What is the current application status of composite casting technology (such as high chromium cast steel/high manganese steel bimetallic) in conical rupture liner plates?

For the lining plate of the cone crusher, the use of high chromium cast iron/high manganese steel bimetallic composite casting technology is an effective technical path to achieve "hard surface wear resistance, tough matrix impact resistance", especially when dealing with extremely hard or highly abrasive ores, which can improve comprehensive performance. The current application status and reliability verification methods are as follows.

️  The current application status of composite technology

This technology combines high hardness wear-resistant alloys (such as high chromium cast iron) with high toughness matrix materials (such as high manganese steel) to form a synergistic performance in specific areas.

Technical direction, key processes and characteristics, performance advantages and current situation

1. Inlaid composite lining plate is a prefabricated high chromium cast iron wear-resistant alloy block that is cast into a high manganese steel matrix through a specific fixture. Targeted, usually pre installed with inserts in key areas with the most severe wear, such as the parallel strip of the lining plate. The practice of Shibang Group has shown that this technology can extend the service life of the lining plate to more than 1.5 times that of a single high manganese steel lining plate.

2. Layered/partitioned composite design combines different materials on different layers or areas of the lining plate according to the stress characteristics of different parts. It embodies the design concept of "making the best use of everything". For example, the upper layer focuses on impact resistance, while the lower layer focuses on wear resistance. This has become an important trend in the current lining structure design, and institutions such as Jiangxi University of Science and Technology have conducted in-depth research on it.

3. Gradient materials and casting infiltration technology form a composite layer with gradient changes in composition and hardness on the surface of the lining plate through casting infiltration process. The interface transition is smoother, which can reduce stress concentration caused by sudden performance changes. This represents a more cutting-edge approach to the preparation of composite materials.

 Interface bonding strength and reliability verification

The reliability of interface integration is the key to technological success, mainly guaranteed through three stages: laboratory physical and chemical testing, computer simulation analysis, and on-site industrial verification.

1. Direct laboratory testing

This is the basis for verifying the quality of the combination, and the main methods include:

Mechanical performance testing: directly measure the interfacial bonding strength through shear, tensile, bending and other tests. Research has shown that the interface bonding strength of carbon steel/high chromium cast iron composite materials prepared by centrifugal casting hot rolling process can reach 392 MPa.

Bending test: specifically designed to simulate failure behavior under complex alternating stresses, it can intuitively evaluate the cracking and expansion of interfaces under bending loads.

Microstructure analysis: Use scanning electron microscopy, electron probe and other equipment to observe whether there are defects such as cracks and pores at the interface, and analyze the diffusion of elements to determine whether it is an ideal metallurgical bonding state.

2. Numerical simulation assisted evaluation

Before the casting is put into production, tools such as finite element analysis (FEA) can be used to simulate the stress distribution of the lining plate under crushing load. By comparing simulated stress with known interface bonding strength, the risk of interface failure under complex alternating stress can be predicted, thereby optimizing the lining structure and composite process.

3. On site industrial verification

This is the final acceptance stage, which mainly includes:

Installation tracking and monitoring: Record the tonnage of processed ore and changes in wear morphology of the new lining plate, and compare it with historical data to evaluate its actual life improvement effect.

Failure Mode Analysis: In the event of abnormal failure (such as extensive delamination of the composite layer), macroscopic and microscopic analysis of the failed component should be conducted to trace whether the root cause of the failure is due to interface bonding issues, design issues, or operating conditions.

 Summary and Recommendations

The bimetallic composite lining technology has moved from theoretical research to industrial application, especially demonstrating performance potential when dealing with harsh working conditions. The core lies in achieving reliable interface metallurgical bonding through reasonable processes.

For equipment managers, when evaluating and selecting such liners, they can focus on the following points:

Clear requirements: Determine whether it is necessary to use composite lining plates based on ore abrasion, equipment load, etc., and which composite form (local casting, layered design) is more suitable.

Review supplier capabilities: Prioritize suppliers who can provide detailed interface inspection reports (such as metallographic photos, combined strength data) and successful application cases.

Standardized installation and maintenance: Even high-performance liners must be installed, filled, and tightened strictly in accordance with the specifications, and checked and tightened during the initial operation to fully utilize their design performance.

If you can provide more specific working condition information (such as crusher model, main crushed ore types), I can further analyze the application potential and selection focus of bimetallic composite lining plates for you.