Scientific selection of materials, the way to durability - Material selection guide for wear-resistant accessories of mining crushing equipment

In the field of mining crushing, the selection of wear-resistant accessories is a core technical decision that affects equipment life, production efficiency, and operating costs. Facing a high-intensity and high wear working environment, scientifically and reasonably selecting accessory materials is a key link in achieving cost reduction and efficiency improvement. This article will systematically analyze the selection logic of wear-resistant parts based on materials science and engineering practice.

1、 Basic considerations for material selection dimensions

Before selecting wear-resistant accessory materials, it is necessary to comprehensively evaluate the following factors:

Material characteristics: hardness, particle size, silicon content, humidity, and corrosiveness of the material.

Equipment operating conditions: crusher type (jaw crusher, cone crusher, impact crusher, etc.), impact energy, linear velocity, and working pressure.

Economic objective: Balance initial procurement costs and service life, and pursue the lowest "ton cost".

2、 Mainstream wear-resistant materials and their applicable scenarios

At present, mature material systems that have been validated for a long time in the industry mainly include the following categories:

1. High manganese steel series

Characteristics: The typical grade is ZGMn13, which undergoes work hardening under strong impact loads, resulting in a significant increase in surface hardness and excellent resistance to impact wear. Meanwhile, its core still maintains good toughness.

Applicable scenarios: Widely used in components such as jaw plates of jaw crushers, rolling and crushing walls of cone crushers, and hammer heads of large hammer crushers that withstand high-strength impacts.

Limitations: Under low to medium stress impact conditions, the work hardening effect is not significant, and the wear resistance cannot be fully utilized.

2. High chromium cast iron/alloy cast iron

Characteristic: Usually refers to cast iron materials with Cr content ranging from 12% to 28%. Its metallographic structure contains high hardness M-type carbides, with high macroscopic hardness and excellent wear resistance.

Applicable scenarios: Suitable for working conditions mainly characterized by cutting wear and abrasive wear, such as the throwing head of vertical shaft impact crusher (sand making machine), the plate hammer of impact crusher, and the hammer head of fine crusher.

Limitations: The toughness is relatively low, and it is prone to fracture when subjected to direct impact from large materials. Therefore, it is necessary to carefully evaluate the impact of working conditions.

3. Medium low alloy steel

Characteristics: By adding alloying elements such as Cr, Mo, Ni, etc., the hardenability, strength, and wear resistance of steel are improved. This type of material achieves a good balance between hardness and toughness, and its performance can be adjusted through heat treatment processes.

Applicable scenarios: Suitable for complex working conditions with both impact and wear, such as impact plate breaking hammers, small and medium-sized hammer heads, and various lining plates. Its comprehensive performance and cost-effectiveness advantages are obvious.

4. Composite technology materials

Characteristics: Adopting technologies such as bimetallic composite casting and surface welding, combining high hardness and high wear resistant materials with high toughness matrix materials to achieve the effect of "sharp cutting edge and strong body".

Applicable scenarios: Suitable for working conditions where different parts of the component are subjected to different forms of wear, such as large hammer heads (made of high chromium cast iron at the hammer end and alloy steel at the handle), which can significantly improve the single use life.

3、 Suggestions for scientific selection process

Condition diagnosis: Clarify the type of crushing equipment, input and output specifications, main wear forms, and historical component failure modes.

Material selection: Based on working condition diagnosis and referring to the above material characteristics, select 2-3 candidate material schemes.

Technical and economic comparison: Calculate the expected lifespan of different material components and the "ton material wear cost" for quantitative comparison.

Small batch trial: Small batch trials can be prioritized on core devices to collect real data and provide a basis for final decision-making.

4、 Beyond Materials: Focus on Manufacturing Process and Quality Control

Materials are the foundation, and processes are the key. Using the same material formula and different smelting, casting, and heat treatment processes may result in significant differences in final performance. Therefore, when choosing, it is important to focus on the supplier's:

Process stability: Whether there are key process equipment such as electric arc furnace refining and intelligent heat treatment production lines.

Quality traceability system: Whether it has the ability to inspect and record the entire process from raw material entry to finished product delivery.

Technical support capability: Can you provide material selection suggestions and customized solutions based on failure analysis.