Wear Resistant Cast Materials for the Mining and

Construction Industry

• Ricardo Fuoco

Fuoco Consultant
Phone: +551199201-3454
Email: [email protected]

Wear resistant cast materials for the mining industry 1

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012
 Outline

• 1. Introduction

• 2. Types of wear in the Mining and Construction Industry

• 3. Wear resistant cast materials for:

• Crushers
• SAG / AG mill
• Balls mill / Vertimill

Wear resistant cast materials for the mining industry

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 2
 Introduction

Wear resistant cast materials for the mining industry

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 3
 Introduction
Typical mining operations

• 1. Drilling

• 2. Blasting

• 3. Comminution

Wear resistant cast materials for the mining industry

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 4
 Introduction
Typical mining operations

Drilling

Wear resistant cast materials for the mining industry

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 5
 Introduction
Typical mining operations

Blasting

Wear resistant cast materials for the mining industry

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 6
 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

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 7
 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

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 8
 Introduction
Typical comminution operation in the construction industry

Crushers

Wear resistant cast materials for the mining industry

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 9
Types of wear in the mining industry
(comminution)

Wear resistant cast materials for the mining industry

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 10
Types of wear in the mining industry
(comminution)

Vertimill

Wear resistant cast materials for the mining industry

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Types of wear in the mining industry
(comminution)
High stress abrasion and impact

Vertimill
Vertimill

Wear resistant cast materials for the mining industry

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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

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Types of wear in the mining industry
(comminution)
High stress abrasion and impact

High stress grinding abrasion

Abrasion

Vertimill

Wear resistant cast materials for the mining industry

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 Types of wear in the mining industry
(comminution)

• Crushers:
• High stress abrasion
• Gouging abrasion
• High impact forces

Wear resistant material with high toughness:

Characteristics:
Aust
High toughness
Some abrasion resistance
Wear resistant cast materials for the mining industry
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 Types of wear in the mining industry
(comminution)

• AG/SAG mills and large balls mills:

• High stress grinding abrasion
• Scratching and micro-cracking resistant
• Medium to high impact forces

Wear resistant material with some toughness:

Characteristics:
Cr-Mo low alloy steels
Abrasion resistance
Some toughness
Wear resistant cast materials for the mining industry
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 Types of wear in the mining industry
(comminution)

• Small ball mills and Vertimills:

• Low stress scratching abrasion
• Low impact forces

Very high wear resistant material:

Characteristics:
High Cr white cast iron
Very high abrasion resistance

Wear resistant cast materials for the mining industry

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 Types of wear in the mining industry
(comminution)
• Hardness (and wear resistance):
Hardness (HB)
700
600
500
400
600 HB
300
200
100
0
450 HB

n
)

)
)

c)
tic
ed

Series1
al

ro
ti
it i

375 HB
rm

r li

si

I
in

st
en
ea
fo
l(

Ca
320 HB

t
(p
de

ar
ee

te
(m
l(
St

hi
ee
ld

W
St

l
ee
ie

200 HB
l

Cr
ee
df

ld

st

st
Ha

ie

Hi
y
df

lo

y
lo
Ha

al

al
w

w
lo

lo
o

o
M

M
-
Cr

-
Cr

Wear resistant cast materials for the mining industry

Ricardo Fuoco - 2nd BRICS Foundry Forum - China – May 8-11, 2012 18
 Types of wear in the mining industry
(comminution)
• Charpy Impact test (toughness):

Impact (J)
200
180 200 J

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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Wear resistant cast materials
Crusher parts

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Types of crushers: Primary gyratory

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Types of crushers: Jaw crusher

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Types of crushers: Cone crusher

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Austenitic Mn steel - Typical castings

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Austenitic Mn steel - Typical castings

Wear resistant cast materials for the mining industry

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 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

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 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

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Wear resistant cast materials
Austenitic Mn Steels for Crushers Parts
Surface layer: microstructure
after deformation

400 to 500 HB

Core: original microstructure

200 HB

Wear resistant cast materials for the mining industry

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 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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 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

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 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

Wear resistant cast materials for the mining industry

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31
 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

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Austenitic Mn Steels – Heat treatment

• Typical problem in the heat treatment (low toughness).

Incomplete solution HT
(low temperature or insufficient time)

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Austenitic Mn Steels – Heat treatment

• Typical problem in the heat treatment (low toughness).

Complete solution HT but ineffective quenching (low cooling rate promotes

continuous carbide reprecipitation in the grain boundaries)
Wear resistant cast materials for the mining industry
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 Wear resistant cast materials
Austenitic Mn Steels – Heat treatment

• Typical problem in the heat treatment (low toughness).

Complete solution HT but ineffective quenching (low cooling rate promotes

continuous carbide reprecipitation in the grain boundaries)
Wear resistant cast materials for the mining industry
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 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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 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;

• Most of breakage problems are related to carbide re-

precipitation in the austenitic grain boundary;

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Austenitic Mn Steels

• How to improve the water quench cooling rate?

• Reduce the water temperature during quenching;

• Improve water agitation velocity during quenching;

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
SAG/AG Mills (and large ball mills)

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
SAG/AG Mills (and large ball mills)

Feed end side

Wear resistant cast materials for the mining industry

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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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 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

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 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
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 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

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 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
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Wear resistant cast materials
SAG/AG Mills – Typical castings

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
SAG/AG Mills – Alloy specification

• Typical Specification: Cr-Mo steels

• Cr-Mo steels (Pearlitic microstructure): 320 / 375 HB

• Cr-Mo steels (Martensitic microstructure): 350 / 400 HB

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
SAG/AG Mills – Heat treatment

• Critical step in the production: Heat Treatment

• Pearlite – Normalizing (forced/calm air) and tempering

• Martensite – Quenching in forced air and tempering

Wear resistant cast materials for the mining industry

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 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

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 Wear resistant cast materials
SAG/AG Mills – Typical microstructures
• Cr-Mo steel (0.6 / 0.7%C) after forced air normalization
and temper heat treatment

Fully Pearlite
Microstructure

400x
Wear resistant cast materials for the mining industry
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 Wear resistant cast materials
SAG/AG Mills – Typical microstructures
• Cr-Mo steel (0.45%C) after forced air quenching and
temper heat treatment

Tempered
Martensite
Microstructure

200x

Wear resistant cast materials for the mining industry

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 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 (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

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 Wear resistant cast materials
Cr-Mo steels

• How to improve the abrasion resistance?

• Martensite or very fine pearlite microstructure (as a

result of alloying elements content and high forced air-
cooling rate);

• Excessive cooling rate after pearlite transformation

promotes high internal stress in the liners;

Wear resistant cast materials for the mining industry

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 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
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 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.
Wear resistant cast materials for the mining industry
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 Wear resistant cast materials
Improper mill operation causing direct impact of
balls on liners

The direct impact of balls on liners imposes a compressive force

higher than the compressive yield strength of the Cr-Mo steel
Wear resistant cast materials for the mining industry
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 Wear resistant cast materials
Improper mill operation causing direct impact of
balls on liners

The main consequence is the intense deformation of the liners

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Improper mill operation causing direct impact of
balls on liners

Very intense surface deformation on Cr-Mo lioners

Wear resistant cast materials for the mining industry
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 Wear resistant cast materials
Improper mill operation causing direct impact of
balls on liners

Crack initiation on the deformed surface layer

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Improper mill operation causing direct impact of
balls on liners

Evidences of loose particles in the

deformed surface of the liners due to
the surface cracks

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Improper mill operation causing direct impact of
balls on liners
Evidences of crack propagation initiated in the deformed layer and
propagated in the direction of the center of the liners which should
promote a line fracture

Crack initiation in the

deformed surface layer

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Cr-Mo steels

• How to minimize the crack formation and crack propagation

during direct impact of ball on liners?

• Prefer a very fine pearlite microstructure;

• Crack initiation and propagation are easier in continuous microstructure like

bainite and martensite than in discontinuous microstructure like pearlite (formed
by layers);

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Balls mills and Vertimills

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Balls mills

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Vertimills

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Vertimills – Grinding mechanism

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Ball mills – Typical wear parts

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Vertimills – Typical wear parts

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Typical wear parts – Coal mills parts and ball mills

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Typical wear parts – Pump parts

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Alloy specification

• Typical specification: ASTM A532

• Grade II B : 14 – 18% Cr / 2.0 – 3.3% C

• Grade II D : 18 – 23% Cr / 2.0 – 3.3% C

• Grade III A : 23 – 28% Cr / 2.5 – 3.5% C

• Eutectic and hypereutectic grades

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Alloy specification

Eutectic and hypereutectic

grades

ASTM A532 Grade III A

ASTM A532 Grade II D

ASTM A532 Grade II B

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
Heat treatment

• Critical step in the production: Heat Treatment

• Solution (austenite destabilization) at 950 – 1000°C

• Quenching in forced air / calm air
• Tempering

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Microstructures

1000x
1000x SEM,500x
SEM, 2000x
Wear resistant cast materials for the mining industry
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 Wear resistant cast materials
Wear mechanism (erosion)

Abrasive wear of high chromium white cast iron initiate by microcutting

of martensite matrix and than by microcracking of primary carbides

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Wear mechanism (erosion)

Carbides HV= 1500

Martensite HV=700
Wear resistant cast materials for the mining industry
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 Wear resistant cast materials
Wear mechanism (erosion)

– Carbides (M7C3) has high hardness > 1500 HV

– Most important abrasive is quartz (silica) with 1.000 to
1.300 HV

HV= 700

HV= 1500

HV= 700

Wear resistant cast materials for the mining industry

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 Wear resistant cast materials
High Cr white cast irons

• How to improve the abrasive wear resistance of high

Chromium white cast iron?

• Since quartz (silica) is harder than the martensite, the

microcutting mechanism should be minimized by higher
primary carbide volume fraction;

Wear resistant cast materials for the mining industry

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Wear resistant cast materials
Microstructures – Near eutectic

1000x SEM, 2000x

Wear resistant cast materials for the mining industry
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Wear resistant cast materials
Microstructures – Eutectic grades

1000x SEM, 2000x

Wear resistant cast materials for the mining industry
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Wear resistant cast materials
Microstructures – Hypereutectic grades

200x
Wear resistant cast materials for the mining industry
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 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;

• OBS: Tentative of increase the hardness of white cast irons (from 600 to
700/750 HB) by using a high cooling rate heat treatment has no practical
effect on the abrasive wear resistance (since quartz > 1,000 HV). Normally,
high cooling rate heat treatment increases the internal stress levels of the
casting and results in higher risk of breakages in field;

Wear resistant cast materials for the mining industry

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