Ultrasonic hardness tester

Introduction

An ultrasonic hardness tester is a portable hardness tester that uses the ultrasonic contact impedance (UCI) method to measure the hardness of the metallic materials, and it is used in the manufacturing, the quality control, the inspection, and the field applications for the hardness testing of the metals. The ultrasonic hardness tester measures the hardness by the measurement of the change in the resonant frequency of a vibrating rod with a diamond indenter, when the indenter is pressed into the material with a defined load; the contact area between the indenter and the material affects the resonant frequency, which is related to the hardness, and the tester calculates the hardness value, expressed in the Vickers, the Rockwell, or the other hardness scales; the ultrasonic hardness tester consists of the measuring probe with the vibrating rod and the indenter, the electronic unit, and the display, and it provides a rapid and a portable measurement, with features such as the various hardness scales, the data logging, and the small access for the measurement in the confined areas; the ultrasonic hardness tester is used for the hardness testing of the metals, for the testing of the gears, the shafts, the molds, the coatings, and the other components, for the quality control, for the field inspection, and for many other applications, and it is an essential instrument for the hardness testing. Ultrasonic hardness testers are used in the manufacturing, in the quality control, in the maintenance and the inspection, in the laboratories, and for many other applications. With their ultrasonic method, ultrasonic hardness testers are essential for the portable hardness testing.

Ultrasonic Hardness Tester LUHT-T2010

Ultrasonic Hardness Tester measures a wide hardness range, including HV (10 to 1999), HB (76 to 618), (41 to 105), (20.3 to 68), and (60.7 to 85.6). It is suitable for testing materials ...

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Standards

ISO 6508-1:2015-Metallic materials-Rockwell hardness test-Test method

Complies with the above standards, but is not limited to them.

Features

1. Ultrasonic hardness tester for non-destructive hardness measurement using ultrasonic contact impedance (UCI) method.

2. Portable hardness tester with ultrasonic probe for fast, non-destructive testing of metals on production parts and welds.

3. Suitable for manufacturing, metalworking, weld inspection, automotive, aerospace, power, and field quality control.

4. Includes tester body, ultrasonic probe (Vickers diamond), calibration test block, cables, and operation manual.

5. Supports UCI hardness measurement (HV, convertible to HRC/HRB/HBW) of ferrous and non-ferrous metals, thin parts, welds.

FAQ

Q1: What testing scenarios is this tester mainly applied to?

A: The ultrasonic hardness tester (UCI - Ultrasonic Contact Impedance) is used in manufacturing, metalworking, weld inspection, automotive, aerospace, power generation, oil/gas, and field quality control to perform fast, non-destructive hardness measurement of metallic materials using an ultrasonic probe with a Vickers diamond indenter, making it ideal for testing finished parts, thin components, welds, coatings, and large/heavy assemblies where traditional bench hardness testers cannot be used. It supports weld inspection (weld metal, heat-affected zone (HAZ), base metal - hardness testing of welds per ISO 15614, AWS D1.1, API standards (hardness limits for welds, e.g., <350 HV for carbon steel welds to prevent cold cracking); UCI is ideal for welds because it is non-destructive, portable, and can test small areas (weld bead, HAZ) with minimal indentation), automotive and aerospace (finished components (gears, shafts, bearings, turbine blades, landing gear, structural parts - non-destructive testing without damaging finished surfaces; case-hardening depth verification (surface hardness + hardness profile by grinding layers), heat treatment verification (quenching, tempering, induction hardening, carburizing, nitriding)), power generation (turbine components, boiler tubes, pressure vessels - in-situ hardness testing on installed equipment (cannot bring to lab); creep damage assessment (hardness decrease indicates material degradation/creep), weld overlay/cladding hardness), oil and gas (pipeline welds, drill collars, valves, wellhead equipment - field hardness testing, sour service (NACE MR0175/ISO 15156 hardness limits <22 HRC for sulfide stress cracking resistance)), metal manufacturing and processing (incoming material inspection, in-process QC, heat treatment batch verification, finished product certification, large/heavy parts (too big for bench tester - UCI is portable, test on shop floor)), tool and die (cutting tools, dies, molds - hardness of working surfaces, small/complex geometries), and research/field QC (on-site testing, failure analysis, material identification, batch consistency). UCI method: Probe has Vickers diamond (136 degree) attached to an ultrasonic rod resonating at ~100 kHz. When diamond is pressed onto sample with fixed force (typically 1 kgf = 9.8 N), the contact impedance changes with indentation area (harder material = smaller indent = higher contact impedance = higher resonant frequency shift). Measures frequency shift, converts to Vickers hardness (HV). Indentation is very small (~10-50 micrometers, nearly non-destructive - much smaller than Rockwell/Brinell), so suitable for finished parts. Fast (1-2 seconds per reading).

Q2: What standards does the tester comply with?

A: The ultrasonic hardness tester follows relevant ISO, ASTM, DIN, ASME and GB/T standards including ISO 16859 (metallic materials - UCI method - ultrasonic contact impedance method for hardness testing - parts 1-3: principles, verification, calibration of blocks), ASTM A1038 (standard test method for portable hardness testing by ultrasonic contact impedance method), DIN 50159 (testing of metallic materials - hardness test by ultrasonic contact impedance method), ASME Code Case (for pressure equipment, if applicable), and GB/T standards for UCI hardness testers. The hardware complies with applicable portable hardness tester standards (force accuracy, probe frequency, diamond geometry per ISO 16859-2) and EMC (IEC 61326). Calibration uses certified hardness test blocks (reference blocks traceable to national standards per ISO 16859-3, ASTM A1038; typically HV blocks at low/mid/high hardness, e.g., 200, 400, 600 HV). For weld inspection, follow ISO 15614 (welding procedure qualification), AWS D1.1, API 5L/1104, NACE MR0175/ISO 15156 (sour service hardness limits). For regulated industries (aerospace, nuclear, pressure vessels), follow applicable material standards and quality systems (ISO 9001/AS9100/IATF 16949). For safety-critical components, UCI results may need confirmation with bench Vickers/Brinell per some standards (UCI is a comparative/portable method).

Q3: What is the warranty period for the whole tester and key components?

A: The whole ultrasonic hardness tester is covered by a 12-24 month warranty (portable instruments often 2 years). The tester body, electronics, display, and ultrasonic probe housing are covered, while Vickers diamond indenter (wear part - diamond can chip/crack, especially on hard/rough surfaces; expensive replacement; the diamond is bonded to ultrasonic rod and is a critical component), calibration test block (wear/replaceable - surface gets indented over time, use unused area or replace), batteries/rechargeable battery (wear - capacity decreases over 2-3 years), and probe cable (wear - can fatigue at connector) are consumables/accessories. Damage from improper use, diamond chipping (from impact, testing on very hard/rough surfaces, dropping probe - avoid; diamond tip is fragile), probe overload (exceeding contact force, pressing too hard - can damage ultrasonic rod/diamond), liquid/corrosive ingress, dropping (portable units), or unauthorized repair is excluded. Extended warranty and service contracts (calibration, probe replacement) may be available. Electronics last 5-10 years; diamond indenter needs periodic replacement (1-5 years depending on use/abuse; chipped diamond gives inaccurate readings).

Q4: Is this device difficult to operate? Is professional training required?

A: Operation is straightforward for basic use (calibrate, press probe on sample, read display). No professional training required for routine measurement, but proper technique (probe orientation, surface prep, force application) is important for accuracy. We provide operation manuals. Proper setup (charge battery (portable) or connect power, turn on, allow warm-up (1-5 min for stabilization), select hardness scale (HV (Vickers - UCI native), HRC, HRB, HBW, HRA - convert via built-in tables; note: conversions are approximate, HV is most accurate), select material group (some testers allow material-specific calibration curves (steel, stainless, aluminum, copper, cast iron) for better accuracy), calibration (calibrate with certified hardness test block (choose block close to expected sample hardness; for wide range, multi-point calibration at low/mid/high HV (e.g., 200, 400, 600 HV); place probe perpendicular to block surface, apply steady force until beep/reading (1-2 seconds); verify reading matches block certificate within tolerance (typically +/- 3% or +/- 10 HV); if off, recalibrate or adjust; calibrate before each use or at start of shift, after probe change, after battery change, and if temperature changes significantly), sample preparation (UCI requires relatively smooth, flat test surface (rough scale/oxide/coating affects readings - remove with grinder/sander (fine grit, 120-240 grit or finer), then polish if high accuracy needed; for welds: grind weld crown flush, remove oxide; surface roughness Ra <2 micrometers recommended for best accuracy; do NOT over-grind (can work-harden surface, especially austenitic stainless steel - use gentle grinding, low heat, or chemical etching to remove work-hardened layer), ensure test area is flat (curved surfaces need correction or use special probe foot; convex surfaces give higher readings; for cylindrical parts, use correction factor or flexible probe), sample thickness >= 1 mm (UCI indent is small, but very thin samples (<0.5 mm) may flex; use support behind), avoid testing near edges (>= 2 mm from edge), holes, weld toes (stress concentrations), sample must be rigidly supported (no vibration, no movement - hold probe steady or use test stand for repeatability), test execution (hold probe perpendicular (90 degrees) to surface (angle error >5 degrees affects readings; use probe guide or stand for consistency), apply steady, gradual force until probe reaches full contact (do not jerk, do not apply excessive force; built-in force mechanism applies fixed load (1 kgf standard, some probes 3, 5, 10 kgf for softer/rougher materials)), hold until reading stabilizes (1-2 seconds, beep indicates complete), read display (HV or converted scale; some show average of multiple readings), repeat (3-5 readings per test point, average; for welds: test weld center, HAZ, base metal at specified locations per welding standard; report individual and average), move to next location (spacing >= 2 mm between indents to avoid work-hardening zone), post-test (turn off, clean probe tip (wipe with soft cloth - do not use abrasive on diamond), inspect diamond for damage (under magnifier if readings are erratic), store probe in protective case, record results (sample ID, location (weld/HAZ/base), scale, individual readings, average, date, operator, equipment ID; for weld certification, include sketch/map of test locations), maintenance (regular cleaning (after each use - clean probe diamond, exterior; weekly: clean probe connector, check cable for damage), diamond inspection (check for chips/cracks at tip (under 10x magnifier; chipped diamond = erratic/high readings; replace if damaged), battery check (recharge regularly; replace if capacity reduced), calibration (every 3-6 months with certified test blocks (multi-point), or per quality system; if probe replaced, recalibrate), probe cable inspection (check for fatigue/cracks at connector, replace if intermittent), troubleshooting (readings inconsistent (probe not perpendicular, surface rough/not flat, sample moving/vibrating, diamond chipped, force inconsistent - use stand/guide, prepare surface, stabilize, inspect diamond), readings too high (surface work-hardened from grinding (especially stainless steel), probe angle, convex surface without correction, calibration block wrong - remove work-hardened layer (chemical etch or re-polish), hold perpendicular, apply correction, recalibrate), readings too low (surface decarburized/soft layer (grind off), diamond worn/changing, force too low, calibration off - grind surface, inspect/replace diamond, verify force, recalibrate), probe not reading (diamond not contacting (gap), cable loose/disconnected, battery low, probe failure - check contact, cable, battery, service), calibration fails (test block worn (use unused area or new block), diamond damaged, probe out of calibration - replace block/diamond, recalibrate/service), and safety (diamond hazard (Vickers diamond is hard/sharp - do not touch tip, avoid dropping probe; diamond can shatter if struck - handle carefully), moving parts (probe extends under force - keep fingers clear), sample handling (sharp metal parts, hot parts (after welding/heat treatment - allow to cool; UCI is affected by temperature - test at room temp (10-35 degrees C per ISO 16859; hot parts need correction or special high-temp probe), eye protection (when grinding samples, metal chips; use safety glasses), electrical (battery-powered safe; use approved charger), do not test on very rough surfaces without prep (damages diamond, inaccurate), do not overload probe (excessive force damages ultrasonic rod/diamond), for field use: secure sample/location (fall hazard, working at heights - follow safety protocols)) are important for accurate UCI hardness testing.

Q5: What is the typical lead-time for order delivery?

A: Standard models require 7-30 working days. In-stock units can ship within 3-7 working days. Custom configurations or large built-to-order systems may require additional time, and we confirm the exact schedule before order confirmation.

Q6: Is regular calibration required? What is the recommended calibration cycle?

A: Calibration recommended every 3-6 months (or per quality system) using certified hardness test blocks (reference blocks traceable to national standards per ISO 16859-3, ASTM A1038; multi-point calibration at low/mid/high hardness (e.g., 200, 400, 600 HV) covering expected range; force verification with certified load cell (every 12 months per ISO 16859-2); diamond indenter geometry verification (annually or when replaced). If probe is replaced, tester is dropped, or readings seem off, recalibrate immediately. Routine verification with test block before each use or at start of shift (quick check on one or two blocks). For ISO 17025/AS9100/IATF 16949 labs, follow applicable calibration schedules and maintain records (calibration certificates, test block ID, as-found/as-left data, probe ID, force verification). UCI testers are portable and subject to drift from probe wear, diamond degradation, and electronic drift - regular calibration is essential, especially for weld certification and regulatory compliance. Note: UCI is a comparative method - accuracy depends on calibration matching sample material and hardness range; for critical applications, correlate with bench Vickers/Brinell.

Q7: Are supporting consumables universal?

A: Ultrasonic probe/Vickers diamond (replacement - specific to tester brand/model (Proceq Equotip, NewSonic, etc.); use OEM or certified compatible probe with correct diamond geometry and frequency; probes are NOT universal across brands), calibration test blocks (certified HV blocks - universal from hardness supply but must be certified traceable; use for UCI calibration), batteries/rechargeable battery pack (specific to model), probe cable (specific to model), carrying case, and cleaning supplies are available from NDT/hardness supply companies, though probes and cables are brand-specific (use OEM or certified compatible to maintain accuracy and warranty). Long-term consumable cost includes probe/diamond replacement (expensive ($500-$2000+), periodic if chipped/worn) and calibration blocks (periodic if surface fully used).

Q8: Can I customize parameters or supporting accessories?

A: Customization includes probe type/force (standard 1 kgf (9.8 N) probe for general/hard materials; 3, 5, 10 kgf probes for softer/rougher materials (larger indent, better averaging); motorized probe (fixed force, high repeatability); high-temperature probe (for hot parts up to 200-300 degrees C); thin-part probe; curved surface probe), measurement scales (HV (native), HRC, HRB, HBW, HRA, HR15N (superficial) - selectable; material-specific conversion curves (steel, stainless, aluminum, copper, cast iron, titanium)), display/control (basic (LED, single reading) or advanced (color display, statistics (mean, std dev, min/max), data logging (1000+ readings), USB/Bluetooth/WiFi export, PC software, weld test mapping, 21 CFR Part 11 for pharma/nuclear), accessories (motorized test stand (for lab/high repeatability), calibration test blocks (multiple HV values), extra probes (various forces), probe guides (for perpendicular alignment on curved/flat surfaces), high-temp probe, carrying case, spare batteries, printer, calibration certificate (ISO 17025), certifications (CE, FCC, ISO 9001, ISO 16859/ASTM A1038 compliance), language and accessories. Additional probes, blocks, and accessories can be ordered separately.

Q9: Does the purchase include on-site installation and commissioning service?

A: Standard delivery includes ultrasonic hardness tester, probe (Vickers diamond), calibration test block (one), battery/charger, carrying case, and instruction manual. On-site installation is not required for portable units (charge, calibrate, use). On-site training is not included for standard orders but can be arranged at additional cost (for weld inspectors, QC teams on proper technique, surface prep, weld mapping per ISO/AWS/API, and result interpretation/correlation with bench methods). Remote guidance provided. For motorized test stand systems: basic setup guidance provided. Always calibrate with certified test block before testing production/weld parts.

Q10: What types of samples are compatible with this equipment?

A: The ultrasonic hardness tester measures hardness of metallic materials including ferrous metals (carbon steel, alloy steel, stainless steel (austenitic, martensitic, ferritic - note: austenitic stainless can work-harden from grinding; use gentle prep), tool steel, cast steel, cast iron (gray, ductile - UCI works but cast iron graphite affects readings; calibrate with cast iron block)), non-ferrous metals (aluminum and alloys, copper and alloys (brass, bronze), titanium and alloys, nickel alloys, zinc, magnesium), sintered metals (powder metallurgy, cemented carbides (high hardness, use appropriate force)), and coated/clad surfaces (hard chrome plating, thermal spray coatings, weld overlays - thin coatings need low force and verification; coating must be thicker than indentation depth (~10-50 micrometers; for thin coatings use microhardness/nanoindentation instead)). UCI is especially good for: finished parts (small indent, nearly non-destructive), large/heavy parts (portable, test on-site), welds/HAZ (small test area, portable), thin parts (>= 0.5-1 mm, small indent), and complex geometries (portable probe). NOT compatible with: Very soft materials (aluminum <50 HV, copper, lead, rubber, plastics - UCI diamond may penetrate too much, indent large; use low-force probe or other method (Rockwell HRB/HRF, Vickers low load)), non-metals (rubber, foam, wood, ceramics (some very hard ceramics can be tested but diamond may wear; use special setup), very rough surfaces (must grind/polish smooth; as-cast/scale surfaces not suitable without prep), very thin materials (<0.5 mm - sample flexes, inaccurate; use microhardness), coated surfaces thinner than indentation depth (measures substrate, not coating; use microhardness/nanoindentation), and extremely hard materials (>1000 HV or cemented carbides with standard probe (diamond wear; use appropriate calibration)). Also not ideal for heterogeneous materials with large grain structure (cast iron, brass - small UCI indent may hit individual grains; use larger force or average many readings, or use Brinell). IMPORTANT: Ultrasonic Contact Impedance (UCI) hardness testing fundamentals: (1) What is UCI? A portable, non-destructive hardness test method using an ultrasonic probe. The probe contains a Vickers diamond indenter (136 degree pyramid) bonded to the end of an ultrasonic rod that resonates longitudinally at ~100 kHz. When the diamond is pressed onto the test surface with a fixed force (typically 1 kgf = 9.8 N), it creates a small indentation. The contact impedance between diamond and sample changes with the size of the indentation (contact area). Harder material = smaller indent = higher contact impedance = higher resonant frequency (or smaller frequency shift from free resonance). The instrument measures the frequency shift and converts it to Vickers hardness (HV). (2) Why UCI? - Non-destructive: Indent is very small (~10-50 micrometers diagonal, much smaller than Rockwell (~100-500 micrometers) or Brinell (1-5 mm)). Suitable for finished parts, no visible damage. - Portable: Handheld probe + battery-powered meter. Test on-site, on large/heavy parts, in field. - Fast: 1-2 seconds per reading. - Small test area: Can test weld beads, HAZ, small features. - Direct HV reading: Native Vickers scale (convertible to HRC/HRB/HBW). (3) How it compares: - vs Rockwell/Brinell (bench): UCI is portable, non-destructive, fast, but less accurate (+/- 3-5% vs +/- 1-2% for bench) and requires smooth surface. Bench methods are reference standards. - vs Leeb (rebound) hardness: UCI is more accurate, less affected by sample mass/thickness (Leeb needs heavy/rigid sample; UCI works on thin parts), smaller indent, but more expensive and probe is fragile. Leeb is cheaper, more rugged, but needs large sample mass (>5 kg) and makes larger indent. - vs Vickers (bench/micro): UCI uses same Vickers diamond principle, but portable and dynamic (ultrasonic). Bench Vickers is reference, more accurate, but not portable and slower. (4) Key factors affecting accuracy: - Surface preparation: UCI requires smooth surface (Ra <2 micrometers). Roughness, scale, oxide, coatings cause errors. Grind with fine grit (120-240), polish if needed. Avoid work-hardening (especially austenitic stainless steel - use gentle grinding, low heat, or chemical etch to remove work-hardened layer). - Probe angle: Must be perpendicular (90 degrees) to surface. Angle error >5 degrees affects readings. Use guide/stand. - Force: Fixed force (1 kgf standard). Inconsistent force = inconsistent readings. Motorized stand improves repeatability. - Sample support: Sample must be rigid, no vibration. Thin/flexible samples need backing support. - Material matching: UCI is calibrated for specific materials. Testing material different from calibration block (e.g., aluminum calibrated on steel block) gives bias. Use material-specific calibration or correction. - Curved surfaces: Convex surfaces give higher readings; need correction factor or special probe foot. - Temperature: Test at 10-35 degrees C (ISO 16859). Hot parts need high-temp probe or correction. - Diamond condition: Chipped/worn diamond = erratic readings. Inspect regularly. (5) Standards: ISO 16859 (UCI method, parts 1-3), ASTM A1038, DIN 50159. For welds: ISO 15614 (WPQR), AWS D1.1, API 1104, EN ISO 15614. For sour service: NACE MR0175/ISO 15156 (hardness <22 HRC / ~235 HV for carbon steel in sour service). (6) Calibration: - Use certified HV test blocks (traceable to national standards). - Multi-point calibration (low, mid, high hardness) for best accuracy across range. - Calibrate before each use, after probe change, after battery change, if temperature changes. - Verify with check standard during use (every 20-30 readings or per shift). (7) Common errors: - Poor surface prep (biggest error - rough/scaley surface = wrong readings). - Work-hardened surface from grinding (especially stainless steel - gives high readings; remove with chemical etch or re-polish). - Probe not perpendicular (angle error). - Testing on curved surface without correction (high readings on convex). - Calibrated on steel, testing aluminum (material mismatch - use material curve). - Chipped diamond (erratic readings - inspect/replace). - Sample too thin/unsupported (flex = low/inconsistent). - Ignoring temperature (hot/cold parts affect readings). - Too few readings (UCI has more scatter than bench; take 3-5 readings, average). - Converting HV to HRC without noting conversion is approximate (report actual HV for critical use; conversions per ASTM E140/ISO 18265 are material-dependent). (8) When to use UCI vs other methods: - Finished parts, non-destructive requirement -> UCI (small indent) or Leeb (larger indent). - Welds/HAZ, small areas -> UCI (small test area, portable) or microhardness (bench, more accurate). - Large/heavy/field parts -> UCI or Leeb (portable). - Thin parts (<5 mm) -> UCI (works on thin) or microhardness (Leeb needs >5 kg mass). - High accuracy/certification -> Bench Vickers/Brinell/Rockwell (reference methods); UCI as screening/field confirmation. - Very hard materials (>65 HRC) -> UCI or bench Vickers (Rockwell max ~70 HRC). - Soft non-ferrous -> Rockwell HRB/HRF or low-load UCI.