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Knoop hardness test

The Knoop hardness test is a microindentation method for assessing material hardness, particularly effective for thin coatings, small specimens, and brittle materials like ceramics and glass, where it applies light loads using a diamond indenter shaped as a rhombic-based pyramid with unequal diagonals. The hardness number (HK) is calculated by dividing the applied test force by the projected area of the indentation, which is determined from the length of the long diagonal, enabling precise measurements with minimal surface disruption.^[1]^[2] Developed in the late 1930s at the National Bureau of Standards (now the National Institute of Standards and Technology), the test was introduced by Frederick Knoop, Chauncey C. Peters, and Walter B. Emerson to overcome limitations in prior hardness methods, such as the Vickers test, which could cause cracking in fragile samples under load. Their 1939 publication detailed the indenter's design and application, stemming from earlier exploratory work on pyramidal tools for low-force testing, and a U.S. patent for the device was granted to Knoop in 1937.^[1]^[3] In practice, the indenter features a rhombus base with diagonals in a 7:1 ratio (long to short), angles of 172°30' longitudinally and 130° transversely, and edge angles of 86°15', producing an elongated indentation that penetrates deeper along its major axis for a given load. Test loads range from 1 gf (9.807 × 10⁻³ N) to 1 kgf (9.807 N), with the method standardized in ASTM E384 for microindentation hardness of metals and alloys, and in E92 for broader metallic applications, ensuring consistent procedures for indentation spacing, measurement, and reporting.^[1]^[2] The test's advantages include reduced risk of subsurface cracking in brittle materials due to its shallow depth-to-width ratio, suitability for closely spaced indentations to map hardness gradients, and applicability across diverse fields like metallurgy, materials science, and quality control in coatings and precision components. It remains a key tool in research and industry, with reference materials like NIST SRM 1893 providing certified values for calibration.^[3]^[4]

Principles of the test

Indenter geometry

The Knoop indenter is a highly polished, pointed, rhombic-based pyramidal diamond, specifically designed as an elongated four-sided rhombohedral shape to produce precise, shallow indentations in materials.^[5] This geometry features a long diagonal that is approximately 7.114 times the length of the short diagonal, enabling the formation of an elongated impression suitable for microhardness assessment.^[2] The indenter is typically fabricated from synthetic type IIa diamond, chosen for its exceptional hardness, durability, and ability to maintain geometric precision under repeated use without wear or deformation.^[6] The precise angles defining the indenter's edges are 172° 30' for the included longitudinal angle along the long diagonal and 130° for the transverse angle along the short diagonal, ensuring a sharp apex and controlled penetration.^[7] These specifications result in an asymmetrical indentation where the impression's depth is approximately 1/30 of the long diagonal length, minimizing subsurface damage and allowing for testing on thin layers or brittle samples.^[8] The rhombohedral asymmetry directs stress primarily along the long axis, producing a rhombus-shaped mark that facilitates accurate measurement of the extended diagonal while reducing edge effects in heterogeneous microstructures.^[9]

Indentation process

In the Knoop hardness test, a predetermined load is applied to the rhombohedral diamond indenter, typically ranging from 10 gf to 1 kgf (0.098 N to 9.807 N), to press it into the material surface and create a shallow, elongated impression.^[10] This load is delivered through a testing machine that ensures precise and controlled force application, resulting in minimal deformation beyond the immediate contact area.^[11] The indenter's geometry, with an included longitudinal angle of 172° 30' along the long diagonal and a transverse angle of 130° along the short diagonal, facilitates shallow penetration, with the depth of indentation being about 1/30 of the long diagonal length.^[12] This limited penetration depth, roughly half that of a comparable Vickers indenter, reduces the risk of cracking in brittle materials such as ceramics or glass by distributing stress over a longer surface area.^[9] The applied load is maintained for a dwell time of 10 to 15 seconds, allowing the material to respond fully and form a stable indentation without excessive creep or recovery effects.^[9] Upon removal of the load, the resulting mark appears as a rhombus-shaped impression with unequal diagonals, the long diagonal being approximately seven times the length of the short one, enabling subsequent optical evaluation.^[11]

Procedure

Sample preparation

Proper sample preparation is essential for the Knoop hardness test to achieve accurate and repeatable results, as the micro-scale indentations are highly sensitive to surface conditions and specimen integrity.^[10] The test surface must be flat and meticulously polished to minimize irregularities that could distort the indentation geometry or diagonal measurements. For reliable microhardness testing, the surface roughness should be less than 0.5 µm Ra, ensuring precise formation of the elongated Knoop indent without edge effects or cracking.^[9]^[13] Thin or small specimens, common in applications like coating evaluation or brittle material analysis, require mounting in a stable medium to facilitate handling, polishing, and secure positioning under the indenter. Thermosetting epoxy resins are widely used for this purpose, encapsulating the sample to create a uniform block that prevents movement and protects delicate edges during preparation.^[11]^[4] Contaminants such as oils, dust, or oxidation layers must be removed prior to testing, as they can alter the contact between the indenter and surface, leading to erroneous hardness values. Standard cleaning involves ultrasonic baths with solvents like acetone or ethanol, followed by drying to yield a pristine, oxide-free surface.^[14]^[15] For thin sections, the specimen thickness must be at least one-third the length of the long diagonal of the indentation (approximately 10 times the indentation depth) to avoid substrate effects or deformation from the mounting material influencing the measured hardness, per ISO 4545-1 and ASTM E384.^[16]^[17]^[10]^[18]

Testing steps

The Knoop hardness test procedure involves a series of precise steps to ensure accurate indentation and measurement, typically conducted using a microscope-equipped microhardness tester.^[10] The first step is the selection of an appropriate test load, which depends on the material's properties and the sample's thickness to produce a measurable indentation without substrate influence or cracking. For bulk materials, loads around 500 gf (approximately 4.9 N) are common, while lower loads such as 10-50 gf are used for thin films or coatings to limit penetration depth to less than one-tenth (10%) of the film's thickness. The chosen load should result in an indentation with a long diagonal of at least 20 μm to ensure reliable measurement, avoiding forces below 25 gf that may yield qualitative results.^[19]^[18]^[19]^[20] Next, the prepared sample is positioned on the tester's stage, ensuring the test surface is flat and perpendicular to the axis of the rhombic-based diamond indenter. Under the integrated microscope, the operator focuses on the desired test location and aligns the indenter precisely above it, often using a filar eyepiece or digital imaging for accuracy. The rhombic-based indenter, with its elongated pyramid shape, is then lowered into contact without shock or vibration.^[10]^[18]^[19] The selected load is then applied gradually, reaching full force within 7-10 seconds to prevent dynamic effects. This load is maintained for a dwell time of 10-15 seconds, allowing the material to deform plastically under stable conditions, after which the load is unloaded automatically or manually. The indenter's contact velocity during loading should not exceed 0.070 mm/s to ensure controlled penetration.^[10]^[18] To achieve statistical reliability, multiple indentations—typically 5-10 per sample area—are performed across the surface. These must be spaced sufficiently to avoid stress field interactions from adjacent indentations, with a minimum distance of 2.5 times the long diagonal between centers and at least twice the diagonal from sample edges or features. For more precise control in anisotropic materials, spacing may be adjusted to 3.5 times the short diagonal for side-by-side positions. After each indentation, the surface is refocused under the microscope before proceeding.^[19]^[18]

Calculation

Hardness formula

The Knoop hardness number, denoted as HK, is defined as the applied test force divided by the projected surface area of the indentation, expressed in units of kgf/mm². This projected area is approximated as that of a rhombus formed by the indentation's diagonals, where the long diagonal L (in mm) is measured, and the short diagonal is approximately L / 7.114 based on the indenter's geometry. The resulting primary formula is

HK = 14.229 \times \frac{P}{L^2},

where P is the applied load in kgf and the constant 14.229 derives from the indenter's rhombic pyramid shape, specifically $2 \times 7.114, accounting for the fixed ratio of the diagonals. ^[21]^[22] For measurements using smaller scales, an alternative form of the formula adjusts for gram-force (gf) and micrometers (µm):

HK = 14229 \times \frac{P}{d^2},

where P is in gf and d is the long diagonal in µm; this is equivalent to the primary formula after unit scaling by factors of 1000. ^[21]^[4] To convert HK values to SI units, multiply by the gravitational constant, yielding HK (MPa) ≈ HK (kgf/mm²) × 9.807, since 1 kgf/mm² equals approximately 9.807 N/mm².

Measurement considerations

In Knoop hardness testing, the indentation is measured using optical microscopy to determine the length of the long diagonal, as this dimension alone is used in the hardness calculation.^[23] High-resolution microscopes with a calibrated stage are employed, typically at magnifications ranging from 400x to 1000x, to ensure precise visualization of the elongated indentation for loads under 1 kgf.^[24] According to ASTM E384-17, the diagonal should span 25% to 75% of the field of view to minimize measurement errors, with higher magnifications recommended for indentations smaller than 20 μm.^[19] For a valid measurement, the two halves of the long diagonal must not differ by more than 10%, indicating proper indenter alignment and load application; greater asymmetry invalidates the result.^[19] Additionally, the indentation must be clear, symmetrical, and free from cracks or other defects, as any cracking—common in brittle materials—compromises accuracy by altering the effective compliance and geometry.^[19]^[25] Several factors can introduce errors in diagonal measurement. Surface tilt exceeding 2° leads to non-uniform pressure distribution, causing distortions in the indentation shape that affect diagonal length accuracy.^[19] In thin samples, edge effects near the specimen boundary can similarly distort the indentation due to unconstrained deformation or substrate influence.^[19] Vibrations during loading or inadequate stabilization also contribute to variability.^[19] Modern Knoop testers incorporate automation through digital imaging systems, which capture and analyze the indentation via software for automated diagonal length determination, improving precision and reducing operator variability compared to manual methods.^[22] These systems, compliant with ASTM E384, exhibit slightly larger but consistent repeatability intervals, making them suitable for high-throughput testing.^[19]

Applications

Material types

The Knoop hardness test is particularly well-suited for brittle materials such as ceramics, glasses, and minerals, where the shallow and elongated indentation minimizes the risk of cracking or subsurface damage that could occur with deeper-penetrating indenters.^[9]^[26]^[27] This method allows for reliable hardness measurements on these materials without compromising the sample integrity, as the indenter's geometry produces a penetration depth approximately half that of a Vickers indenter under similar loads.^[9] Thin coatings and films, including metallurgical coatings like oxide layers and metal platings, as well as semiconductor layers, are effectively evaluated using the Knoop test due to its ability to produce indentations with depths on the order of microns, preventing substrate influence in layers as thin as a few micrometers.^[26]^[28]^[29] The test's microhardness range, typically involving loads up to 1 kgf, ensures precise assessment of surface properties without delamination or excessive deformation.^[9] For anisotropic materials, such as single crystals like sapphire (alumina) or minerals including hematite, the Knoop indenter's elongated rhomboidal shape enables directional hardness assessment by aligning the long axis of the indentation with specific crystallographic orientations, revealing variations in hardness due to crystal structure.^[30]^[31]^[32] This capability is valuable for studying slip systems and mechanical anisotropy in these materials. The test is also ideal for small or delicate parts, such as microelectronics components and dental materials like resin composites or ceramics, where the minimal indentation size and low applied forces avoid structural damage to fragile or miniature specimens.^[24]^[28]^[33]

Industrial uses

In manufacturing, the Knoop hardness test is widely employed for quality control, particularly in assessing case hardening depth on components such as gears and cutting tools, where precise measurement of surface hardness gradients is essential to ensure durability and performance under load.^[34] This method allows for evaluation of thin hardened layers, typically ranging from 0.05 to 1 mm in depth, by creating shallow indentations that minimize subsurface damage while mapping hardness variations across the material cross-section.^[35] In materials research within metallurgy, the Knoop test facilitates the evaluation of phase transformations and alloy compositions by providing microscale hardness profiles that reveal differences in microstructural phases, such as martensite or austenite in heat-treated steels.^[36] Researchers use it to quantify hardness anisotropy in polycrystalline alloys, enabling correlation between composition, processing conditions, and mechanical properties without compromising sample integrity.^[37] For failure analysis in aerospace components, the Knoop hardness test is applied to investigate surface treatments and wear mechanisms, such as in turbine blades or landing gear parts, where it detects localized hardness changes indicative of fatigue, corrosion, or inadequate coating adhesion.^[38] This approach supports root-cause determination by traversing indentations along wear tracks or treated surfaces, often under loads as low as 10 gf to preserve evidence for further metallographic examination.^[39] In biomedical applications, the Knoop test is utilized to assess the hardness of implants and restorative dental materials, including titanium alloys for orthopedic devices and composite resins for fillings, ensuring biocompatibility and resistance to masticatory forces.^[40] It is particularly valuable for brittle ceramics like zirconia used in dental crowns, where the elongated indenter produces indentations with minimal cracking, allowing accurate measurement of surface hardness values typically between 1200 and 1600 HK.^[41]

Advantages and disadvantages

Benefits over other methods

The Knoop hardness test produces shallower indentations compared to macrohardness methods like Brinell and Rockwell, minimizing substrate effects when evaluating thin coatings or layers. This shallower penetration—approximately half the depth of a Vickers indentation at the same load—allows accurate measurement of surface properties without significant influence from underlying softer substrates, which is particularly beneficial for films thinner than 10 micrometers.^[22]^[9]^[42] In brittle materials such as ceramics and glass, the elongated rhombic shape of the Knoop indenter distributes stress more evenly, reducing the risk of cracking compared to the square-based Vickers indenter, which can propagate cracks more readily under similar loads. This design enables reliable testing of fragile components where other microhardness methods might cause damage.^[9]^[27] The Knoop test exhibits high sensitivity to material anisotropy, with hardness values varying based on the orientation of the indenter's long axis relative to the crystal structure, making it valuable for studying directional properties in single crystals or textured materials. For instance, in gadolinium calcium oxyborate crystals, hardness anisotropy shows distinct maxima and minima over a 180° rotation, linked to active slip systems.^[43]^[44] Additionally, the Knoop method supports a wide load range from 1 gf to 1 kgf, facilitating seamless transitions between micro- and macro-scale testing on the same equipment without modifications. In microhardness applications, this versatility provides greater precision than the Vickers test due to the longer measurement diagonal at equivalent depths.^[9]^[27]^[45]

Limitations

The Knoop hardness test exhibits higher sensitivity to surface finish compared to methods like Vickers, as rough surfaces can distort the elongated indentation, particularly affecting the measurement of the long diagonal due to its greater length and shallower depth.^[27]^[36] This requires meticulous polishing of the specimen to ensure optical clarity, as imperfections can lead to inaccurate diagonal readings.^[22] The asymmetrical rhombohedral shape of the Knoop indenter introduces measurement variability, where imprecise alignment can result in distorted indent shapes, such as kite-like forms instead of rhombuses, potentially causing errors in diagonal assessment.^[46] Standards like ASTM E384 require the measured short-to-long diagonal ratio (y/x) to not exceed 1.1; indentations exceeding this are invalid due to misalignment, beyond which results are deemed unreliable.^[47]^[46] The test is time-intensive, with each cycle typically requiring 30 to 60 seconds for indentation and dwell time, plus additional optical microscopy for measuring the long diagonal, making it less automated and slower than Rockwell testing.^[27]^[48] For very soft materials, the Knoop test is not ideal, as the shallow penetration depth under low loads may produce unreliable indentations that are prone to elastic recovery or insufficient definition, limiting accurate hardness determination below certain load thresholds.^[36]^[26]

Standards and equipment

International standards

The Knoop hardness test is standardized internationally to promote uniformity in methodology, equipment verification, and result reporting across laboratories. The primary standards are ASTM E384 from the American Society for Testing and Materials (ASTM International) and ISO 4545-1 from the International Organization for Standardization (ISO), which outline procedures for microindentation hardness testing using the Knoop indenter.^[10]^[49] ASTM E384, designated as the "Standard Test Method for Microindentation Hardness of Materials," encompasses Knoop hardness measurements for a broad range of materials, specifying test forces from 0.0098 N to 9.8 N (1 gf to 1000 gf). It details Knoop-specific requirements, including load application durations, acceptance criteria for indentation quality (such as limits on cracking or irregularity), and verification protocols for indenter geometry and machine performance to ensure measurement accuracy.^[10] ISO 4545-1, titled "Metallic materials — Knoop hardness test — Part 1: Test method," focuses on metallic materials and prescribes test forces from 0.009807 N to 19.613 N, with indentations requiring a long diagonal length of at least 0.020 mm for reliable readings. The standard emphasizes indenter verification through profilometry or optical comparison, along with controlled test conditions like surface preparation and environmental factors to minimize variability.^[49] These standards differ in unit conventions for expressing Knoop hardness values: ASTM E384 employs the traditional kgf/mm², whereas ISO 4545-1 permits SI units such as N/mm² (equivalent to MPa) or GPa for consistency with international metric practices.^[10]^[49]^[50] Standardization efforts for the Knoop test, invented in 1939 at the U.S. National Bureau of Standards, emerged in the mid-20th century to formalize its application beyond initial research. ASTM first codified Knoop hardness testing under E92 in 1957 for broader metallic applications, with microindentation aspects detailed in E384 (first published in 1975 and revised periodically), while ISO 4545 was introduced in 2005 and revised in 2017 and 2023 to accommodate modern optical imaging and automated systems for enhanced precision.^[10]^[49]

Calibration and apparatus

The apparatus for the Knoop hardness test consists of a microhardness tester featuring a rhombohedral diamond indenter designed to produce elongated indentations, an integrated optical microscope with magnifications typically ranging from 100x to 1000x for accurate diagonal measurements, and a load application system capable of applying controlled forces between 1 gf and 1 kgf using either dead-weight mechanisms or electromagnetic load cells to ensure precise and repeatable indentation.^[22]^[51]^[10] Indenter calibration involves verifying the geometry using certified reference blocks, where indentations are made and measured to confirm the long-to-short diagonal ratio adheres to the ideal 7.114:1, with acceptable deviations limited to ensure measurement precision, as deviations can affect hardness calculations.^[10]^[52] This process, detailed in standards like ASTM E92 for reference block preparation, helps detect wear or misalignment in the indenter tip.^[2] ISO 4545-2 provides methods for verification and calibration of Knoop testing machines, including periodic checks of indenter geometry and load application.^[53] The complete testing system requires periodic calibration according to ASTM E384, encompassing checks for load accuracy within ±1% of the applied force to maintain reliable indentation depth and verification of stage flatness to prevent positional errors during sample mounting and testing, using control charts to monitor consistency and detect changes.^[10] In the 2020s, modern automated Knoop hardness testers have incorporated high-resolution CCD cameras for digital imaging, enabling software-assisted diagonal measurement and reducing operator variability while supporting high-throughput testing in quality control environments.^[54]^[55]

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Knoop indenter, showing angles between the edges of the flat pyramidal diamond point. Approximate ratios are: length : width=7.1:1, and length : depth= 30:1.
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### Summary of Knoop Shallower Indentations and Substrate Effects
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1 The indenter shall meet the specifications for Knoop indenters. See Test Method E 384. 7.2.2 Fig. 1 shows the indenter and its maximum usable dimensions. The ...
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