In the core crushing operations of mining, cement, metallurgy and other industries, the hammer is the "heart" of the crusher, and its wear resistance directly determines the equipment efficiency, downtime maintenance frequency and overall pbarsuction cost. Traditional single-material hammers (such as pure high manganese steel) are often unable to cope with increasingly harsh working conditions. The triple protection technology that integrates high manganese steel toughness base, insert hard alloy bars to enhance impact wear resistance, and hard alloy hardfacing to enhance abrasive wear protection is leading the technological trend of a new generation of super wear-resistant crusher hammers.
1. Core technology analysis: triple protection, synergistic efficiency
Tough matrix: high manganese steel (such as ZGMn13, Mn18)
Core advantage: Excellent work hardening ability. Under strong impact loads, the surface hardens rapidly (HB500 or above) to form a hard wear-resistant layer, while the core maintains good toughness to resist impact fracture.
Role: Provides strong support and impact resistance for the entire hammer head, and is a reliable "foundation" for alloy bars inlay and hardfacing layer.
Pioneer in impact wear resistance: insert carbide bars
Core advantages: Ultra-high hardness, excellent compressive strength and wear resistance, especially good at resisting high-speed impact chiseling wear of large pieces of materials.
Function: Just like embedding "steel nails" at the forefront of the impact, directly bearing and crushing large pieces of materials, greatly protecting the matrix, and significantly extending the overall life of the crusher hammer head.
Anti-abrasive wear barrier: surface carbide hardfacing
Core advantages: Provides extremely high and uniform surface hardness, specifically against abrasive wear such as micro-cutting and furrowing of small and sharp materials.
Function: Cover the entire working surface with "wear-resistant armor", effectively resist the erosion and wear of material flow, and fill the protection gap between insert alloy bars.
2. Performance Leap: Significant Advantages over Traditional Hammers
Double Wear Life: Under comprehensive protection, the life can usually reach more than 3-5 times that of traditional high manganese steel hammers, and the improvement is higher in some extreme working conditions.
Impact toughness guarantee: The high manganese steel matrix and the strong and tough insert structure ensure that it is not easy to break as a whole or the alloy bars collapses when subjected to violent impact.
Continuous and efficient operation: Greatly reduce the frequency of shutdown and replacement, improve equipment operation rate and pbarsuction efficiency.
Reduced overall cost: Although the cost of a single piece is high, the ultra-long life significantly dilutes the cost of crushing a ton of material, reduces spare parts inventory and labor replacement costs.
Adapt to complex working conditions: The tolerance to harsh working conditions such as high-silicon content ores, highly abrasive materials, mixed materials and large-block material impact is significantly enhanced.
3. Successful application verification
A large granite crushing plant: After replacing the traditional high-manganese steel hammer, the average service life of the basalt crushing condition increased from about 15 days to 60 days+, the cost of the hammer per ton of stone decreased by more than 40%, and the equipment utilization rate increased by 25%.
Cement plant limestone crushing line: Facing highly abrasive limestone, the life of the hammer was extended from 3 weeks to 4 months, effectively solving the pain point of frequent shutdowns and ensuring the continuity of raw material supply.
Iron ore crushing system: In the crushing of iron ore containing high-hardness quartz, it shows excellent anti-micro-cutting ability, and the life is 2-3 times longer than that of a single alloy hammer.
4. Selection and application points
Accurate matching of working conditions: According to the hardness, particle size, moisture content, processing capacity and crusher model power of the crushed material, customized design of alloy bars material/size/arrangement, hardfacing layer thickness/hardness/welding material formula.
Strictly control process quality:
The high manganese steel matrix must meet the composition standards, have uniform structure, and no casting defects.
The inlay process ensures that the alloy bars and the matrix are 100% metallurgically bonded, without voids or cracks.
The hardfacing process needs to control the dilution rate, ensure the hardness of the coating, and avoid thermal cracks and peeling.
Conclusion
The composite hammer head of high manganese steel insert alloy bars + hard alloy hardfacing achieves a perfect balance between impact toughness and wear resistance by scientifically integrating the advantages of different materials. The ultra-long life, operational stability and significant economic benefits it brings make it an ideal choice for harsh crushing conditions, and provide strong core component support for modern efficient and low-consumption crushing operations.
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