Key Components:
Jaw plates (fixed jaw and movable jaw), concaves, mantles, blow bars, hammers, liners (shell and end liners), screen plates, grate bars, sprockets, chain links, track shoes, feeder bottom plates, supports, and frame structural castings; individual part weights range from 1 kg to 500 kg.
Wear-Resistant Casting Solutions for Mining Machinery
Mining machinery is another core sector we serve. Our castings are used in mineral processing and aggregate production equipment such as jaw crushers, cone crushers, impact crushers, hammer crushers, ball mills, rod mills, screening machines, feeders, and conveyors. These machines operate under extremely harsh conditions involving ore impact, high-stress abrasive wear, and wet corrosion, where the wear resistance and toughness of castings directly determine maintenance intervals and operating costs.
We produce a wide range of wear-resistant castings, including high manganese steel, medium-alloy steel, high chromium cast iron, low-alloy high-strength steel, and bimetal composite castings. By precisely controlling chemical composition and heat treatment, we balance wear resistance and toughness to provide long-life wear solutions for mining, aggregates, cement, power generation, and related industries.
Complete Wear-Resistant Material System: Mn13/Mn18 high manganese steel, Cr20/Cr26 high chromium cast iron, low-alloy wear-resistant steel, bimetal composites, and ceramic inserts cover different crushing conditions.
Mature Water Toughening Process: High manganese steel is water-toughened at 1050-1100?C, producing a tough austenitic structure; after work hardening in service, surface hardness can exceed HB 500.
Impact Resistance Without Fracture: Optimized alloy composition and grain-size control help wear parts resist breakage and spalling under high-impact loads, reducing unplanned downtime.
Customized Service-Life Solutions: We recommend materials and structures based on ore hardness, particle size, feeding method, and crusher model, improving service life by 20%-80% versus conventional parts.
Guaranteed Interchangeability: Mating surfaces of jaw plates, concaves, and other crusher parts are inspected piece by piece to ensure direct replacement without secondary fitting.
The following are typical examples of mining machinery castings (8 items shown); other specifications can be customized based on customer drawings and original equipment models:
| No. | Part Name | Common Materials | Process / Remarks |
|---|---|---|---|
| 1 | Jaw Plate (Fixed / Movable) | Mn13Cr2 / Mn18Cr2 High Manganese Steel | Water toughening, work-hardening wear resistance |
| 2 | Concave / Mantle | Mn18Cr2 / High Manganese Steel + Ceramic Inserts | Cone crusher set, interchangeable installation |
| 3 | Blow Bar (Impact Crusher) | Cr26 High Chromium Cast Iron / Bimetal Composite | Hardness HRC >=58, impact resistant |
| 4 | Hammer (Hammer Crusher) | High Chromium Cast Iron / High Manganese Steel / Bimetal | Wear and impact resistant, replaceable head design |
| 5 | Ball Mill Liner | CrMo Alloy Steel / Mn13 / High Chromium Cast Iron | Shell and end liners, noise reduction and wear resistance |
| 6 | Screen Plate / Grate Bar | Mn13 / High Chromium Cast Iron / 65Mn | High open area, wear resistant and anti-clogging |
| 7 | Sprocket / Chain Link | 42CrMo / 40Cr / 35CrMo | Tooth-surface hardening, for conveyor systems |
| 8 | Feeder Bottom Plate / Support | ZG40Mn / 42CrMo / S355JR | High-strength structural component, weldable |
- Hardness Testing: After water toughening, the matrix hardness of high manganese steel is HB =500. High chromium cast iron reaches HRC >=58, and low-alloy wear-resistant steel reaches HRC 48-55.
- Impact Toughness: High manganese steel V-notch impact energy Akv >=118 J; high chromium cast iron toughness can be controlled to >=8 J when required, helping prevent fracture risk.
- Metallographic Structure: Austenitic grain size of high manganese steel is rated Grade 4 or above; M7C3 carbide distribution and content in high chromium cast iron are inspected.
- Dimensional and Assembly Fit: Mating surfaces of jaw plates, concaves, and similar parts are checked one by one to ensure interchangeability and proper wedge fastening contact.
- Non-Destructive Testing: Structural parts undergo MT/UT inspection; wear parts receive 100% visual inspection to ensure they are free from cracks, pores, and casting defects.
- High-manganese jaw plates and concaves for an iron ore crushing line: Mn18Cr2 material, with service life improved by more than 30% compared with standard Mn13 parts.
- High-chromium blow bars for limestone and granite aggregate lines: Cr26 material, matched with PF series impact crushers, producing excellent particle shape.
- CrMo alloy steel liners for gold and copper mine ball mills: Wear and impact resistant, reducing liner replacement downtime and improving mill operating rate.
- Coal mine conveyor sprockets and chain links: 42CrMo quenched and tempered + tooth-surface hardening, stable batch supply.
- Recommended combinations: Fixed and movable jaw plate sets, concave + mantle sets, and complete blow bar/hammer sets supplied together to reduce purchasing management costs.
Frequently Asked Questions (FAQ)
We recommend suitable wear-resistant casting materials and heat treatment processes according to mineral hardness, particle size, equipment model, impact load, and service-life targets.
How should I choose between high manganese steel and high chromium cast iron?
High manganese steel is recommended for high-impact, large-particle applications because it work-hardens, resists impact, and is less likely to fracture. High chromium cast iron is better for medium- or low-impact abrasive wear because it offers excellent hardness and wear resistance, though with lower toughness. We can recommend the most suitable material based on ore hardness, particle size, and crusher model.
Can you guarantee the service life of wear parts?
Service life depends on ore hardness, particle size, feeding method, crusher parameters, and other operating factors. We can provide estimated life based on similar mine conditions, then track wear after installation and continue optimizing material and structure.
Can you produce bimetal composite wear parts?
Yes. We can produce high chromium cast iron + carbon steel bimetal composite hammers and liners, combining a high-hardness wear surface with a tough, fracture-resistant base for both wear performance and safety.
Can jaw plates and concaves be made interchangeable with the original machine?
Yes. We manufacture according to the host machine model and drawings, inspect mating surfaces piece by piece, and ensure installation dimensions match the original equipment so customers can replace parts directly without rework.
Request a Wear Casting Solution for Mining Machinery
Please provide the crusher or mill model, ore hardness and particle size, processing capacity, and current wear condition; we will recommend the most cost-effective wear-resistant material solution.