ASTM D6110 Plastic Charpy Impact Test of Notched Specimens, ASTM D6110 Charpy impact tester

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ASTM D6110– Standard Test Method for Determining the Charpy Impact Resistance of Notched Specimens of Plastics

ASTM D6110 is the core international test standard dedicated to evaluating plastics’ flexural shock fracture resistance, the primary testing protocol for our industrial pendulum-type Charpy impact testing machines. This standard quantifies impact toughness by measuring energy consumed when standardized pendulum hammers break milled-notched plastic specimens in a single pendulum swing. Similar with ISO 179 (plastic Charpy impact) but has entirely distinct technical specifications.

All test specimens for ASTM D6110 require precision milled notches. The machined notch creates controlled stress concentration, triggering brittle fracture instead of ductile failure to deliver consistent, repeatable impact test data. Test outcomes are formally reported as absorbed impact energy per unit specimen width, a critical metric for plastic material quality control and R&D verification.

This standardized procedure is widely known as the notched bar impact test, covering both Charpy and Izod impact test setups. In Charpy and Izod testing workflows, the machined notch consistently concentrates stress to replicate real-world brittle breakage scenarios, enabling labs and manufacturers to accurately assess plastic brittleness and shock resistance with compliant impact testing equipment.

Keywords: ASTM D6110 Charpy impact tester, pendulum impact testing machine, plastic notched bar impact tester, Charpy Izod impact test equipment, flexural shock resistance test for plastics, milled notch specimen impact test, plastic brittle fracture measurement, absorbed impact energy test, standardized pendulum hammer tester, polymer impact toughness inspection

Test Principle

A notched plastic specimen is supported as a horizontal simple beam on two anvils. A pendulum hammer swings down and strikes the specimen opposite the notch, midway between the supports, breaking it in a single swing.

The energy absorbed is derived from the loss of pendulum potential energy (read from a dial or digital encoder), corrected for windage, bearing friction, and pointer inertia.

The milled notch (45°, tip radius 0.25 ± 0.05 mm) creates a stress concentration that promotes brittle rather than ductile fracture, reducing scatter.

Key energy loss factors accounted for in calculation: fracture initiation energy, crack propagation energy, vibration loss, striker-specimen friction, and toss energy for broken specimen fragments (especially dense brittle plastics).

Standard Test Specimen Information

1, Core Specimen Dimensions

Overall length: 124.5–127.0 mm (4.90–5.00 in.); span between two anvils fixed by machine design.

Specimen depth (thickness): minimum 6.10 mm, maximum 12.7 mm (0.500 in.); sheet stock thicker than 12.7 mm must be machined down to 12.7 mm square cross-section.

Width: adjustable within limits; sheet materials use sheet thickness as specimen width (3.00–12.7 mm).

Notch geometry (mandatory): included V-notch angle = 45 ±1°, notch root radius = 0.25 ±0.05 mm (0.010 ±0.002 in.); the angle bisector plane must be perpendicular to specimen flat surface.

ASTM D6110 Plastic Charpy Impact Test of Notched Specimens

2, Specimen Preparation Rules

Molding: Follow ASTM D647 standard mold practice for injection/compression molded specimens; cross-laboratory tests must use unified molds and molding procedures.

Sheet material cutting: Prepare specimens along both machine (lengthwise) and transverse directions to test anisotropic impact performance unless otherwise specified.

Notching rules: Notch on the thinner side of asymmetric specimens; compression-molded parts notch parallel to molding pressure direction. Use a dummy backup bar behind the last specimen during milling to avoid edge chipping.

Composite thin specimens (thickness <6.35 mm): Stack multiple thin pieces to reach total width 6.35–12.7 mm (not recommended, as interlayer friction distorts energy absorption data).

Testing equipment required for ASTM D6110 plastic impact test:

Component	Specifications
Pendulum Charpy Impact Tester	Rigid heavy base paired with two fixed specimen anvils; rigid frame and bearings to avoid alignment deviation and vibration energy loss during impact and crack growth. Standard base pendulum: nominal energy of 2.7 ± 0.14 J (2.0 ± 0.10 ft-lbf). Add-on weights or multi-energy pendulums are allowed for high-toughness plastics; each 4.5 N added weight raises capacity by 2.7 J. Pendulum striker edge radius: 3.17 ± 0.12 mm (0.125 ± 0.005 in.); striker transverse center must align within 0.40 mm of specimen midpoint anvil centerline.
Pendulum Energy Ranges	1J, 2J, 4J, 5J, 7.5J, 15J, 25J, 50J. Energy capacity where absorbed energy (W) is 10–80% of available energy (E). Use the pendulum with the highest energy if multiple qualify.
Notching Device	Milling machine, engine lathe or dedicated notch cutter with carbide/diamond-tipped cutting blades; adjustable cutter speed and feed rate. Auxiliary centering jig for consistent specimen positioning during notching.

Component

Specifications

Pendulum Charpy Impact Tester

Rigid heavy base paired with two fixed specimen anvils; rigid frame and bearings to avoid alignment deviation and vibration energy loss during impact and crack growth.

Standard base pendulum: nominal energy of 2.7 ± 0.14 J (2.0 ± 0.10 ft-lbf).

Add-on weights or multi-energy pendulums are allowed for high-toughness plastics; each 4.5 N added weight raises capacity by 2.7 J.

Pendulum striker edge radius: 3.17 ± 0.12 mm (0.125 ± 0.005 in.); striker transverse center must align within 0.40 mm of specimen midpoint anvil centerline.

Pendulum Energy Ranges

1J, 2J, 4J, 5J, 7.5J, 15J, 25J, 50J.

Energy capacity where absorbed energy (W) is 10–80% of available energy (E).

Use the pendulum with the highest energy if multiple qualify.

ASTM D6110 Plastic Charpy Impact Test of Notched Specimens

Notching Device

Milling machine, engine lathe or dedicated notch cutter with carbide/diamond-tipped cutting blades; adjustable cutter speed and feed rate.

Auxiliary centering jig for consistent specimen positioning during notching.

Key Test Parameters

1, Notching Process Parameters

Dry cutting: cutter speed 54–150 m/min, feed rate 89–160 mm/min.

Water-cooled cutting: cutter speed 54–150 m/min, feed rate 36–160 mm/min.

High cutter speed + slow feed + no coolant causes severe thermal stress at notch root; excessive feed/speed ratio induces surface cracking on specimens.

2, Pendulum Energy Control

Valid test criterion: Net absorbed breaking energy ≤85% of pendulum nominal energy. If exceeding 85%, switch to higher-energy pendulum weight and re-test with new specimens.

Windage & friction correction: Recalculate correction factors daily, after pendulum weight replacement or pendulum swap.

Mandatory Test Stipulations

Fracture validity: Only fully broken specimens are recorded; partial fracture, hinge break, or unbroken bars are discarded.

Notch inspection: Before formal testing, machine multiple trial specimens, inspect notch angle/radius via X1 microscopic procedure; replace cutter if geometry fails tolerance limits. Trial specimens cannot be used for official impact data.

Specimen defect rejection: Discard specimens with twist ≥0.05 mm at impact contact point (twisted samples absorb 20–30% excess energy and generate false high toughness values).

Replicate testing: Minimum 5 specimens per material batch; standard interlaboratory precision round-robin uses 9 specimens per material type.

Step-by-Step Test Procedures of ASTM D6110 Plastic Charpy Impact test:

Pre-calibrate the pendulum impact machine: Measure windage and friction correction factors daily; adjust friction washers, striker alignment, and pendulum rigidity if out of tolerance.

Prepare and condition notched specimens following humidity/temperature rules; inspect notch geometry.

Measure and record each specimen’s width and notch depth with micrometers, reject defective samples.

Mount specimen horizontally on two anvils, center the notch between supports using a centering jig; ensure pendulum strikes the surface opposite the V-notch.

Lift and lock the pendulum in release position, reset energy indicator dial/digital readout to zero.

Release pendulum freely to strike the specimen once; record the raw indicated breaking energy after fracture.

Calculate net breaking energy with windage/friction correction formulas. If energy exceeds 85% of pendulum nominal capacity, upgrade pendulum energy and retest new specimens.

Repeat steps 4–7 for all replicate specimens of the same material.

Compute average impact resistance and standard deviation for valid complete-fracture data.

Industrial Application Fields

ASTM D6110 is widely adopted across polymer manufacturing and end-product industries for material screening, incoming QC, molding process optimization, and failure analysis:

Automotive: Exterior bumpers, interior dashboard trim, door panels, reinforced nylon structural parts, plastic piping systems.

Electronics & Electrical: Appliance housings, circuit board enclosures, cable insulation, rigid electronic casings (ABS, PC blends).

Construction: PVC/CPVC water pipes, window profiles, insulation sheets, composite structural plastic profiles.

Consumer Goods: Toys, furniture plastic components, sports equipment, kitchen rigid plastic utensils and containers.

Medical Plastics: Rigid medical device housings, disposable sterile plastic packaging (non-hygroscopic rigid polymers).

Packaging: Rigid protective cases, thick-walled plastic bottles, industrial transport crates.

Composite Materials: Glass-fiber-reinforced plastics, cloth-laminated thermoplastics, thermoset phenolic resins.

Related Test standard:

Standard	Relationship
ISO 179-2:2020	Part 2: Instrumented impact test (measures force-time/deflection curves)
ISO 13802	Specifies pendulum impact tester requirements
ISO 2818	Specifies specimen preparation for plastic sheets
ISO 179-1	Plastics -- Determination of Charpy impact properties
ISO 180	Izod impact test (alternative specimen mounting: cantilever beam)
ASTM D256	Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics

Importance of ASTM D6110 Testing for Plastic Materials

Evaluate notch sensitivity: Real plastic components contain unavoidable stress concentrators (notches, holes, sharp edges). The V-notched Charpy test simulates worst-case impact failure, identifying brittle polymers prone to sudden cracking under minor shock in service.

Quality control of manufacturing variations: Minor deviations in molding temperature, cooling rate, filler content, or notch processing parameters drastically alter impact resistance. Consistent D6110 data verifies stable production batches and detects defective molding or raw material lots.

Support product design and failure analysis: Test data provides mechanical design input for plastic part wall thickness, fillet radii, and structural reinforcement; post-fracture specimen observation distinguishes brittle low-energy fracture vs. ductile high-energy failure modes to diagnose field breakage failures.

Charpy Impact is a single point test that measures a materials resistance to impact from a swinging pendulum. Charpy impact is defined as the kinetic energy needed to initiate fracture and continue the fracture until the specimen is broken. The values obtained can be used for quality control or to differentiate general.

QK-20 notch sample reparation machine is used to process the non-metal material impact test specimen notch, such as the plastics, organic glass etc., it’s an ideal notching machine for plastic impact test. Surface with nickle coating, more reliable.

ZQK-20A Sample preparation notch machine for impact tester is used to process the non-metal material impact test specimen, such as the plastics, organic glass etc., The equipment uses electric drive and is equipped with specialized cutting tools, allowing for fast and precise processing of standard-compliant specimen notches.

Q1: What exactly is ASTM D6110?

A1: ASTM D6110-18 is the official ASTM standard test method to measure the flexural shock fracture resistance (notched Charpy impact toughness) of plastic specimens via a single pendulum swing. It quantifies the energy absorbed to fully break a V-notched plastic beam, with primary results reported as J/m (energy per specimen width). It only shares a similar name with ISO 179 but has fully different technical rules, so data cannot be cross-compared directly.

Q2: Why is ASTM D6110 testing critical for plastic materials?

A2:It simulates real-world stress risers (sharp corners, scratches, weld lines, mold gates) via a controlled V-notch, evaluating notch sensitivity — the top root cause of sudden brittle failure in plastic parts.

It quantifies dynamic toughness for material selection, comparing neat resins, impact-modified blends, fiber-reinforced plastics, and thermosets.

It acts as batch quality control: minor shifts in molding, formulation, or post-processing drastically change impact values to flag defective raw materials or unstable production.

It identifies ductile-brittle transition temperatures, critical for outdoor, low-temperature automotive/construction plastic components.

It provides standardized, repeatable data for supplier-customer material acceptance agreements to eliminate lab-to-lab disputes.

Q3: What plastics can be tested by ASTM D6110?

A3: All rigid thermoplastics (PP, ABS, PC, PVC, nylon, PET), glass/carbon fiber reinforced plastics, cloth-laminated composites, and rigid thermosets (phenolic). Thin sheet plastics are also allowed (stacked composite specimens permitted as a last resort). Soft flexible elastomers are not suitable for this test method.

Q4: Why is a machined notch mandatory? Can I skip notching if my material is already brittle?

A4: No—the notch is the defining feature of this test. The 45° milled notch creates a controlled stress concentration that forces a brittle (rather than ductile) fracture, drastically reducing data scatter. Without a notch, ductile plastics will stretch and neck rather than break cleanly, making results irreproducible. Even inherently brittle plastics require a standardized notch to ensure comparable results across labs and batches.

Q5: What are the mandatory notch geometry tolerances per D6110?

A5: Included angle = 45 ±1°, notch root curvature radius = 0.25 ±0.05 mm. If the cutter produces notches outside these limits, all specimens must be discarded and the cutting blade replaced. An optical microscope (≥60× magnification) is required to verify notch geometry via Appendix X1 inspection procedures.

Q6: How do I prepare specimens from plastic sheets thicker than 12.7 mm?

A6: Any sheet stock over 12.7 mm thickness must be machined down to a standard 12.7 mm maximum depth before testing. Specimen width equals the original sheet thickness for sheets 3.00–12.7 mm thick. Specimens shall be cut both lengthwise and crosswise to test anisotropic impact performance unless otherwise specified by material specs.

Q7: Can I use stacked thin plastic sheets as a composite specimen?

A7: The standard discourages composite stacked specimens, as interlayer friction and adhesive/solvent effects distort absorbed energy readings. If thin-material Charpy data is mandatory, stack layers to reach total width 6.35–12.7 mm and clearly document this composite preparation in the final test report.

Q8: How is ASTM D6110 different from ISO 179 (the other common plastic Charpy test)?

A8: ASTM explicitly warns: the two standards share only a title. Key differences include:

Different specimen dimension tolerances, notch geometry requirements, and anvil spans

Unique pendulum energy, velocity, and correction factor rules

Distinct conditioning and notching protocols

Results from the two tests are not interchangeable—never compare ASTM D6110 data to ISO 179 data directly.

Q9: What if the broken specimen absorbs over 85% of the pendulum’s nominal energy?

A9: This result is invalid and must be discarded. The pendulum lacks sufficient energy to fully fracture the specimen under standard conditions. Install a higher-energy pendulum or add calibrated weights, re-calibrate friction/windage corrections, and test new replicate specimens.

Q10: Where must the pendulum striker hit the specimen?

A10: The striker impacts the flat surface opposite the V-notch, with the notch perfectly centered between the two specimen anvils. Misalignment will cause uneven fracture and artificially high/low energy absorption values. A centering jig is recommended for consistent positioning.

Q11: What units are required for reporting impact resistance per D6110?

A11: The mandatory primary unit is J/m (joules per meter) (net breaking energy divided by specimen width). Reporting kJ/m² is optional; if using this secondary unit, the cross-sectional area under the notch must also be documented in the report. Direct conversion between J/m and kJ/m² is not possible without notch cross-section data.

Q12: How many replicate specimens are required for a valid test batch?

A12: A minimum of 5 specimens per material sample is required. Interlaboratory precision round-robin testing uses an average of 9 specimens per material grade to generate repeatability (r) and reproducibility (R) precision data shown in Table 1 of the standard. Standard deviation shall be calculated and reported to two significant figures.

Q13: What is the difference between ASTM D6110 (Charpy) and ASTM D256 (Izod)?

A13: ASTM D6110 Charpy: Specimen horizontally supported at both ends; striker hits the side opposite the notch; results in J/m.

ASTM D256 Izod: Specimen vertically clamped as a cantilever beam; striker hits the notched face directly; results in J/m or ft·lbf/in.

Test geometry and stress distribution differ drastically, so impact values cannot be directly converted or compared between the two standards.

Q14: Can ASTM D6110 test data be directly compared with ISO 179 Charpy data?

A14: No. The standard explicitly states the two standards only share a similar title, with major differences in specimen dimensions, machine striker geometry, notch tolerances, energy calculation formulas, and reporting rules. Test results from D6110 cannot be used interchangeably with ISO 179 values for material qualification or acceptance.

Q15: Why do my test results show large data scatter between identical specimens?

A15: Common root causes:

Inconsistent notch geometry (worn cutting blades, unregulated cutting speed/feed, thermal damage at notch root);

Specimen twist over 0.05 mm at the impact contact point (twisted specimens absorb 20–30% excess energy);

Poor pendulum alignment, loose machine base, or uncalibrated windage/friction corrections;

Insufficient conditioning time or inconsistent moisture content (especially hygroscopic plastics);

Mixed fracture modes (some brittle low-energy breaks, some ductile high-energy breaks) within the same batch.

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