Extending the Lifespan of Measuring Tools: Materials, Wear, and Surface Precision

Measuring tools play a critical role in manufacturing and quality control. Their precision and durability directly impact the reliability of the final product. Due to their frequent use—especially on demanding sections like the GO side—it’s essential to choose the right materials and production processes to extend their service life.

Choosing the Right Material: Which Tool Steels Perform Best?

For durable gauges, cold work tool steels are among the top choices. These steels are designed for wear resistance and toughness in demanding conditions. Some of the most commonly used tool steels for measuring applications include:

1.2482
1.3505
1.2550
1.2080

A key alloying element in these materials is chromium (Cr), which enhances corrosion resistance—a factor that significantly contributes to extended tool life. Another important component is carbon (C). A high carbon content improves hardenability, which is the material's ability to reach high hardness values after heat treatment, typically around 58–62 HRC for these steels.

Balancing Hardness and Ductility

However, with increased hardness comes a trade-off: reduced ductility. This means that while the tool becomes more resistant to wear, it also becomes more brittle and prone to cracking under high stress. The heat treatment process must therefore be carefully controlled to balance these two properties.

Understanding Wear: How Gauges Lose Accuracy Over Time

Wear directly affects the accuracy of measuring tools:

In plug gauges, the measured dimension tends to decrease over time.
In caliper-type gauges, the measured dimension tends to increase.

Once the wear tolerance is exceeded, the gauge becomes unusable. That's why high wear resistance is essential when selecting materials for precision tools.

When Steels Aren’t Enough: The Role of Carbide Alloys (Widia)

In cases where wear tolerance is extremely tight, even high-grade tool steels may wear out too quickly. Here, carbide alloys, commonly known as Widia, are the preferred choice.

Did you know? The term Widia is an abbreviation of the German "Wie Diamant", meaning "like diamond"—highlighting the material’s exceptional hardness and wear resistance.

Widia tools are ideal for high-precision applications due to their superior durability and lifespan.

Surface Roughness: The Hidden Factor in Tool Wear

Another crucial factor influencing wear is the surface roughness of the measuring face. A rougher surface generates higher friction between the gauge and the part being measured. Increased friction results in faster wear.

Therefore, to reduce wear and extend tool life, it’s important to ensure the measuring surface is: