Automotive industry

Various hardness testing applications at Hardening plants, component suppliers and automotive manufacturers

widest variety of applications for hardness testing as well as highly diverse requirements for the necessary hardness testing machines. Test specimens range from small screws to raw materials, door panels, engine components, transmission parts, such as gear wheels, and welded joints. If, for example, large numbers of the same workpieces need to be tested every day (such as a random sample of every production batch or a 100% test) or many in-process tests, such as CHD measurements, need to be performed, then a high degree of automation in the hardness testing process and the possibility of unmanned testing are key criteria in selection of the appropriate hardness testing machine.

Hardening plants, component suppliers and automotive manufacturers

Our references

Quality control of case hardened automotive components - with DuraJet

Component variation, according to production line
Maintain process speed
Minimise operator input
Simple operation of the hardness tester
Light and compact machine

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I couldn't find a hardness tester like the DuraJet from any other supplier on the market.

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Hardness testing in the automotive industry

Application Examples

Automated hardness testing - with DuraVision Semi-Automatic or DuraJet G5

It is possible to integrate a hardness tester into a production line via a hardware interface. This enables external control of the machine.

External machine control
Option to connect foot switch

Both the DuraVision Semi-Automatic universal hardness tester and the DuraJet G5 Rockwell tester are equipped with an additional interface. This additional interface allows 100% tests to be conducted without having to remove test specimens from the production process.

Another option is to connect the available foot pedal to the interface, in order to use this for performing the clamping movement to fix a workpiece. The significantly simplifies handling in tests on large, unwieldy components.

Test data management - with DuraJet G5

In order to save all available test data simply and clearly, the DuraJet G5 Rockwell tester can archive the data in a structured manner.

Standard test data management
Grouped test data management, e.g. for batches, departments, etc.

The preferred type of test data management is selected prior to testing. In the standard test data management system, all results are stored in a collective list.

If test data needs to be associated with individual users or user groups, specific components, batches or departments, then the grouped data management function should be used. All the determined test results are compiled in separate lists, allowing them to be clearly represented, exported or saved as a report. The groups created can be reloaded at any time and augmented with additional test results.

Weld sample mapping - with DuraScan Automatic (50, 70, 80) and areaMASTER software module

The fully automatic DuraScan micro hardness tester in combination with the areaMASTER software module is suitable for determining the hardness distribution of a weld sample and displaying it clearly.

Contour scan with edgeAssistant
Automatic test point distribution
Depiction of the hardness distribution

After selecting the test type (mapping) and test method (e.g. HV1) in the ecos Workflow operating software, the next step is for the contour of the specimen to be traced automatically with the help of edgeAssistant. Subsequently, all that remains to be done is to enter the required test point spacings. The software automatically distributes these across the specimen and the measurement can be started.

Once the measurement has been completed, a hardness profile of the weld sample (similar to a finite element analysis) is provided, which clearly displays the hardness distribution in a colour "hardness map" (in 2D or 3D).

More about the AareaMASTER

Multiple testing of embedded specimens - with DuraScan Automatic and ecos Workflow software module

Up to twelve embedded specimens, each comprising several test sequences, can be measured fully automatically with the DuraScan micro hardness tester in combination with the ecos Workflow multi-specimen software module.

Automatic testing of up to twelve embedded specimens
Test points positioned quickly and easily with the help of the overview camera
High travel through asymmetric arrangement

Up to twelve embedded specimens can be inserted and processed in parallel using the ecos Workflow multi-specimen software module. The test data and test sequence can be specified for each individual specimen, and the measurement can then be executed fully automatically. Positioning of test points and test sequences is simplified by the overview camera.

ecos Workflow

Micro hardness testing of welded joints - with DuraScan Automatic (70,80)

Weld sample testing according to DIN EN ISO 9050 can be conducted simply, in a time-saving manner, with the fully automatic DuraScan micro hardness tester.

Simple test sequence creation
Positioning with a panorama function
Time-saving template mode

First, the test type (sequential) and test method (HV0,1-HV5) are selected in the ecos Workflow operating software. The test points can be arranged conveniently in a grid pattern in the test point editor. The test sequences can be adapted automatically to the contours of the workpiece using the line and polygon tool. Another integrated tool makes it possible to adhere to the standard-compliant spacings. The position of the test sequences can then be defined simply and transparently in the real-time image. Larger specimens are likewise completely mapped using the panorama function.

A template for every measured and archived specimen is also created automatically. This template can then be used with the next weld seam and positioned on the workpiece using the rotation axis. In this way, even complicated test tasks can be carried out quickly in a matter of clicks.