Materialography & Hardness Testing in Defence and Security
In the military sector, quality assurance is of utmost importance, as the operational readiness of systems and equipment depends on the safety and reliability of every component. Standards such as DIN EN 9100 and the military AQAP guidelines embed quality objectives right from the development and production stages. Comprehensive risk management, including complete traceability, automated testing methods, and statistical process control, ensures that sources of error are identified and addressed early. This also includes metallographic examinations: Through microscopic analysis of alloys, purity, corrosion behavior, and microstructures are assessed to test safety-critical components for long-term durability and to meet the high quality requirements of the defence industry.
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Ground Defence
Ammunition
Aerospace
Ground Defence
Metallography and hardness testing are central to ground defence and armor because they examine the microstructure of metallic materials and evaluate their properties. Metallographic analyses can identify microstructures, grain sizes, phase distributions, and defects, such as cracks or inclusions. These findings are crucial for developing and ensuring the quality of armor steels and alloys used in vehicles, protective plates, and fortifications. The goal is to produce materials that are strong, tough, and resistant to ballistic and mechanical stress to ensure optimal protection and durability in the defence sector. Armor and specially developed armor steel are essential components of ground defence. They protect vehicles, equipment, and personnel from enemy fire, explosions, and other battlefield dangers. High-quality armor steel combines hardness, toughness, and elasticity to prevent projectile penetration while ensuring structural integrity. Effective armor significantly increases the survivability and operational capability of ground forces, contributing to the fulfillment of military missions.
Metallography in ground defense
In the ground defense the armor parts or the large, calibrated ammunition are the related parts. The manufacturing process of these parts is mostly forging, and the physical and mechanical properties of these parts must be provided through heat treatment. The quality control after heat treatment must be done by metallographic analyses as well as hardness testing. Below are the most important analyses in metallographic area:
- Microstructure analysis on the edge and core
- Comparing the microstructure on the edge and core
- Steel cleanliness grade determination
- Determining of Inclusion content of steel
For the accurate and high-quality preparation of the samples the accuracy should be provided from the very first steps like cutting. Plan grinding is also very vital step to save time and energy in the preparation of the samples in the ground defense. Below you will find some of the advantages of QATM machines, consumables and accessories in ground defense area:
- Accurate cutting machines with the cut-off disc from 75mm till 600 mm
- Fast hot mounting presses like QPRESS 40 help you to save your time by 35%
- Stone grinding machine QGRIND XL with the accuracy of 0,1 mm.
- Plenty of clamping tools and sample holders give the opportunity to clamp samples with all possible shapes for cutting, grinding and polishing.
Hardness Testing in Ground Defence
Ground‑defence materials such as shells, armour plates or heavy structural parts must endure extreme loads. Modern hardness testing enables precise, reproducible evaluation of a material’s resistance to indentation and ensures components meet stringent defence standards. QATM offers tailor‑made systems ranging from standalone testers to fully automated in‑line solutions.
Applications in Ground defence
- Artillery Ammunition (155 mm): Fully automated BHT system mills the shells, performs Brinell/Rockwell/Vickers hardness tests, and classifies projectiles up to 8 tons.
- Artillery Ammunition (155 mm): Fully automated BHT system mills the shells, performs Brinell/Rockwell/Vickers hardness tests, and classifies projectiles up to 8 tons.
- Artillery Ammunition (155 mm): Fully automated BHT system mills the shells, performs Brinell/Rockwell/Vickers hardness tests, and classifies projectiles up to 8 tons.
Advantages of Hardness Testing with QATM-Equipment
- Precise and reliable results for safety-critical components.
- Flexibility through Rockwell, Vickers, and Brinell methods for various materials and formats.
- Customized solutions and automation via robotic handling, surface processing, and data interfaces.
Ammunition
Examining the microstructure of metallic components, such as bullet casings, warheads, and detonators, allows one to analyze material defects, microstructural formations, and heat treatment conditions in detail. This ensures that the materials used possess the necessary mechanical properties, such as strength, toughness, and reliability, when subjected to extreme loads. Thus, metallographic examinations contribute significantly to the safety, functionality, and performance of modern ammunition and ordnance.
Application example: Protectile
A cartridge is made of four pieces. The projectile, case, propellant and the primer. The projectile is a piece which leaves a gun after firing. Before the projectile was just from lead, but nowadays the projectile always has a jacket and in most cases the jacket is from Tombac, which is a copper alloy with more than 65% copper. The case is mostly from brass, the propellant is gun powder, and the primer is what makes the powder ignite. Metallographic analyses on projectile and the case can be performed. The most important analyses are:
- Checking the jacket on the edge of the projectile
- Coating thickness measurement on the projectile
- Analyses the core of the cartridge by grinding down the cartridge and preparation the target area.
QATM cutting machines like Qcut 200 A can perform an accurate cutting, near to the target surface. In addition, the table grinder and polisher of QATM, with the possibility of automatically dosing till the final polishing, make the preparation of ammunition parts easier than ever.
- High range of consumables which give you the opportunity to find the optimal preparation for your samples.
- Automatic preparation with automatic dosing give you the highest reproducibility.
- Gap-free mounting material supports the coating during preparation to ensure the best results.
Direct Vickers Hardness Testing on Cartridge Cases with Qness 60 A+ EVO
The Qness 60 A+ EVO enables precise Vickers hardness testing directly on the surface and base of cartridge cases. Using HV2 and HV5 methods, the system allows for testing at various heights - ideal for consistent quality control in ammunition production.
Aerospace
In the aerospace industry, metallography and hardness testing are essential for ensuring the quality and safety of materials. These methods analyze the microstructure of high-performance alloys used in engines, structural components, and heat protection systems in detail. Metallographic examinations can identify grain boundaries, phase distributions, and potential weak points, such as cracks or inclusions. These examinations ensure that materials can withstand extreme loads, temperature changes, and high safety requirements. Thus, metallography makes a decisive contribution to the reliability and longevity of aircraft and aerospace systems.
Steel in defense industry
Armor steel, also known as security steel or ballistic security steel, is used to protect against external threats, especially ballistic impacts such as projectile fire. Various types of steel are used for armor, including stainless steel, manganese steel, and high-strength manganese hard steel (Hadfield steel). The metallography analysis and hardness testing on these steel parts are part of the quality control in manufacturing process. The most important analyses of these parts are as follows:
- Mostly martensitic microstructure analyses
- Metallographic preparation for Brinell hardness testing
- Inclusion content and cleanliness grade determination
The premium cut-off discs of QATM, offers our customers the possibility to cut different steel types. No matter normal structural steel or ballistic steel till to HB 700, QATM offers appropriate consumables for cutting of all these steel types.
- High range of cut-off discs to cut different armor steels
- Options like pulsed cutting, rotational clamping tools or different cutting modes make the contact and wear between the sample and the cut-off disc as low as possible.
- Diamond grinding discs like VEGA with high removal rate, available in various grain sizes from 250 µm till 10 µm make the preparation of armor steel samples shorter than ever before.
Aluminum in defence industry
Aluminum and its alloys play a critical role in the defence industry due to their unique combination of light weight, high strength, and excellent corrosion resistance. These materials are extensively used in the manufacturing of military vehicles, aircraft, naval vessels, and protective armor. Their favorable properties contribute to enhanced mobility, fuel efficiency, and payload capacity, while maintaining structural integrity and durability. As a result, aluminum alloys support the development of advanced, high-performance defence systems and equipment.
Below are some important metallographic analyses for Aluminum and its alloys:
- Assessment of grain size, phase distribution and morphology using optical as well as scanning electron microscope.
- Porosity and inclusion analysis
- Precipitate characterization in Aluminum alloys
The QATM UV-mounting machine, QMOUNT, can mount aluminum and its alloys in one minute. Dia-COMPLETE suspensions, a mixture of diamond and lubricant, solve the problem of imprinted particles when preparing aluminum alloys.
- Fast mounting methods like UV-mounting with QMOUNT
- Automatic dosing with finished mixed diamond suspensions like Dia-COMPLETE
- Various samples holder for the samples with or without mounting
Titanium in defense industry
Titanium and its alloys are highly valued in the defense industry for their exceptional strength-to-weight ratio, corrosion resistance, and ability to withstand extreme temperatures. These materials are extensively utilized in the production of aircraft, missiles, naval ships, and armor plating, offering both structural and protective advantages. The use of titanium alloys enhances operational performance by reducing weight and increasing durability, contributing to improved mobility, fuel efficiency, and survivability in demanding military environments.
Below you will find the most important metallographic analyses of Titanium and its alloys in defense industry:
- Texture analyses which is an assessment of crystallographic orientation using EBSD analyses under SEM.
- Alphas case evaluation: Identification of the brittle alpha case layer formed during high-temperature processing, which can affect surface properties and fatigue resistance.
- Phase distribution analyses
QATM with its fully automatic grinder and polishers and with the preparation method with just 3 steps, offers you the preparation method with the best quality and in the shortest time. QATM SiC-stones with the grain size of P80 and P150 are able to grind the Titanium samples plan without deforming the surface. QPOL 250 Bot with a stapler for changing the grinding. The QPOL 250 Bot, for example, is equipped with a practical media changer for changing the grinding discs/SiC papers and polishing cloths, offering you maximum reproducibility.
Advantages
- Fully automatic sample preparation with the access management on QPOL 250/300 Bot.
- 3-Step preparation method which can save time and energy in preparing Ti-samples.
- Accuracy and reproducibility in the preparation of Ti samples with the ability to program all details in the QATM machine software.
Electronic components in defense industry
Like any other industries, defense industry is also very dependent on the electronic and microelectronic parts. Using KI in the defense industry makes the demand for more electronic parts more than ever before. There are two main objectives in the metallographic preparation of electronic components. The first is to identify possible defects in the printed circuit boards (PCBs), and the second is to check the solder joints, the microstructure of individual components, and the connectivity of the parts to monitor the various stages of the manufacturing process.
- Defect analyses of possible defects in PCB parts.
- Metallographic analyses on solder joints.
- Controlling the structure of the electronic parts.
QATM's extensive experience in metallographic preparation of various electronic and microelectronic parts gives us a deep understanding of the appropriate machines, consumables, accessories, and parameters to achieve the best results in the shortest possible time.
- Cold mounting materials, such as KEM 20, have a hardening time of approximately 15 minutes, provide the best mounting for copper and its alloys.
- The fine polishing suspension EPOSIL F 0.1 µm, which contains colloidal silicon oxide and has an automatic dosing option (QDOSER+), provides the best results after short fine polishing of electronic samples.
With QATM, you benefit from the following advantages
Reliability under the toughest conditions
In the defence sector, the highest demands are placed on safety, precision, and traceability. Every component — from small precision parts and cartridges to massive armoured steel plates — must perform reliably under extreme conditions.With QATM hardness testing solutions, you ensure that your materials consistently meet the required strength and durability standards.
Quality Testing Across All Component Types
Whether it’s fine precision components, cartridge cases, or large structural parts, our hardness testing systems deliver reproducible and traceable results for every application.Using state-of-the-art testing technology, we ensure end-to-end quality assurance - from material incoming inspection to final acceptance. Our systems support all common test methods:Vickers, Rockwell, and Brinell – flexibly adaptable to meet any testing requirement or material specification.
Custom Systems and Automation for Large-Scale Projects
For large-scale defence applications, QATM develops customized hardness testing machines in close cooperation with MAKKON GmbH (Austria).These include special Brinell testing portals for armoured steel plates and inline hardness testing systems for 155 mm ammunition.Together, QATM and MAKKON provide turnkey solutions combining advanced hardness testing know-how with cutting-edge automation and mechanical engineering.
Intelligent Software for Maximum Process Security
Our software platform Qpix Control 2 ensures intuitive operation, 3D visualization, automated testing sequences, and extensive data export and documentation options.AI-based image analysis guarantees maximum accuracy, even on rough or etched surfaces — a crucial advantage for safety-critical components in defence applications.
Flexible Test Methods and Tailored Fixtures
QATM systems are designed for maximum flexibility and can be configured to perfectly match your specific testing process.For complex geometries or hard-to-reach areas, our experts design custom fixtures and special testing solutions, ensuring reliable results even where conventional systems reach their limits.
Application Examples
- Qness 10 / 60 A+ EVO - Fully automated micro hardness testing on cartridge cases and bullets, including AI-supported image evaluation and automatic Z-positioning for different sample heights.
- Qness 3000 E EVO - Customized macro hardness tester for large and heavy workpieces up to 350 kg, featuring a roller conveyor, crane loading, and pneumatic positioning system.
- Qness 3000 A+ EVO - Fully automatic portal-type hardness tester for components up to 1000 kg, with extended test area, safety light barriers, and CE-compliant enclosure.
Your Benefits at a Glance
Creating Confidence Through Quality: With our proven expertise in hardness testing and materials evaluation, we provide the foundation for safety, reliability, and trust — from material qualification to field deployment.
QATM Products & Contact
QATM offers a wide range of innovative and robust instruments for materialography, metallography and hardness testing. Our experts know the requirements of each branch of industry and and will be happy to assist in finding the right solution for your application.
