Crusher Wear Parts

Material Selection For Crusher Wear Parts

Different types, different working conditions, need to select the right material for your wear parts.

Manganese Steel

The wear resistance of manganese steel with an austenitic structure is attributable to the phenomenon of work hardening. The impact and pressure load result in a hardening of the austenitic structure on the surface. The initial hardness of manganese steel is approx. 200 HV (20 HRC, hardness test according to Rockwell). The impact strength is approx. 250 J/cm². After the work hardening, the initial hardness can thereby increase to an operational hardness of up to approx. 500 HV (50 HRC). The deeper-set, not yet hardened layers thereby provide for the great toughness of this steel. The depth and hardness of the work-hardened surfaces depend on the application and type of manganese steel. The hardened layer penetrates down to a depth of approx. 10 mm. Manganese steel has a long history. Today, this steel is used mostly for crusher jaws, crushing cones, and crushing shells.

Manganese steel is used to cast jaw plates, cone crusher liners, gyratory crusher mantle, and some side plates.

Martensitic Steel

Martensite is a completely carbon-saturated type of iron that is made by quick cooling-off. It is only in the subsequent heat treatment that carbon is removed from the martensite, which improves the strength and wears properties. The hardness of this steel ranges between 44 to 57 HRC and the impact strength between 100 and 300 J/cm².Thus, with regard to hardness and toughness, martensitic steels lie between manganese and chrome steel. They are used if the impact load is too little to harden the manganese steel, and/or good wear resistance is required along with good impact stress resistance.

Martensite steel is used to cast impact crusher blow bars.

Chrome Steel

With chrome steel, the carbon is chemically bonded in the form of chromium carbide. The wear resistance of chrome steel is based on these hard carbides of the hard matrix, whereby the movement is hindered by offsets, which provides for a high degree of strength but at the same timeless toughness. To prevent the material from becoming brittle, the blow bars must be heat-treated. It must thereby be observed that the temperature and annealing time parameters are exactly adhered to. Chrome steel typically has a hardness of 60 to 64 HRC and a very low impact strength of 10 J/cm². To prevent breakage of chrome steel blow bars, there may not be any unbreakable elements in the feed material.

Chrome steel is used to cast impact crusher blow bars, VSI crusher feed tube, distribute plate…

Alloy Steel

Alloy steel also widely use in casting crusher wear parts. With this material, the crushed material can be dressed by magnetic separation. However, alloy steel crusher wear parts are easily broken, so this material can not use to cast the largest parts, only suit to cast some small parts, weight less than 500kg.

Alloy steel is used to cast gyratory crusher concave segments, jaw plates, cone crusher liners, and others.

TIC Inserts Crusher Wear Parts

We use titanium carbide bars insert crusher wear parts to help wear parts get more good working life when crushing hard material.

TIC inserts alloy steel is used to cast jaw plates, cone crusher liners, and impact crusher blow bars.

Tips For Prolong Crusher Wear Parts Span Life

After spending a lot of money on a crusher, you don’t want to keep spending more money on crusher wear parts.  Those wear parts aren’t cheap and having to buy more parts than normal means you’re cutting into your bottom line. While parts will always have to be replaced eventually, the following 3 simple tips will help reduce your costs in the long term and keep your equipment up and running.

1. Choose the right material for your wear parts based on working conditions. Such as if you crush construction rubbish by impact crusher, the blow bars can not choose chrome steel because it has steel, the right choice is manganese steel or martensitic steel.
2. Watch material feed mix and size. Crushers, no matter the type, can only handle feed of a certain size. Constantly approaching the maximum feed size for the crusher will put undue stress on the crusher, causing premature failure of the parts and may also cause drive issues. You should also ensure what you are feeding can be crushed. While some crushers can hand a reasonable amount of steel, others cannot. And even if a crusher can handle some steel like rebar, it does not mean you should abuse its capabilities and expect a crusher to always handle things like large steel plates, compressed gas cylinders, or floor safes. You may get lucky and have no issues, or you may spend a few hours or days down while replacing parts.
3. Conduct frequent inspections. When you take a couple of minutes each day or week to look over the crusher, belts, feeder, and screens, you can notice issues starting to build up before they become a real problem and require parts and downtime to fix. For example, if you notice blow bars are wearing on one side faster, you can work to feed material on the opposing side, allowing the bar to last longer before reaching the point where it must be flipped or replaced. You may also look to adjust settings so less material is returning to be crushed, thus reducing wear on one side of the bar.