Skip to content

Relationship Between Hardness and Tensile Strength

Materials Science · FE Reference Handbook section

Materials Science
1 formulas
10 exam-style examples
~47 min
All Materials Science lectures

Handbook notes for this section

Definitions and conditions exactly as the handbook states them.

  • For plain carbon steels, there is a general relationship between Brinell hardness and tensile strength as follows:

Core formulas for this FE topic

Definitions, applicability, units, assumptions and worked examples for each relation.

Worked exam-style examples

The four ways this section is written on the real exam — thoughts first, then equations, then substitution.

Example 1
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength

A steel component measures 165 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 5.

Given

  • BHN=165BHN = 165
  • ASTMgrainsizen=5ASTM grain size n = 5

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×165=82,500psi=82.5ksiTS = 500 \times 165 = 82,500 psi = 82.5 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(5−1)=16grains/in2N = 2^(5 - 1) = 16 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈83ksi;N=16grains/in2TS \approx 83 ksi; N = 16 grains/in^{2}

Why the other options are there

  • 0.33 ksi (ratio inverted)
  • 32 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 2
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (2)

A steel component measures 391 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 8.

Given

  • BHN=391BHN = 391
  • ASTMgrainsizen=8ASTM grain size n = 8

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×391=195,500psi=195.5ksiTS = 500 \times 391 = 195,500 psi = 195.5 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(8−1)=128grains/in2N = 2^(8 - 1) = 128 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈195.5ksi;N=128grains/in2TS \approx 195.5 ksi; N = 128 grains/in^{2}

Why the other options are there

  • 0.78 ksi (ratio inverted)
  • 256 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 3
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (3)

A steel component measures 343 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 6.

Given

  • BHN=343BHN = 343
  • ASTMgrainsizen=6ASTM grain size n = 6

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×343=171,500psi=171.5ksiTS = 500 \times 343 = 171,500 psi = 171.5 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(6−1)=32grains/in2N = 2^(6 - 1) = 32 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈171.5ksi;N=32grains/in2TS \approx 171.5 ksi; N = 32 grains/in^{2}

Why the other options are there

  • 0.69 ksi (ratio inverted)
  • 64 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 4
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (4)

A steel component measures 203 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 5.

Given

  • BHN=203BHN = 203
  • ASTMgrainsizen=5ASTM grain size n = 5

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×203=101,500psi=101.5ksiTS = 500 \times 203 = 101,500 psi = 101.5 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(5−1)=16grains/in2N = 2^(5 - 1) = 16 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈101.5ksi;N=16grains/in2TS \approx 101.5 ksi; N = 16 grains/in^{2}

Why the other options are there

  • 0.41 ksi (ratio inverted)
  • 32 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 5
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (5)

A steel component measures 183 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 6.

Given

  • BHN=183BHN = 183
  • ASTMgrainsizen=6ASTM grain size n = 6

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×183=91,500psi=91.5ksiTS = 500 \times 183 = 91,500 psi = 91.5 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(6−1)=32grains/in2N = 2^(6 - 1) = 32 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈92ksi;N=32grains/in2TS \approx 92 ksi; N = 32 grains/in^{2}

Why the other options are there

  • 0.37 ksi (ratio inverted)
  • 64 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 6
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (6)

A steel component measures 344 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 6.

Given

  • BHN=344BHN = 344
  • ASTMgrainsizen=6ASTM grain size n = 6

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×344=172,000psi=172.0ksiTS = 500 \times 344 = 172,000 psi = 172.0 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(6−1)=32grains/in2N = 2^(6 - 1) = 32 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈172.0ksi;N=32grains/in2TS \approx 172.0 ksi; N = 32 grains/in^{2}

Why the other options are there

  • 0.69 ksi (ratio inverted)
  • 64 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 7
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (7)

A steel component measures 236 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 8.

Given

  • BHN=236BHN = 236
  • ASTMgrainsizen=8ASTM grain size n = 8

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×236=118,000psi=118.0ksiTS = 500 \times 236 = 118,000 psi = 118.0 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(8−1)=128grains/in2N = 2^(8 - 1) = 128 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈118.0ksi;N=128grains/in2TS \approx 118.0 ksi; N = 128 grains/in^{2}

Why the other options are there

  • 0.47 ksi (ratio inverted)
  • 256 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 8
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (8)

A steel component measures 176 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 4.

Given

  • BHN=176BHN = 176
  • ASTMgrainsizen=4ASTM grain size n = 4

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×176=88,000psi=88.0ksiTS = 500 \times 176 = 88,000 psi = 88.0 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(4−1)=8grains/in2N = 2^(4 - 1) = 8 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈88ksi;N=8grains/in2TS \approx 88 ksi; N = 8 grains/in^{2}

Why the other options are there

  • 0.35 ksi (ratio inverted)
  • 16 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 9
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (9)

A steel component measures 220 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 5.

Given

  • BHN=220BHN = 220
  • ASTMgrainsizen=5ASTM grain size n = 5

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×220=110,000psi=110.0ksiTS = 500 \times 220 = 110,000 psi = 110.0 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(5−1)=16grains/in2N = 2^(5 - 1) = 16 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈110.0ksi;N=16grains/in2TS \approx 110.0 ksi; N = 16 grains/in^{2}

Why the other options are there

  • 0.44 ksi (ratio inverted)
  • 32 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

Example 10
Hardness-to-strength conversion and ASTM grain size — Relationship Between Hardness and Tensile Strength (10)

A steel component measures 277 BHN. Estimate its tensile strength from the hardness relationship, then determine how many grains per square inch at 100× correspond to an ASTM grain size number of 6.

Given

  • BHN=277BHN = 277
  • ASTMgrainsizen=6ASTM grain size n = 6

Find

Approximate tensile strength and grains per in² at 100×

Start with the thinking

  • For steels the empirical relation between hardness and tensile strength is TS ≈ 500 × BHN in psi.
  • The ASTM grain size number doubles the grain count for every increment of one.

Step-by-step solution

  1. Formula — TS (psi) ≈ 500 × BHN

  2. Substituting

    TS=500×277=138,500psi=138.5ksiTS = 500 \times 277 = 138,500 psi = 138.5 ksi
  3. Formula

    N=2(n−1)grainsperin2at100×N = 2^(n-1) grains per in^{2} at 100\times
  4. Substituting

    N=2(6−1)=32grains/in2N = 2^(6 - 1) = 32 grains/in^{2}
  5. Interpretation — finer grains (higher n) raise yield strength through the Hall-Petch effect

Answer:
TS≈138.5ksi;N=32grains/in2TS \approx 138.5 ksi; N = 32 grains/in^{2}

Why the other options are there

  • 0.55 ksi (ratio inverted)
  • 64 grains/in² (exponent off by one)

Reference: FE Reference Handbook — Materials Science → Relationship Between Hardness and Tensile Strength

© 2026 Dr. Steve Efe. Civil Engineering Capstone Studio. All rights reserved.