Manganese steel is renowned for its high strength and abrasion resistance, making it the ideal material for manufacturing crusher liners that can withstand the intense impact and abrasion encountered during the crushing process. By prolonging the service life of the crusher and enhancing its operational efficiency, manganese steel crusher liners offer a cost-effective solution for improving the overall performance of crushing equipment.
The most common types of manganese steel crusher liners are as follows:
1. High Manganese Steel Jaw Crusher Liners: These are typically divided into fixed and movable jaws, with shapes and sizes determined by the specific jaw crusher model and specifications.
2. Manganese Steel Cone Crusher Liners: These liners include both the molar wall and the crushing wall. Their shape and structure are more complex, requiring adaptation to the crushing principle and working mode of the cone crusher.
3. Manganese Steel Impact Crusher Wear Parts: These parts are typically installed in the crushing chamber of the impact crusher to withstand the impact and counter-impact of materials.
4. Hammer Crusher Liners: These liners are typically in the form of long strips or blocks and are distributed inside the crusher cavity to protect the machine and assist in crushing materials.
Each type of crusher liners is designed and manufactured to meet the specific working needs and crushing process requirements of different types of crushers.
When selecting the most suitable crusher liners for your needs, it is advisable to consider the following factors:
1. Material Characteristics: It is important to understand the hardness, humidity, particle size, and corrosiveness of the material to be crushed. For high hardness materials, it is necessary to choose a stronger, more wear-resistant liner material.
2. Type of Crusher: Different types of crushers (such as jaw crushers, cone crushers, impact crushers, etc.) have different working principles and crushing methods, which in turn require different liner shapes, structures, and sizes.
3. Liner Material: In addition to manganese steel, other materials are available, including high-chrome cast iron liners, alloy steel liners, and so on. The choice of material should be made according to budgetary constraints and the actual needs of the application. For example, high-chrome cast iron offers high wear resistance but is relatively expensive.
4. Quality and Workmanship: High-quality liners are typically produced through a meticulous casting process, free from defects such as porosity, slag entrapment, and surface irregularities.
When selecting the optimal crusher liners, it is essential to consider a multitude of variables. If you are seeking a dependable supplier of manganese steel crusher wear part, we invite you to contact CAFU.
Crusher liners is an important part of the crusher. It is usually installed in the crushing chamber of the crusher, directly in contact with the crushed material, commonly used in cone crusher, jaw crusher, impact crusher, gyratory crusher. its main functions include:
1. Protect the crusher body: Reduce the wear and impact of materials on the crusher body and prolong the service life of the crusher.
2. Improve crushing effect: Through reasonable liner shape and design, it can optimize the crushing process of materials and improve the crushing efficiency and product quality.
3. Enhance the crushing force: Change the trajectory and force state of the material to enhance the effect of crushing force.
The materials of crusher liners are mainly as follows, and the performance characteristics of each material are as follows:
1. High-manganese steel: Manganese crusher liners have good toughness and work-hardening properties. When subjected to heavy impact and extrusion, the surface will harden rapidly, thus improving wear resistance. However, under low impact load or low stress wear conditions, the work hardening effect is not obvious, and the wear resistance may not be as good as some other materials.
2. Alloy steel: Alloy steel crusher liners higher hardness, high strength, wear resistance is better. Through the reasonable proportion of alloying elements, you can get different performance, adapt to a variety of working conditions.
3. Wear-resistant cast iron: With high hardness and certain toughness, relatively low cost. However, in the extremely harsh wear environment, its wear resistance may be slightly inferior.
4. Ceramic composite materials: Ceramic composite series, including high manganese steel ceramic composite materials, alloy steel ceramic composite materials, high chromium ceramic composite materials. Extremely high hardness, excellent wear resistance and good chemical corrosion resistance. However, ceramic composite materials are more brittle and may be prone to fracture under strong impact.
The crusher wear part selects different materials with different wear resistance and strength characteristics to adapt to different crushing conditions and material characteristics. Its shape and structure are also various, such as corrugated, serrated, etc., to meet different crushing needs.
In practice, the selection of crusher wear liners requires comprehensive consideration of the crusher working conditions, the type of material to be crushed, the cost and other factors to achieve the best results and economic benefits.
Wear plate is a kind of plate with high abrasion resistance, usually made of special alloy material, which can withstand high-intensity abrasion and impact. In the industrial field, wear plate is widely used in mining, metallurgy, cement, coal and other industries in equipment such as crusher, conveyor, hopper and so on, in order to protect the body structure of the equipment and extend the service life of the equipment.
Wear plate screen, on the other hand, is a kind of screen made of wear plate with higher wear resistance and strength, which can be used for a long time in harsh working environment. It is usually used for screening and classifying various materials such as ores, coal, sand and gravel. The features of wear resistant plate screen include:
1. High abrasion resistance: able to withstand the abrasion and impact of materials, prolonging the service life of the screen mesh.
2. high strength: high strength and rigidity, able to withstand greater material pressure and impact.
3. good screening effect: the screen hole size is accurate, can effectively screen out materials of different particle size.
4. easy to install and maintain: it can be customized and installed according to different plant requirements, and it is easy to maintain.
The following factors should be considered when selecting wear plates and wear plate screens:
1. Working environment: including the nature of the material, hardness, particle size, temperature, humidity and other factors, as well as the working conditions and requirements of the equipment.
2. Abrasion resistance requirement: according to different working environment and application requirements, select materials and specifications with appropriate abrasion resistance, such as NM400, NM450 and NM500.
3. Strength and rigidity requirements: Ensure that the wear-resistant plate and screen can withstand the pressure and impact of the material during the working process.
4. Sieve hole size and shape: Select the appropriate sieve hole size and shape according to the particle size requirements of the materials to be screened.
5. Installation and maintenance convenience: consider the installation and maintenance difficulty of wear plate and screen mesh, so as to replace and repair them in the course of use.
CAFU is a professional supplier of wear plate spare parts, we have a variety of thickness of wear plate to meet different customers' needs. Professional processing equipment can meet the requirements of cutting, drilling, bending, rolling and welding of wear plate spare parts for users' related equipment.
Our advantage:
• Custom wear plate parts in various shapes
• Quick quotation
• Fast delivery
• Reliable quality with material certificates
Contact us today for custom made wear plate parts with precise dimensions for your machines.
Ensuring the quality of manganese steel casting needs to be done from several aspects, the following are some key measures:
1. Raw material control
• Selection of high quality manganese steel raw materials to ensure that their chemical composition meets the standard requirements.
• The manganese content plays a key role in the performance of the product. Within a certain range (e.g. Mn13Cr2, 11.5-14%), the higher the manganese content, the better the performance of the product in general, but the cost of the raw material will be higher accordingly.
• Strict incoming inspection of raw materials is carried out.
2. Casting process design
• Carefully design the casting process programme, including casting method, pouring system, risers and cold iron settings.
• According to the shape, size and performance requirements of the casting, reasonably determine the casting parameters, such as pouring temperature, pouring speed and so on.
• Selection of casting process, such as sand water glass casting process and disappearing mould casting process.
3. Mould making
• 3D scanner and 3D modelling to make the manganese steel casting conform to the overall geometry and ensure perfect installation and fitment with the machine.
• Manufacture high precision moulds to ensure the dimensional accuracy and surface quality of the castings.
• Regular maintenance and inspection of the moulds to repair the worn and damaged parts in time.
4. Melting process control
• Select the medium frequency electric furnace which has the advantages of high melting efficiency, energy saving, environmental protection and convenient operation.
• Strictly control the melting process temperature, time and stirring and other operations to ensure uniform composition of the liquid steel.
• Adopt suitable deoxidation and refining process to remove the gas and inclusions in the liquid steel.
5. Pouring operation
• Avoid splashing and oxidising of molten steel during pouring to ensure smooth filling of molten steel.
• Control the pouring speed and time to ensure that the solidification sequence of the castings is reasonable.
6. Heat treatment
• Formulate reasonable heat treatment process according to different applications, such as water toughening, etc., to improve the structure and properties of castings.
• Strictly control the heat treatment temperature, time and cooling speed and other parameters.
7. Quality Inspection
• Conduct a comprehensive quality inspection of castings, including appearance inspection, dimensional measurement, chemical composition analysis, mechanical properties testing, hardness analysis, etc.
• Use non-destructive testing methods, such as ultrasonic testing, PT testing, etc., to detect defects within the castings.
In conclusion, to ensure the quality of manganese steel casting, it is necessary to carry out strict control and management in all aspects such as raw materials, process design, production operation, quality inspection, etc., in order to ensure that the product quality meets the design requirements.
We usually have three options when choosing vibrating screen mesh, including:
• Vibrating Wire Mesh Screen
• Polyurethane Screen Mesh
• Rubber Vibrating Screen Mesh
Of the above three types of screen mesh, vibrating wire mesh screen has the most open area, averaging about 60% or so, making woven screen mesh the most efficient compared to the other two materials.
Vibrating wire mesh screen has the following advantages:
• Widest range of applications
• Largest open area, wire available in various diameters
• Wires available in 65Mn and stainless steel for both abrasion and corrosion resistance
• Lowest cost of ownership
• Most accurate particle sizing
• Faster installation and quicker changeover for frequent screen changes of different mesh sizes.
However, the more openings a vibrating screen mesh has, the shorter its wear life will be. Therefore, choosing a wire with high quality wear resistance, such as the high grade 65Mn material, will help to extend the life of the vibrating screen mesh and reduce downtime. Users should also strike a balance between wear life and efficiency when choosing screen mesh material for vibrating screens.
Vibrating wire mesh screen is the most commonly used vibrating screen mesh product. In most vibrating screen applications, vibrating wire mesh screen is the preferred choice of most users due to its highest open area and because of its ease of installation, which provides maximum flexibility for screening different sizes of materials.
Reinforced ceramic lined elbows are one of the common types of ceramic lined pipe. In the process of conveying highly abrasive materials (often used in pneumatic conveying systems), the outside of the 90° elbow is the most prone to wear, so ceramic lined pipe manufacturers will be reinforced with a layer of abrasive wear layer at the elbow, also known as backpack wear-resistant ceramic lined elbows.
The reinforcing layer is welded to the elbow of the 90°ceramic lined elbows and covers almost the entire back of the elbow. The inside of the welded steel plate is filled with a wear-resistant material, and the reinforcing layer filling port is closed after the material has cured, thus forming a strong and durable second layer of wear-resistant layer, which prolongs the service life of the wear-resistant ceramic lined elbow and reduces the frequency of elbow replacement.
This backpack ceramic lined elbows has high strength and toughness with excellent heat and aging resistance. It can operate at temperatures from -50°C to 350°C for extended periods of time. It is mainly used in pneumatic conveying systems to resist impact wear from highly abrasive materials.
For example, copper slag, garnet, quartz sand and other materials with a Mohs hardness of about 7, such materials usually have sharp edges, such solid-gas mixtures for a long time in the ceramic lined elbows scouring, elbow ceramic lining will be worn through in a period of time, at this time, to strengthen the wear-resistant layer will play a second layer of protection, so that the pipeline system can continue to be used normally, thereby reducing the downtime.
CAFU is an expert in the manufacture and application of wear-resistant ceramic lined pipe elbows, we aim to design and provide the best wear-resistant piping solutions for the majority of users in the actual application and supply the best quality wear-resistant piping products.
Heat resistant alloy castings for cooler grate plates typically have the following characteristics and benefits:
Exceptional heat resistance: Can tolerate the high temperatures generated in the cooler section without significant degradation.
High strength and durability: To withstand the mechanical stresses and loads from the material passing over them.
Resistance to abrasion: As the material moves across, it helps prevent excessive wear.
Good thermal shock resistance: Able to handle the rapid temperature changes that occur.
Optimal alloy composition: The alloy is composed of elements that provide the necessary heat resistance and other properties.
For example, alloys like nickel-based or chromium-based alloys might be used. These alloys ensure that the clinker cooler grate plates can function effectively for a long time, maintaining the efficiency of the cooling process and reducing the need for frequent replacements. The specific alloy composition and design of the heat resistant alloy castings are carefully selected to meet the demanding requirements of the cement plant's operating conditions.
Rubber lined steel pipe is a type of pipe that combines the strength and durability of steel with the corrosion resistance and flexibility of rubber.
The rubber lining provides several benefits. It helps to prevent corrosion and wear, extending the service life of the pipe. It also offers good sealing properties, reducing the risk of leaks. Additionally, the rubber lining can provide some insulation and noise reduction.
This type of pipe is commonly used in various industries, such as mining, chemical processing, and water treatment. It is suitable for transporting abrasive or corrosive fluids, as the rubber lining protects the steel pipe from damage.
For example, in the mining industry, rubber lined steel pipes are used to transport slurries and other abrasive materials. In the chemical industry, they can handle corrosive chemicals. In water treatment plants, they are utilized for the conveyance of water with different chemical compositions.
Overall, rubber lined steel pipe is a valuable option when there is a need for a pipe that combines strength, corrosion resistance, and other specific properties for different applications.
This paper will outline the methods for enhancing the impact resistance of wear-resistant ceramic rubber composite liners.
Wear-resistant ceramic rubber composite liners offer an effective anti-wear solution for applications involving sliding and impact wear, such as those found in the cement, steel, mining, and iron and steel industries. However, in many practical applications, wear-resistant ceramic-rubber composite liners are also susceptible to brittleness and a lack of impact resistance.
Consequently, in practical applications, the constant improvement of the impact resistance of wear-resistant ceramic rubber composite liners will assist in the extension of the service life of the wear-resistant ceramic liner and the reduction of equipment downtime.
The steel backing plate ceramic rubber composite liner is composed primarily of alumina, with a rubber bonding layer and a steel backing plate. Following vulcanisation, the alumina ceramic exhibits high wear resistance (HRA ≥ 90), while the rubber provides cushioning properties. The steel backing plate enhances the overall mechanical properties of the wear-resistant lining plate, rendering it superior to conventional metal wear-resistant lining plates. Through the study of practical applications and the implementation of special processes, ceramic industry engineers can further enhance the general wear-resistant ceramic composite liner's impact resistance.
• The surface design of the liner incorporates a ceramic raised structure:
The ceramic raised structure serves to disperse the impact force, thereby reducing the likelihood of fragmentation of the steel backing plate ceramic rubber composite liner. This method is commonly employed in the industry to enhance the impact resistance of the ceramic liner.
• Increase the surface rubber exposure area of the composite liner:
Wear-resistant ceramic rubber composite liner due to ceramic impact resistance is weak, ceramic block between the reasonable gap design (or the use of cylindrical or hexagonal ceramic materials), can be through the liner surface exposed rubber, to enhance the overall impact resistance of the composite liner.
• Toughness enhancement treatment of alumina ceramics:
A certain proportion of zirconium oxide is added to the alumina, which can greatly enhance the impact resistance of the wear-resistant ceramics.
Alumina wear-resistant ceramic rubber composite liner through the ceramic block raised design, while increasing the surface area of vulcanised rubber, and with the help of alumina composite zirconium oxide and other processes, so that the wear-resistant ceramic rubber composite liner to further enhance the impact resistance, and therefore can better adapt to most of the heavy sliding abrasion, strong impact abrasion and other working conditions.
This paper aims to provide an overview of the key industrial applications of ceramic wear plates with CN bonding layer or studs, including ceramic polyurethane wear plates for chutes and hoppers.
Ceramic wear plates with CN bonding layer or studs (including ceramic polyurethane wear plates for chutes and hoppers) have a wide range of applications in power plants, steel industry, ports, mining, cement industry, chemical industry, lithium battery production and other fields due to their excellent wear resistance, high temperature resistance and unique corrosion resistance properties.
Specific applications include:
• Belt conveyor system and block material transfer system in power plants
These include bucket wheel reclaimer body and disk, belt conveyor hopper, raw coal hopper, coal feeder gate, coal mill exits chute and other equipment.
• The ultra-high temperature equipment in power plants
Examples of such equipment include burner square nozzle, W-flame burner cone, tail flue, air preheater baffle, air preheater support rod, and coal mill static ring.
• Wear-resistant ceramic linings for steel industry
1. Feeding system: bucket wheel reclaimer, hopper, etc.
2. Mixing system: mixing hopper, mixing cylinder scraper, etc.
3. Sintering system: ore dressing hopper under vibrating screen, raw material transport chute, etc.
• Ceramic wear plates for ore dock
Ceramic wear plates with CN bonding layer or studs are suitable for use in a variety of applications, including berth fixing hoppers, bucket wheel reclaimer fixing hoppers, belt conveyor station fixing hoppers, ship unloader hoppers, and more.
• Ceramic wear plates for the mining industry
Rubber-backed ceramic liners and ceramic polyurethane wear liners are suitable for a wide range of applications, including those requiring sliding and impact wear.
• Cement industry
The product range includes powder separator guide ceramic composite blades, powder separator cone ceramic linings, cyclone ceramic linings, and so on.
Due to their array of exceptional properties, ceramic wear plates with CN bonding layer or studs are extensively utilized in a multitude of industrial applications. The preceding overview of the applications of wear-resistant ceramic products is but a partial representation of the extensive range of potential applications. For further information on product applications, please consult with industry professionals or supplier.
As a key component of the rotating shaft of the cement mill, the contrarotating ring plays a vital role in preventing large particles of dust from entering the sealing chamber, thereby safeguarding the bearings.
The original process for this cement plant spare parts utilises ST 37-2+HVOF with an HRC of approximately 60.
The contrarotating ring creates friction with another sealing part when the spindle is rotating, which over time accelerates the wear of the surface, leading to a decline in sealing performance. Therefore, the maintenance department of the cement plant needs to replace this part periodically.
Due to the high cost of the contrarotating ring produced by the HVOF process, it is necessary to first accurately machine the ordinary steel plate to an outer diameter of 1200mm, an inner diameter of 1010mm, a thickness of 12mm, and to maintain the surface flatness. These production requirements are very high. Subsequently, tungsten carbide must be sprayed on both sides using high-speed oxy-fuel spraying technology. Finally, the surface roughness of Ra1.6 can be achieved through the processing of a large grinding machine.
The high purchase cost of the HVOF contrarotating ring places significant pressure on the user. Following a technical analysis between our customer and Cafu's technical team, it was decided to replace the original cement plant spare parts with a contrarotating ring made of NM400 wear-resistant steel plate. This is a high-quality wear-resistant steel from China that can be used in a wide range of applications that require resistance to abrasion. It is a good alternative to many composite wear-resistant materials.
Cafu has applied its specialised production process to the manufacture of the contrarotating ring, using high-quality wear-resistant steel plates, which are laser cut, lathed and finely ground, to produce the perfect replacement for the high velocity oxygen fuel (HVOF) technology contrarotating ring. The cost is only about one-third of the original cost, which greatly reduces the maintenance cost and creates a greater value return for our cement plant customers.
Cafu, as a leading supplier of spare parts for cement plants, offers a comprehensive range of wear parts, in addition to providing assistance to customers in improving existing processes. Our mission is to provide the best wear-resistant spare parts solutions for users and their shareholders through the implementation of practical projects.
The wear pipe is a piping system for conveying high-velocity, high-concentration solid particulate media. Its inner wall is specially treated to provide excellent wear resistance and extend the service life of the pipe. Rubber-lined composite steel pipe is a common type of wear-resistant pipe, which consists of an outer steel pipe and an inner rubber lining.
The natural rubber (NR) lining is characterized by its high abrasion resistance and corrosion resistance, rendering it well-suited for the conveyance of general solid particles of media, such as ore and coal. The styrene-butadiene rubber (SBR) lining, on the other hand, exhibits high abrasion resistance and strength, rendering it suitable for the conveyance of abrasive media, such as coal mill dust, powder, and dust.
The CR (neoprene rubber) lining exhibits superior oil resistance and ozone resistance, rendering it well-suited for conveying oil-containing media, chemical media, and ultraviolet radiation environments.
The EPDM (ethylene-propylene rubber) lining boasts exceptional abrasion resistance, corrosion resistance, and high-temperature resistance, rendering it an optimal choice for transportation in high-temperature environments, such as flue gas discharge systems and high-temperature ash transportation.
Rubber-lined composite steel pipes are employed in a number of fields and contexts, including:
The chemical industry is one of the primary applications of rubber-lined composite steel pipes. These pipes are particularly suited to the handling of corrosive media, high-temperature media, and high-pressure media. They can be used to convey acids, alkalis, solvents, salts, and various chemicals, including those that are corrosive to metals.
The oil and gas industry is another area in which rubber-lined composite steel pipes are extensively utilized. These pipes are employed in the extraction, transportation, and storage of oil and gas. They are utilized for the transportation of corrosive media, reservoir water, and natural gas, as well as in oil wells to enhance the efficiency of oil recovery.
The power industry employs rubber-lined composite steel pipes for the conveyance of cooling water, circulating water, and wastewater. These pipes are also utilized for the conveyance of coal ash, coal mill emissions, and other solid particulate matter, as well as coal and oil fuels in thermal power plants.
The mining industry is another area in which rubber-lined composite steel pipes are extensively utilized. These pipes are employed in the conveyance of ores, coal, and tailings. In order to withstand the rigors of the mining environment, which includes the potential for abrasion and corrosion, as well as the impact of high-velocity fluids and solid particles, the pipes must be constructed from materials that are resistant to these ills.
In brief, rubber-lined composite steel pipe are employed in a multitude of industrial sectors, including the chemical, petroleum, natural gas, food, pharmaceutical, electric power, and mining industries. This is due to their exceptional corrosion, abrasion, and high-temperature resistance.
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