Precision Ultrasonic Hardness Tester New Energy Battery Pole Piece Roll Hardness Measurement Solution

I. Test Specimens and Requirements:

Workpiece: Pole piece roll of new energy battery (Fig. 1).

Product diameter: 800mm

Chrome plating thickness: plating 200μm

Roughness: Ra 0.006um

Circular runout: 2um

Measurement requirements: Measure the chrome hardness of the battery pole piece roll

Instrument used: Roll hardness tester SU-300M

Fig. 1. Battery Pole Piece Rolls

II. Challenges Faced by Clients:

1. Rockwell hardness tester, Brinell hardness tester, Vickers hardness tester, the product is too large to measure directly. It is necessary to measure the product after cutting, which is inefficient, and the product can only be scrapped after detection. In practice, this test method is not suitable for batch inspection.

2. The portable Leeb hardness tester uses the Leeb impact principle to measure the hardness of the product, which has high requirements for the size and weight of the measured workpiece, and can only measure large and medium-sized workpieces (theoretical requirement of 5kg). It cannot measure special-shaped workpieces, small workpieces, thin workpieces (including electroplating, spray coating, nitride layer, etc.). Therefore, it is not possible to test the chrome hardness of rolls with Leeb hardness.

The customer's quality manager was faced with the challenge of lacking the testing equipment to control the chrome hardness of the rolls and wanted to find an efficient, non-destructive hardness measurement solution.

III. Solutions:

Based on the customer's current challenges, we decided to use an ultrasonic hardness tester to measure the specimen.

The single measurement time of the ultrasonic hardness tester is about 4 seconds/time, which is more than 17 times higher than the measurement efficiency of the desktop Rockwell hardness tester and more than 40 times higher than the measurement efficiency of the desktop Vickers hardness tester.

The indentation diameter after measurement by the ultrasonic hardness tester is 0.026mm. The indentation diameter after measurement by the Rockwell hardness tester is 0.484 mm (see Figure 2 for the indentation). After measuring with ultrasonic hardness tester, it will not affect the user's subsequent assembly and use.

Sinowon Precision's ultrasonic hardness tester adopts a small load test force, which can measure the chrome hardness of the battery pole piece roll in batches without damaging the workpiece after calibration, so as to effectively ensure the production quality of the product.

Figure 2. Using Sinowon VM-500 high-definition microscope to magnify 412 times to observe the comparison of ultrasonic hardness measurement indentation and Rockwell hardness measurement indentation diameter

IV. Test Results.

Statistics and analysis of data measured by ultrasonic hardness tester on roll samples.

Note: The values marked in red are the maximum and minimum values of the same specimen measured 6 times.

The test time is about 4 seconds, see the test video for details.

V. Test Pictures

VI. Test Conclusions:

Through the above data analysis, the following conclusions are drawn:

The ultrasonic hardness tester is simple to operate, has high stability, and only needs to prepare a surface treatment sample of the same material as the tested product, which can achieve accurate hardness measurement.

Ultrasonic hardness tester has the advantages of fast speed, portability, high precision, etc., which can solve many irregular, large workpieces, and workpieces that cannot be tested by desktop hardness tester. It can be used for on-site hardness inspection of large quantities of finished workpieces, and there is no need to worry about the problem of product scrap after hardness testing.

The ultrasonic hardness tester uses a small load test force to measure thinner workpieces that the Leeb hardness tester cannot measure, such as thin plates, thin-walled pipes, electroplating layers, spray coatings, nitriding surfaces, carburized surfaces, and other surface hardness. No visible indentations are left on the surface of the workpiece after the test. Therefore, it is ideal for high-end users who require no damage to the surface of the product, and can perform hardness measurement without damaging the finished product.

With SPC data processing software, it supports online data and historical data to receive statistics, visualized measurement data, intuitive icon display, can set upper and lower limits, highlight abnormalities, support saving and export reports, and test data can be traced.

Sinowon Precision SU-300 series ultrasonic hardness tester provides an efficient on-site hardness testing solution for modern industrial production. While improving the quality control of the enterprise, it reduces the loss of the enterprise and increases the profit of the enterprise.

The following parameters can be measured by the [motorized ultrasonic hardness tester SU-300M with special bracket for motorized probe rolls]:

1. Material quality assessment: hardness measurement can help evaluate the material quality of rolls. High hardness generally indicates that the material is harder, with better wear resistance and durability.

2. Roll performance evaluation: By measuring the hardness of the roll, its performance characteristics can be evaluated, such as its ability to withstand high pressure and heavy loads. The higher the hardness, the more the roll is generally able to withstand greater pressures and loads.

3. Chrome plating quality inspection: Chrome plating is a commonly used protective coating, which can provide wear resistance and corrosion resistance on the surface of the roll. By measuring the hardness of the chrome plating, its quality and thickness can be evaluated to ensure that it has adequate protective properties.

4. Quality control: Hardness measurement is an important part of quality control, which can be used to ensure consistency and standardization in the roll manufacturing process. By measuring the hardness regularly, any non-conforming rolls can be detected and appropriate measures can be taken to repair or replace them

VII. Brand Recommendations:

Dongguan Sinowon Precision Instrument Co., Ltd. is a high-tech enterprise, a national standard formulation enterprise for ultrasonic hardness testers, a leader in the ultrasonic hardness tester industry, and a leading enterprise in the export of ultrasonic hardness testers. With 300 dealer service outlets in China, it is the first brand for users to buy ultrasonic hardness testers.