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Wear resistant cast materials for the mining industry
- 2. Outline
• 1. Introduction
• 2. Types of wear in the mining industry (comminution)
• 3. Wear resistant cast materials to:
• Crushers
• SAG/AG mill
• Balls mill / Vertimill
• 4. Summary
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 3. Introduction
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 4. Introduction
Typical mining operations
• 1. Drilling
• 2. Blasting
• 3. Comminution
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 5. Introduction
Typical mining operation
Drilling
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 6. Introduction
Typical mining operation
Blasting
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 7. Introduction
Typical comminution operation in the mining industry
• Comminution:
• 1. Crushing
• 2. Grinding (AG/SAG Mills, Ball Mills and Vertimills)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 8. Introduction
Typical comminution operation in the mining industry
1. Crushers
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 9. Introduction
Typical comminution operation in the mining industry
1. Crushers 2. SAG Mill
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 10. Introduction
Typical comminution operation in the mining industry
1. Crushers 2. SAG Mill 3. Ball Mill/Vertimill
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 11. Types of wear in the mining industry
(comminution)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 12. Types of wear in the mining industry
(comminution)
Vertimill
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 13. Types of wear in the mining industry
(comminution)
High stress abrasion and impact
Vertimill
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 14. Types of wear in the mining industry
(comminution)
High stress abrasion and impact
High stress grinding abrasion
Vertimill
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 15. Types of wear in the mining industry
(comminution)
High stress abrasion and impact
High stress grinding abrasion
Erosion
Vertimill
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 16. Types of wear in the mining industry
(comminution)
• Crushers:
• High stress abrasion
• High impact forces
• Gouging abrasion
Wear resistant material with high toughness:
Austenitic Mn steels
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 17. Types of wear in the mining industry
(comminution)
• AG/SAG mills and large balls mills:
• High stress grinding abrasion
• Medium impact forces
• Scratching and micro-cracking resistant
Wear resistant material with some toughness:
Cr-Mo low alloy steels
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 18. Types of wear in the mining industry
(comminution)
• Small ball mills and Vertimills:
• Erosion
• Low stress scratching abrasion
• Low impact forces
Very high wear resistant material:
High Cr white cast iron
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 19. Types of wear in the mining industry
(comminution)
• Hardness (and wear resistance):
Hardness (HB)
700
600
600 HB
500
400
450 HB
300 Series1
375 HB
320 HB
200
100 200 HB
0
Hadfield Hadfield Cr-Mo low Cr-Mo low Hi Cr White
Steel (initial) Steel alloy steel alloy steel Cast Iron
(deformed) (pearlitic) (martensitic)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 20. Types of wear in the mining industry
(comminution)
• Charpy Impact test (toughness):
Impact (J)
200
200 J
180
160
140
120
100 Series1
80
60
40
20 10 J 15 J 2J
0
Hadfield Steel Cr-Mo low alloy Cr-Mo low alloy Hi Cr White Cast
(initial) steel steel Iron
(pearlitic) (martensitic)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 21. Wear resistant cast materials
Crusher parts
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 22. Wear resistant cast materials
Types of crushers: Primary gyratory
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 23. Wear resistant cast materials
Types of crushers: Jaw crusher
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 24. Wear resistant cast materials
Types of crushers: Cone crusher
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 25. Wear resistant cast materials
Austenitic Mn steel - Typical castings
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 26. Wear resistant cast materials
Austenitic Mn steel - Typical castings
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 27. Wear resistant cast materials
Austenitic Mn Steels for Crushers Parts
• Typical Spec described in the ASTM A128 Grades B and C:
• 12 – 14% Mn / 1.1 – 1.25% C
• High Mn special grades:
• 17 - 19% Mn
• 19 - 22% Mn
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 28. Wear resistant cast materials
Austenitic Mn Steels for Crushers Parts
High Mn special
grades
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 29. Wear resistant cast materials
Austenitic Mn Steels for Crushers Parts – wear mechanisms
Gouging abrasion (deep surface scratching and high energy indentation)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 30. Wear resistant cast materials
Austenitic Mn Steels for Crushers Parts
Surface layer: microstructure
after deformation
400 to 500 HB
Core: original microstructure
200 HB
© Metso WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
- 31. Wear resistant cast materials
Austenitic Mn Steels – Heat treatment
• Critical step in the production: Heat Treatment
• Solution heat treatment at 1050 – 1100°C
• Quench in water
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 32. Wear resistant cast materials
Austenitic Mn Steels – Heat treatment
Microstructure in the as cast condition Microstructure after solution HT
Charpy impact energy = 10J Charpy impact energy = 180J
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 33. Wear resistant cast materials
Austenitic Mn Steels – Heat treatment
• Typical problem in the heat treatment (low toughness).
Incomplete solution HT Complete solution HT but ineffective
(low temperature or insufficient time) quenching (low cooling rate)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 34. Wear resistant cast materials
Austenitic Mn Steels – Heat treatment
• Typical quenching problem
TTT curves of carbides re-precipitation during the cooling after solution
of Hadfield austenitic steel
© Metso WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 35. Wear resistant cast materials
Austenitic Mn Steels – Heat treatment
• Typical quenching problem
Solution
Carbide re-precipitation
TTT curves of carbides re-precipitation during the cooling after solution
of Hadfield austenitic steel
© Metso WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 36. Wear resistant cast materials
Austenitic Mn Steels – Heat treatment
• Typical quenching problem
Effect of the grain boundaries coverage by continuous carbide re-precipitation in the
Charpy impact energy of different grades of Hadfield austenitic manganese steels
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 37. Wear resistant cast materials
Austenitic Mn Steels
• The main problems in austenitic Mn steels production are
related to heat treatment;
• Ineffective heat treatments develops microstructures with
carbides which result in low toughness and possibility of
breakage problems in field.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 38. Wear resistant cast materials
SAG/AG Mills (and large ball mills)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 39. Wear resistant cast materials
SAG/AG Mills (and large ball mills)
Feed end side
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 40. Wear resistant cast materials
SAG/AG Mills (and large ball mills)
Discharge side (grates)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 41. Wear resistant cast materials
SAG/AG Mills (and large ball mills)
Lifting effects of the shell liners illustrated by charge motion simulation
(TCS - Total Critical Speed)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 42. Wear resistant cast materials
SAG/AG Mills (and large ball mills)
Lifting effects of the shell liners illustrated by charge motion simulation
(TCS - Total Critical Speed)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 43. Wear resistant cast materials
SAG/AG Mills (and large ball mills)
Lifting effects of the shell liners illustrated by charge motion simulation
(TCS - Total Critical Speed)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 44. Wear resistant cast materials
SAG/AG Mills (and large ball mills)
Charge motion illustration showing the atriction and the impact grinding
mechanisms.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 45. Wear resistant cast materials
SAG/AG Mills – Typical castings
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 46. Wear resistant cast materials
SAG/AG Mills – Alloy specification
• Typical Specification: Cr-Mo steels
• Cr-Mo steels (Pearlitic microstructure) - 320 HB
• Cr-Mo steels (Martensitic microstructure) - 375 HB
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 47. Wear resistant cast materials
SAG/AG Mills – Heat treatment
• Critical step in the production: Heat Treatment
• Pearlitic – Normalizing and Tempering
• Martensitic – Quenching in blown air and tempering
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 48. Wear resistant cast materials
SAG/AG Mills – Heat treatment (TTT curve)
• Schematic TTT curves of Cr-Mo steel showing the formation of Pearlite
and Martensite during the heat treatment.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 49. Wear resistant cast materials
SAG/AG Mills – Typical microstructures
• Cr-Mo steel (0.6%C) after normalizing and temper heat treatment
Pearlite
Spheroidized
Pearlite
400x
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 50. Wear resistant cast materials
SAG/AG Mills – Typical microstructures
• Cr-Mo steel (0.45%C) after quenching and temper heat treatment
200x
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 51. Wear resistant cast materials
Cr-Mo steels
• The main problems in Cr-Mo steels production are related to
heat treatment;
• Inadequate microstructures and hardness result in low wear
resistance (premature wear) or low toughness and possibility of
breakage problems in field;
• Improper mill operation frequently promote direct impact of balls
on liners resulting in accelerated wear and risk of breakage.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 52. Wear resistant cast materials
Improper mill operation causing direct impact of balls on liners
Charge motion simulation Charge motion simulation
(< 75% TCS - no impact) (> 75% TCS - direct impact on liners)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 53. Wear resistant cast materials
Improper mill operation causing direct impact of balls on liners
Typical aspect of liner surface after direct impact of balls on liners
promoting accelerated wear and risk of liner breakage.
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- 54. Wear resistant cast materials
Balls mills and Vertimills
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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- 55. Wear resistant cast materials
Balls mills
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 56. Wear resistant cast materials
Vertimills
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 57. Wear resistant cast materials
Vertimills – Grinding mechanism
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 58. Wear resistant cast materials
Ball mills – Typical wear parts
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 59. Wear resistant cast materials
Vertimills – Typical wear parts
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 60. Wear resistant cast materials
Balls mills and Vertimills – Alloy specification
• Typical specification: ASTM A532
• Grade II E : 18 – 23% Cr / 2.0 – 3.0% C
• Grade III A : 23 – 28% Cr / 2.5 – 3.5% C
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 61. Wear resistant cast materials
Balls mills and Vertimills – Alloy specification
ASTM A532 Grade III A
ASTM A532 Grade II E
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 62. Wear resistant cast materials
SAG/AG Mills – Heat treatment
• Critical step in the production: Heat Treatment
• Solution (austenite destabilization) at 950 – 1000°C
• Quenching in calm air / blow air
• Tempering
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 63. Wear resistant cast materials
Balls mills and Vertimills - microstructures
1000x SEM, 2000x
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- 64. Wear resistant cast materials
Balls mills and Vertimills – wear mechanism (erosion)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 65. Wear resistant cast materials
Balls mills and Vertimills – wear mechanism (erosion)
Carbides HV= 1500
Martensite HV=700
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 66. Wear resistant cast materials
Balls mills and Vertimills – wear mechanism (erosion)
– Carbides (M7C3) has high hardness > 1500 HV
– Most important abrasive is quartz with 1.000 to 1.300 HV
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 67. Wear resistant cast materials
High Cr white cast irons
• The main problem in high Cr white cast iron production is crack
formation;
• Premature shake out, inadequate handling and thermal shock
are common causes of cracks in high Cr cast iron castings.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 68. Summary
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
© Metso RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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- 69. Summary
• The most commonly used cast materials in the mining industry
are:
• Austenitic Mn steels – normally used in Crusher
application due to its very high toughness and fairly good
wear resistance;
• Cr-Mo low alloy steels – normally used in SAG/AG
mills application due to its high wear resistance and
reasonable toughness;
• High Cr white cast iron – normally used in ball mills
and vertimills application due to its very high wear
resistance.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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