The hardness results look normal, so why does cracking still occur after cold heading?

COLD HEADING MATERIAL ENGINEERING CLASSROOM · RX-CE-028

Cracks After Cold Heading: What Can Hardness Tell Us?

Original site records show cracked screw heads and an approximately 185 HV0.2 display. The records do not, by themselves, establish a root cause or acceptance limit.

Cracks, hardness tests, and machine screen images are all right in front of us. The issue is not whether there is a single number, but whether that one number can replace all other judgments. Cold-headed screws with obvious head cracks: On-site workpiece—cracks visible on part of the head. The image is used to illustrate the abnormal morphology and should not be used alone to determine the root cause. After cold heading, cracks have already appeared on the screw heads.

RX-CE-028Engineering knowledgeCreation Group Technical Team

Article information

AuthorCreation Group Technical Team
Updated2026-09-19
Original publication2026-09-19

Visible cracks, a hardness record and production photographs provide different kinds of evidence. A single hardness number cannot replace the combined investigation.

Original site parts: cracks are visible in some screw heads; the image does not establish their cause.
Original site parts: cracks are visible in some screw heads; the image does not establish their cause.

What the cracked parts establish

The supplied photographs show cracks in some screw heads after cold heading. Their location and appearance help define the abnormality. They do not identify whether its origin lies in the material, surface condition, part geometry, deformation sequence or another process condition.

Head-crack detail from the original site records; location and appearance are investigation leads.
Head-crack detail from the original site records; location and appearance are investigation leads.
Original site markings identify the area of interest; the markings are preserved.
Original site markings identify the area of interest; the markings are preserved.

What the hardness record establishes

The supplied records include a hardness-testing equipment photograph and a software display reading approximately 185 HV0.2. The display is evidence of a recorded Vickers hardness result under the indicated test designation. It does not provide an acceptance threshold for an unidentified grade or prove the cause of the cracks.

Hardness-testing equipment shown in the original site records.
Hardness-testing equipment shown in the original site records.
Original software interface displaying approximately 185 HV0.2; original-language labels remain unchanged.
Original software interface displaying approximately 185 HV0.2; original-language labels remain unchanged.

A result that appears acceptable must still be interpreted with the grade, delivery condition, test location, applicable method and order requirements. The records shown here do not establish the link between every photographed part, test point and material batch. No hardness conversion or root-cause verdict is inferred.

The production process remains part of the evidence

Original cold-heading production setting; the photograph does not establish a corrective-action result.
Original cold-heading production setting; the photograph does not establish a corrective-action result.

The customer ultimately needs conforming parts from the actual machine and process. The same measured hardness does not establish the same response in another product geometry or at another deformation location. Material condition, part design and forming conditions must be evaluated together.

A useful next step

Bring the abnormal parts, inspection records, material specification and actual use conditions into one traceable comparison. Confirm the material and test references, identify the defective location and forming stage, and compare the relevant process conditions before assigning responsibility.

Creation Group considers material test results together with application performance. Photographs, material dimensions and a description of the abnormality can help define the next investigation step.

Scope of the original records

The original site materials supplied for this article are preserved. Crack photographs illustrate appearance; testing photographs show that hardness records exist; machine photographs illustrate the forming setting. They do not independently establish crack origin, batch correspondence or an effective corrective action. No process setting, acceptance threshold or adjustment method is disclosed or invented.

Frequently Asked Questions

Does an apparently normal hardness result identify the cause of a crack?
No. Hardness describes a test at an identified location and condition. Investigate the abnormal part, material references, product geometry and forming process; the displayed number alone is not a root-cause verdict.
What evidence should a cold-heading investigation bring together?
Use traceable material specifications and test records, representative samples or photographs, the affected part and station, and comparable machine, die and lubrication conditions.
Does one observation establish the root cause?
No. Relate the observation to the material location and actual process, distinguish a possible mechanism from a confirmed finding, and verify corrective actions in representative production.

About Creation Group

Creation Group provides engineering support for cold heading wire, shaped wire and cold-drawn seamless shaped tubes, covering materials, process coordination and failure analysis. Articles distinguish conclusions based on standards, engineering assessments and case information according to the scope of the supporting evidence.

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