Wear Resistant Cast Materials for the Mining Industry
March 22, 2018 | Author: Leon Mills | Category: N/A
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Wear Resistant Cast Materials for the Mining Industry
Ricardo Fuoco METSO Minerals – Brazil
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 2
Introduction
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Introduction Typical mining operations
• 1. Drilling • 2. Blasting • 3. Comminution
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Introduction Typical mining operation
Drilling
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Introduction Typical mining operation
Blasting
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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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 7
Introduction Typical comminution operation in the mining industry 1. Crushers
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Introduction Typical comminution operation in the mining industry 1. Crushers
2. SAG Mill
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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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 © Metso
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Types of wear in the mining industry (comminution)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Types of wear in the mining industry (comminution)
Vertimill
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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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 13
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
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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
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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
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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
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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
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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
200 200 HB
100 0
Hadfield Steel (initial)
Hadfield Steel (deformed)
Cr-Mo low alloy steel (pearlitic)
Cr-Mo low alloy steel (martensitic)
Hi Cr White Cast Iron
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Types of wear in the mining industry (comminution) •
Charpy Impact test (toughness): Impact (J) 200 180 160 140 120 100 80 60 40 20 0
200 J
Series1
10 J
Hadfield Steel (initial)
Cr-Mo low alloy steel (pearlitic)
15 J
Cr-Mo low alloy steel (martensitic)
2J
Hi Cr White Cast Iron
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Wear resistant cast materials Crusher parts
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Wear resistant cast materials Types of crushers: Primary gyratory
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Wear resistant cast materials Types of crushers: Jaw crusher
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Wear resistant cast materials Types of crushers: Cone crusher
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Wear resistant cast materials Austenitic Mn steel - Typical castings
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Wear resistant cast materials Austenitic Mn steel - Typical castings
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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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 © Metso
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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 28
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
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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 © Metso
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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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 © Metso
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Wear resistant cast materials Austenitic Mn Steels – Heat treatment
Microstructure in the as cast condition
Charpy impact energy = 10J
Microstructure after solution HT
Charpy impact energy = 180J
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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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)
Complete solution HT but ineffective quenching (low cooling rate)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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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 © Metso
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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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 RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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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 © Metso
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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.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012 37
Wear resistant cast materials SAG/AG Mills (and large ball mills)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012 38
Wear resistant cast materials SAG/AG Mills (and large ball mills)
Feed end side WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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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 © Metso
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012 40
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 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 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 43
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 44
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 45
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 46
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 © Metso
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012 47
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
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Wear resistant cast materials SAG/AG Mills – Typical microstructures • Cr-Mo steel (0.6%C) after normalizing and temper heat treatment Pearlite
Spheroidized Pearlite
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
400x
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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
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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 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
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Wear resistant cast materials Improper mill operation causing direct impact of balls on liners
Charge motion simulation (< 75% TCS - no impact)
Charge motion simulation (> 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 52
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. © Metso
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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Wear resistant cast materials Balls mills and Vertimills
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012 54
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 55
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 56
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 57
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 58
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 59
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 60
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 61
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 62
Wear resistant cast materials Balls mills and Vertimills - microstructures
1000x © Metso
SEM, 2000x
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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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 64
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 65
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
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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.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
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Summary
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY © Metso
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012 68
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 © Metso
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012 69
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