism.

7. I have never let anyone to replicate my work and present it as their own, and I
never will in the future.

Name: Mpho Matheta Student #: 223084928

Signed ………………………………. Date: 07 September 2023

1
Acknowledgments

I would like to thank the lab personnel Mr Williams Thali for his assistance with
this experiment and for demonstrating how to utilize the provided equipment and
guiding us through the experiment. I also want to express my gratitude to the lab
staff for making the experiment's purpose and required steps clear. They helped
us do the experiment and collect the recordings, and they were able to assist me
with the experiment that I did not understand.

I would like to thank my friends which happen to be 2nd and 3rd year students
which helped me in making my lab report since I was totally clueless. I would also
like to thank our tutors AP Dhliwayo, L Nickson, LB Seabata and KT Senyolo who
have thoroughly explained the experiments to us and took us through the
experiment step by step also for providing their previous lab reports which helped
provide me the picture of what I need to do.

Lastly, I would like to thank the sources found online and the textbooks found in
the library which helped me in the theory or background part.

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Table of Contents
OBJECTIVE OF THE EXPERIMENT ................................................................................ 4
THEORY/BACKGROUNDS .................................................................................................. 4
FORMULAS ............................................................................................................................. 5
APPARATUS ............................................................................................................................ 6
PROCEDURE ........................................................................................................................ 11
RESULTS................................................................................................................................ 11
ANALYSIS OF RESULTS.................................................................................................... 12
DISCUSSION ......................................................................................................................... 18
CONCLUSION ...................................................................................................................... 19
REFERENCES....................................................................................................................... 20

List of Figures
Figure 1: The Rockwell Hardness Testing Schematic Diagram ........................................ 5
Figure 2: Apparatus ................................................................................................................. 6
Figure 3: Apparatus ................................................................................................................. 7
Figure 4: Apparatus ................................................................................................................. 8
Figure 5: Apparatus ................................................................................................................. 9
Figure 6: Apparatus ............................................................................................................... 10
Figure 7: Tensile Test Graph for Aluminium....................................................................... 15
Figure 8: Tensile Test Graph for Mild Steel 1 ..................................................................... 16
Figure 9: Tensile Test of Mild Steel VS Aluminium ............................................................ 16
Figure 10: Endurance of Mild Steel VS Aluminium ......................................................... 17
Figure 11: Tensile Test of Mild Steel VS Aluminium .......................................................... 17

List of Tables
Table 1: Results of The Rockwell Hardness Testing ........................................................... 11
Table 2: Differences Between the Two Materials. .............................................................. 12
Table 3: Mechanical Properties of the two materials ......................................................... 13
Table 4: Testing of the 2 materials ........................................................................................ 14

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OBJECTIVE OF THE EXPERIMENT

• Finding a material's hardness—a measurement of its resistance to

deformation, particularly when subjected to localized stresses or
indentation—is the main goal of the Rockwell hardness test. This testing
technique is frequently used to determine the hardness of materials in
many different industries, including metallurgy, manufacturing, and
quality control.
• Material Characterization: To assess and contrast the hardness of various
substances, such as metals, alloys, polymers, and some non-metallic
substances. When choosing materials for engineering and industrial
processes, this information is crucial.
• Material Testing: To assess the suitability of materials for specific
applications. For example, to determine if a mild steel is hard enough to
resist wear and abrasion in each environment compared to aluminium.

THEORY/BACKGROUNDS

Rockwell hardness testing is a popular technique for determining a material's hardness,

particularly for metals and alloys. Based on the idea that the amount an indenter can
penetrate a material under a certain load is measured, the hardness of the material may
then be calculated (Callister and Rethwisch, 2018).
An established and defined method for determining the hardness of materials is the
Rockwell hardness test. It is based on the indentation hardness concept, which states that
the depth or area of indentation caused by a certain indenter under a known load can be
used to determine how resistant a material is to localized deformation. Rockwell hardness
testing is used in various industries, including metallurgy, aerospace, automotive, and
manufacturing, to assess material hardness and ensure product quality (Ashby and Jones,
2012)
Rockwell hardness testing is known for its speed, simplicity, and versatility, making it a
valuable tool in material characterization, quality control, and research.

The Rockwell Hardness Testing definitions and terminology:

• Insert – to put something (an object, piece of information, etc.) into something else.
• Fasten – to secure or attach one object or component to another, typically by using
some form of mechanical or physical means.
• Rotate – the action of turning or spinning an object around an axis or a central
point.

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 • Loader – a type of heavy equipment or machinery used in construction,
agriculture, mining, and other industries for the purpose of loading materials such
as soil, gravel, sand, or other bulk materials into a truck, conveyor belt, or other
transportation or storage systems.
• Settle - the gradual or deliberate process by which something or someone becomes
well-adjusted, accustomed, or integrated into a particular system, structure, or
environment.’

The following figure (Figure 1) displays the similar schematic design of the Rockwell
Hardness Testing utilized for this experiment for understanding purposes. It provides
some components labelled in their positions.

Figure 1

Figure 1: The Rockwell Hardness Testing Schematic Diagram

FORMULAS
The difference between the 2 materials can be calculated using the following formula:

To determine the difference.

𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 = 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 2 − 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 1

5
Where:
Material 2 – Aluminium
Material 1 – Mild Steel

APPARATUS

Figure 2

6
 Fastening Screw

Indenter

Testing Anvil

Elevation handle

Hand Wheel

Elevating screw rod

sleeve
Figure 3

Figure 3: Apparatus

7
 Aluminium
Material

Mild Steel
Material

Figure 4

Figure 4: Apparatus

8
Load changeover
handle

Back Cover
Switch

Unloading Handle

Loading Handle

Figure 5

9
 Hardness Test
Dial

Figure 6

Figure 6: Apparatus

10
PROCEDURE

1. The diamond indenter was ensured that it was correctly inserted and fastened.
2. Material was put on the Anvil.
3. Test dial was rotated which led to it being freed to 150 kg.
4. The lifting hand-wheel was rotated until pointer was a zero point.
5. The loader was pushed backward which applied the load, we then waited till the
lifting lever settled.
6. After it settled, we then waited for 5 seconds.
7. The lifting lever was pulled up which released the load.
8. The reading of the hardness number was taken.
9. The same procedure was repeated for 3 more readings which obtained 4 in total.
10. The hand wheel was rotated then we removed the material and cleared the
working station.

RESULTS

Test Mild Steel Material Aluminium Material

1 41.5 51.5
2 40.5 53.5
3 39.5 50.5
4 41.5 49
Results of The Rockwell Hardness Testing 1

Table 1

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 ANALYSIS OF RESULTS

Differences Between the Two Materials.

Result Difference
1 𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝟐 − 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝟏
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝑨𝒍𝒖𝒎𝒊𝒏𝒊𝒖𝒎 − 𝑴𝒊𝒍𝒅 𝑺𝒕𝒆𝒆𝒍
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝟓𝟏. 𝟓 − 𝟒𝟏. 𝟓
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝟏𝟎
2 𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝟐 − 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝟏
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝑨𝒍𝒖𝒎𝒊𝒏𝒊𝒖𝒎 − 𝑴𝒊𝒍𝒅 𝑺𝒕𝒆𝒆𝒍
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝟓𝟑. 𝟓 − 𝟒𝟎. 𝟓
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝟏𝟑
3 𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝟐 − 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝟏
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝑨𝒍𝒖𝒎𝒊𝒏𝒊𝒖𝒎 − 𝑴𝒊𝒍𝒅 𝑺𝒕𝒆𝒆𝒍
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝟓𝟎. 𝟓 − 𝟑𝟗. 𝟓
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝟏𝟏
4 𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝟐 − 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝟏
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝑨𝒍𝒖𝒎𝒊𝒏𝒊𝒖𝒎 − 𝑴𝒊𝒍𝒅 𝑺𝒕𝒆𝒆𝒍
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝟒𝟗 − 𝟒𝟏. 𝟓
𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 = 𝟕. 𝟓
Table 2

Mechanical Properties of the two materials

Mild Steel Aluminium
A form of carbon steel with a relatively low Aluminum is a lightweight, adaptable metal with
carbon content (usually less than 0.3% by a variety of mechanical properties (or
weight), mild steel is sometimes referred to as aluminum, as it is spelt in several countries).
low carbon steel. Because of its low cost, Depending on the composition of the alloy and
simplicity in manufacture, and versatility, it is the manufacturing techniques used, aluminum's
one of the most often utilized varieties of steel in characteristics can change.
numerous industrial applications.
Tensile Strength
Compared to other forms of steel, mild steel has Depending on the alloy and temper (heat
a relatively low tensile strength. Mild steel treatment), the tensile strength of aluminum can
typically has a tensile strength that ranges from differ significantly. Tensile strengths for popular
370 MPa to 450 MPa (megapascals), depending aluminum alloys like 6061 and 7075 range from
on the precise composition and heat treatment. 170 MPa to 570 MPa. Even higher tensile
This characteristic gauges how well a material strengths are possible for some high-strength
resists being pulled or stretched. aluminum alloys.
Yield Strength
Mild steel typically has a yield strength of 250 The stress at which aluminum starts to
MPa. It serves as a measure of how much strain permanently deform (plastically deform) under
or load a material can take before undergoing a tensile load is known as yield strength. Yield
permanent plastic deformation, which is an strengths for aluminum alloys typically range
important consideration in design calculations. from 40 MPa to 500 MPa.
Elongation
Because of its high ductility, mild steel can Elongation measures the ability of aluminum to
withstand extensive elongation or deformation deform or stretch before it fractures. Aluminum
before it breaks. Mild steel can exhibit alloys generally have good elongation properties,

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elongation values of 20% to 30% or even more, ranging from 10% to 30% or higher, depending
depending on the particular alloy and on the alloy and temper.
procedure.
Modulus of Elasticity (Young's Modulus)
For mild steel, the Modulus of Elasticity is Aluminum normally has a Modulus of Elasticity
roughly 210 GPa. These characteristic measures of roughly 70 GPa, which is quite low. This
the material's stiffness and its capacity to regain characteristic describes the material's stiffness
its original shape after being deformed. and capacity to regain its original form after
being deformed.
Hardness
When compared to other forms of steel, mild steel Aluminum's hardness varies according on the
is comparably soft and has a low hardness. alloy and temper. In comparison to many other
Depending on the heat treatment and alloying metals, aluminum is generally a soft metal.
components, its hardness can vary, but it is However, heat treatment and other procedures
typically lower than that of medium and high can harden some aluminum alloys.
carbon steels.
Fatigue Strength
Mild steel has a moderate fatigue strength, which Aluminum is suited for applications involving
implies that it can endure repeated cycles of cyclic loads because of its strong fatigue
loading without failing as long as the stresses resistance. The fatigue strength is influenced by
aren't too high. elements like alloy composition, processing, and
cycle count.
Impact Resistance
Since mild steel has a high level of impact Because of its strong energy absorption capacity
resistance, it can be used in applications that and comparatively low density, aluminum has
involve rapid loads or shocks. good impact resistance. This characteristic
qualifies it for use in industries like
transportation and aerospace where impact
resistance is crucial.
Machinability
Mild steel has a low carbon content and a Due to its exceptional machinability, aluminum is
relatively low degree of hardness, making it well-known. It is easily cuttable, drillable,
simple to mill and deal with. It is relatively simple millable, and turnable using standard machining
to cut, weld, bend, and mould. techniques.
Weldability
Mild steel can be easily bonded using a variety of Although welding is possible with aluminum, the
welding techniques, including arc welding, MIG particular alloy and temper can affect how easily
welding, and TIG welding. it can be joined together and how it is joined.
When welding, there are several aluminum alloys
that need specific caution.
Corrosion Resistance
Mild steel is prone to corrosion, particularly when Due to the development of a protective oxide layer
oxygen and moisture are present. It is frequently on its surface, aluminum exhibits exceptional
painted, zinc-coated, or given other protective corrosion resistance. This organic oxide layer aids
coatings to increase its corrosion resistance. in shielding the metal from various
environmental factors.
Table 3

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Testing of the 2 materials
Mild Steel Aluminium
Tensile Testing
Mild steel's yield strength, ultimate Aluminum alloys' yield strength, ultimate
tensile strength, elongation, and modulus tensile strength, elongation, and elastic
of elasticity are all revealed via tensile modulus can all be determined through
testing. Normal characteristics of mild tensile testing. Although these alloys have
steel include good ductility and a low a relatively low tensile strength, they are
tensile strength. renowned for their outstanding
formability and resistance to corrosion.
Impact Testing
Mild steel is subjected to impact testing to Aluminum alloy toughness and impact
learn more about its toughness and resistance are assessed through impact
capacity to sustain shock loads. It is used testing. Although these alloys are
to calculate the temperature at which typically not as strong as others, they
ductile to brittle transitions occur. have good formability and resistance to
corrosion.
Compression Testing
Mild steel's compressive strength and Aluminum alloys' compressive strength
compression elasticity modulus can be and elastic modulus are revealed by
determined through compression testing. compression testing. Although these
Typically, mild steel has a strong alloys are renowned for their formability,
compressive strength. they are weaker than other aluminum
series.
Shear Testing
Shear testing provides information about The shear strength and shear modulus of
the shear strength and shear modulus of aluminum alloys are revealed by shear
mild steel. Mild steel has shear strengths testing. These alloys are appreciated for
that are between 60 and 80 percent of its their corrosion resistance and formability
ultimate tension strengths. For instance, a rather than for their shear strength.
steel with a yield strength of 60 ksi and an
ultimate strength of around 7075 ksi has
a shearing strength of about 5060 ksi.
Table 4

NB: The Aluminium used in the test was the 1000 Series
Aluminium.

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GRAPHS

Figure 7

Tensile Test Graph for Aluminium

15
Figure 8

Tensile Test Graph for Mild Steel 1

Figure 9

Tensile Test of Mild Steel VS Aluminium

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Figure 10

Endurance of Mild Steel VS Aluminium

Figure 11

Tensile Test of Mild Steel VS Aluminium

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DISCUSSION

In a study of aluminum and mild steel, the qualities, uses, benefits and drawbacks of
these two popular engineering materials are compared and contrasted.

➢ ALUMINIUM

• Properties:
Aluminum is a lightweight metal renowned for its great corrosion
resistance due to the creation of a protective oxide layer, superior electrical
conductivity, and low density (approximately one-third that of steel).
Additionally, it has a strong thermal conductivity (Callister and Rethwisch,
2020)

• Applications:
Aluminum is frequently used in the automotive sector for lightweight body
panels and engine parts, in the aerospace industry for aircraft components,
and in construction for structural and architectural aspects.

• Advantages:
The main benefits of aluminum include its light weight, resistance to
corrosion, and ease of forming, making it ideal for applications where
corrosion resistance and weight reduction are crucial (Burrell,2013).

• Disadvantages:
The fundamental disadvantage of aluminum is that it is less strong than
steel, particularly in applications where high tensile strength is required.

➢ MILD STEEL

• Properties:
Low carbon steel with good formability, weldability, and machinability is
known as "mild steel." Due to its moderate tensile strength, it can be used
in a variety of industrial and structural applications (Callister and
Rethwisch, 2020).

• Applications:

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 Pipelines, bridges, and other construction projects frequently use mild
steel. Additionally, it is utilized in the production of engineering
components, automobile parts, and machinery.

• Advantages:
Mild steel is prized for its accessibility, price, and ease of fabrication. It
offers a nice blend of ductility and strength for a variety of applications
(Verhoeven, 2007).

• Disadvantages:
Mild steel is prone to corrosion, thus in corrosive conditions it could need
protective coatings or treatments. Additionally, it is heavier than aluminum
due to its increased density.

CONCLUSION

Rockwell hardness testing offers important information on the hardness characteristics of

aluminium and mild steel. While mild steel is often harder and softer than aluminium, the
latter material is better suited for some applications because to its low density and corrosion
resistance. Contrarily, mild steel's higher hardness qualifies it for uses that call for strength
and durability. The decision between these materials ultimately comes down to the
project's requirements, taking into account things like corrosion resistance, cost, weight,
and load-bearing capacity.

Damage: I observed that the Aluminium took more damage as shown in the table of results
due to the fact that it has low density whereas Mild Steel took less damage because of its
high density.

Results: Theoretically Mild Steel is stronger than Aluminium and even The Rockwell
Hardness Testing proved that.
Recommendation: My Recommendation would be that the lab technician or the tutor who
does the experiment with the students try as much as possible to make sure that the
conditions are the same in the 4 trials for each material because the difference between the
4 tries of the same material is big.

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