EnglishViews: 0 Author: Site Editor Publish Time: 2026-06-15 Origin: Site
The crushing wall is a core wear-resistant component of cone crushers and gyratory crushers. It bears long-term impact, extrusion and friction loads from ores. The microstructure, compactness and mechanical stability of castings directly affect the equipment operating condition. Crushing walls are mostly made of wear-resistant materials such as high manganese steel, ultra-high manganese steel and high-chromium composite steel. Different casting processes are adopted to meet the production requirements of large-size, thick-section and high-wear-resistance products. At present, the large-scale industrial casting processes in the industry include sand casting, iron mold sand-lined casting, lost foam casting, V-process casting and dual-liquid composite casting. Each process adapts to different production scenarios and product specifications with distinct technical characteristics and application scopes.
Water glass sand casting is a traditional basic process for crushing wall production and a common forming method for small and medium-sized crushing wall castings, which is applicable to the casting of various materials including high manganese steel and alloy steel. This process uses water glass as the binder mixed with quartz sand to prepare molding sand. Casting is completed through molding, hardening, box closing and molten steel pouring, relying on the air permeability and fire resistance of the sand mold to form castings.
The core process procedures include sand preparation, mold shaping, cavity drying, box positioning, molten steel pouring, natural cooling, shakeout cleaning and heat treatment. In production, the hardening speed and strength of sand molds can be adjusted by changing the water glass modulus and curing agent dosage to adapt to crushing wall castings with different thicknesses and structures. For high manganese steel crushing walls, water toughening heat treatment is required after forming to refine austenite grains and improve the work hardening performance and wear resistance of castings.
This process features low equipment investment cost, strong mold universality and wide process adaptability, which can meet the mass production of conventional standard crushing walls. The good yieldability of sand molds reduces casting stress generated during solidification and lowers the occurrence probability of crack defects. However, it has obvious limitations, including a high proportion of manual molding, low production efficiency, poor surface roughness of castings, heavy workload of subsequent grinding and finishing, and cumbersome waste sand recycling procedures. It is currently used for mass production and small-batch customization of standard crushing walls.
As an improved process suitable for large high manganese steel crushing walls, iron mold sand-lined casting combines the advantages of metal mold and sand casting, making up for the compactness defects of traditional sand casting. It has been widely applied in the production of crusher wear-resistant parts in recent years. This process adopts a metal mold as the base, with a thin sand layer evenly coated on the inner cavity to complete casting forming relying on the rigidity of the metal mold and the forming characteristics of the sand layer.
The process flow includes metal mold pretreatment, inner cavity sand coating, sand layer drying and curing, box assembly, molten steel pouring, forced cooling, demolding cleaning and subsequent heat treatment. The metal mold can be recycled repeatedly. The surface thin sand layer buffers the thermal shock of high-temperature molten steel and avoids surface defects such as sand adhesion and burning. Meanwhile, the rapid thermal conductivity of the metal mold accelerates the solidification speed of castings and refines the internal metallographic structure.
Compared with traditional sand casting, castings produced by this process have denser internal structures, fewer internal defects such as shrinkage cavities, pores and porosity, higher dimensional accuracy and better surface quality. In addition, waste sand emission is greatly reduced, sand utilization rate is improved, and production energy consumption and pollution emission are more controllable. This process is suitable for the production of large-size and thick-section crushing walls for cone crushers and gyratory crushers, and supports the large-scale manufacturing of medium and large wear-resistant castings, serving as one of the mainstream industrial production processes.
Lost foam casting is a near-net-shape casting process applicable to crushing walls with complex structures and special-shaped curved surfaces, which solves the problems of low forming accuracy and large machining allowance of traditional processes. In this process, a foam plastic model consistent with the size of the crushing wall is made, buried in dry sand and compacted for shaping. Mold removal is not required before high-temperature molten steel pouring. The high-temperature molten steel gasifies the foam model and fills the cavity to complete casting forming.
The core process steps include foam model manufacturing, model bonding and reinforcement, refractory coating dipping and drying, dry sand molding, negative pressure fixing, molten steel pouring, gasification cooling and shakeout cleaning. The whole process adopts non-parting surface molding, eliminating molding defects such as box misalignment and flash burrs, and greatly reducing the allowance for subsequent mechanical processing.
Crushing walls produced by this process have high dimensional accuracy and good contour integrity, which can accurately match the assembly dimensions of crusher equipment. Dry sand can be recycled, the production procedure is simplified, and the labor intensity is lower than that of traditional sand casting. Nevertheless, the process requires high control accuracy for pouring temperature, negative pressure parameters and coating thickness, and parameter fluctuations may cause defects such as slag inclusion and pores. It is mostly used for the production of special-shaped, non-standard and small-medium sized high-precision crushing walls.
V-process vacuum casting, also known as vacuum film suction casting, is a low-pollution and high-precision special casting process suitable for crushing walls made of ultra-high manganese steel and high-chromium alloy steel. Based on the vacuum negative pressure principle, the process attaches plastic films to the mold surface to form a cavity, fills the sand box with dry sand for compaction, seals and vacuumizes to fix the sand mold structure through negative pressure, and then performs molten steel pouring and forming.
The main process flow includes mold cleaning, film heating and suction molding, cavity refractory coating spraying, sand box filling and compaction, film covering and vacuum sealing, pouring, pressure maintaining cooling and pressure relief demolding. No binder is added in the whole forming process, and the sand mold structure is maintained by negative pressure. Castings cool evenly after pouring with uniform internal metallographic structure.
Crushing walls produced by V-process casting have high surface smoothness without surface defects such as sand adhesion and pitting, low internal impurity content and stable mechanical properties. The production process produces no binder waste gas or waste residue with prominent environmental performance, and the dry sand recovery rate is nearly 100%. With a high degree of equipment automation, this process is suitable for batch production of high-quality and high-wear-resistance crushing walls, especially for heavy-duty mining crusher accessories requiring high casting purity and structural uniformity.
The dual-liquid composite casting process is a differentiated process developed to meet the dual requirements of wear resistance and toughness for crushing walls, mainly applied to crushing walls working under high-load and strong-wear conditions. Single-material crushing walls struggle to meet the requirements of matrix impact toughness and working surface wear resistance simultaneously. This process adopts layered pouring of two molten metals with different properties to realize differentiated material matching between the casting matrix and working surface.
The process principle is to pour tough matrix molten steel and high-wear alloy molten steel sequentially. The infiltration effect of high-temperature molten steel forms a stable metallurgical bonding layer between the two metal layers, realizing integrated overall structure without additional bonding or inlaying. The conventional matching scheme adopts high manganese steel as the matrix material to ensure impact resistance and high-chromium alloy as the working surface material to improve wear resistance. In production, the pouring temperature, interval and dosage of the two molten steels need precise control to avoid defects such as delamination, peeling and inclusion. Special quenching and tempering heat treatment are adopted after forming to stabilize the performance of the composite layer.
Crushing walls produced by this process have good impact resistance and fracture resistance in the matrix and excellent wear resistance on the working surface, adapting to high-strength crushing working conditions of hard ores such as granite and basalt. However, the process has high operation difficulty and strict parameter control requirements, with higher production costs than single-material casting processes. It is mostly used for customized production of high-end wear-resistant crushing walls for heavy-duty crushing equipment.
None of the crushing wall casting processes is universally applicable. Process selection in production needs comprehensive consideration of product specifications, material properties, working conditions and mass production scale. Water glass sand casting is suitable for conventional general products with controllable production costs and high universality; iron mold sand-lined casting is applied to the mass production of large and thick-walled crushing walls with stable casting compactness; lost foam casting adapts to special-shaped and high-precision non-standard products; V-process casting focuses on the production of high-quality and low-defect castings; dual-liquid composite casting solves the performance matching problem of accessories under high-wear and strong-impact working conditions in a targeted manner.
The current development direction of crushing wall casting technology focuses on refined parameter control, low-defect forming, energy-saving and environmentally friendly production, and optimized matching of materials and processes. Combined with numerical simulation technology, the pouring and cooling processes are optimized to further stabilize the casting microstructure, improve the working condition adaptability of products, and meet the daily production needs of the mining crushing industry.
