HX900 cast-in-carbide

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1 HX900 cast-in-carbide

2 Cast-in-carbide for the toughest conditions HX900 is a unique wear material combining the wear resistance of cemented carbide with the shock resistance, ductility and forming capability of nodular iron. This is an ideal combination resulting in a hard material that stands well in tough environments and has a long wear life. Used in a wide range of applications, HX900 is implemented in the mining and mineral handling industries, steel works, concrete plants and in road maintenance. It has found use most readily in crushing, fragmentation and grinding operations. In such applications HX900 can easily replace conventional wear resistant steels, castings and hardfacing on wear parts subjected to severe stresses. The high wear resistance of HX900 makes it a material that contributes to new opportunities for improved product quality, reduced down-time and increased productivity. HARD, DURABLE AND FLEXIBLE A typical HX900 product has a wear resistance that is comparable with cemented carbide and a strength that is 80-90% of the strength of pure nodular iron. The wear resistance is generally 3-15 times higher than with common structural steel, nodular iron, welded material or ceramics. HX900 can be produced in various shapes and sizes and can be used in many different types of applications. The composition of the material can be optimized to meet the specific requirements for each application. That makes it a flexible and durable material. COMPARABLE WEAR RESISTANCE Ni-hard HX900 Manganese steel HX900 High chromium cast iron HX900 Hardened steel HX900 Hardfacing HX

3 Material description HX900 is produced in the form of composite or clad. The casting method used in both cases provides a metallurgical bond between the cemented carbide granules or tiles in the wear zone and the nodular iron in the base metal. It is also possible to have a mixture of composite and clad. HX900 COMPOSITE To create the composite of HX900, granules of cemented carbide are added to the nodular iron surface. Composite is ideal to use in products that will be exposed to heavy impact. Approximately 50% of the composite wear zone consist of granules. The granules have a size of 1 to 6 mm (0.04-0,24 ), depending on the application. HX900 CLAD HX900 clad products consist of cemented carbide tiles embedded in the nodular iron surface. The tiles form an almost continuous surface and provide the best protection against wear due to abrasion and erosion. The tiles can be of various shapes and sizes but are usually rectangular with a length and width of 10 to 50 mm ( ) and thickness of 2 to 10 mm ( ) mm ( ) HX900 Clad HX900 Composite 5-20 mm ( ) Nodular iron Nodular iron

4 Versatility leads to various applications There are well proven uses for HX900 within fragmentation, materials handling, surface mining and civil engineering. It can be found in hammers, crusher arms, chutes, liners, mixer paddles, bucket lips and teeth, grader blades etc. Thanks to its high wear resistance, HX900 can replace conventional wear materials at a total lower cost. It can be delivered in various standard shapes or made-to-measure shapes according to the chosen requirements. The examples below are just a few of the applications that are improved with HX900. SLIDING In ducts, troughs, pipes and chutes carrying and guiding flows of material, the curved and restrictive areas are often subjected to heavy impact and abrasive wear. In such applications HX900 gives many times the life of Ni-hard, hardfacing, hardened steel, etc. CRUSHING When sinter is crushed, the crusher arms, breaker bars and crush deck are subjected to heavy wear. HX900 crusher parts last 3-5 times longer than conventional materials such as hard facing, Ni-hard and Cr-steel. A more uniform particle size of the crushed sinter is obtained which facilitates the rest of the process. MILLING In hammer mills, the hammer suffers the greatest wear. In order to increase service life the hammers are often hard faced. Hammers made of HX900 will last 3-8 times longer than conventional materials. MIXING Many types of concrete mixes contain mixing paddles and scraper blades. For optimum mixing efficiency these components are designed to operate with a minimum clearance between the sides and the bottom of the mixer. HX900 composite paddles and scraper blades with cemented carbide tiles embedded in the leading edge have a service life several times longer than competing designs in Ni-hard and brazed carbide tiles. HX900 paddles and blades also require less frequent adjustments due to wear. CUTTING In surface mining operations, large quantities of overburden are often removed with bucket wheel excavators. The buckets are fitted with teeth or cutting lips. In both cases it is important that the original cutting geometry of the teeth or cutting lips is retained in order to maintain power requirements at a constant low level. HX900 cutting teeth have a higher wear resistance than conventional materials and they retain a sharp cutting edge throughout the service life. HX900 liners for wear protection inside and outside the bucket last several times that of conventional steel and reduce downtime. SCRAPING Snow-plowing on roads and highways is often undertaken at high speed. Plowing exposes base asphalt, subjecting the blades and shoes to heavy abrasive and impact wear. HX900 plough blades and shoes last up to 40 times longer than conventional steel blades and shoes. GRINDING At coal-fired power stations coal is ground to powder in impact mills by a rotor which accelerates the lumps of coal and throws them against the armored periphery of the mill. The rotor blades and the breaker blades are subjected to rapid wear. By using HX900 in these parts, service life can be increased by 4-6 times compared with Ni-hard, Cr- and Mn-steel, etc.

5 Sliding Mixing Scraping Crushing Cutting Milling Grinding

Material flow speed: 4 m/s Angle of impact: 15 degrees HX900 Wear plates (Granules) HX900 Wear plates (Tiles) Hardfacing AW5 2x6 mm Hardfacing AW6 2x6 mm Rubber COST Material Personnel Ceramic rubber

6 FIELD TEST WITH HX900 WEAR PLATES The charts below show the results from field tests in a belt conveyor transfer station for iron ore sinter. Liners in different types of material were tested including the HX900. HX900 proved to be both the most cost efficient and the long lasting of the materials tested. Material flow speed: 4 m/s Angle of impact: 15 degrees HX900 Wear plates (Granules) HX900 Wear plates (Tiles) Hardfacing AW5 2x6 mm Hardfacing AW6 2x6 mm Rubber COST Material Personnel Ceramic rubber Chilled cast iron Mild steel BS C Manganese steel Cost (USD) for 100,000 t/m² used surface Cost: The wear cost in USD for the liners at a 100,000 tonnes/m2 material flow. The total cost refers to the material cost ( purchase price for the liners ) and the personnel. ( assembly, and exchanging worn-out liners ) HX900 Wear plates (Granules) HX900 Wear plates (Tiles) Hardfacing AW5 2x6 mm Hardfacing AW6 2x6 mm Rubber Ceramic rubber Chilled cast iron Mild steel BS C Manganese steel TONNAGE Output in 100,000 t Tonnage: The amount of material that has been dropped on the liners before they are considered worn-out.

7 HX900 liners in a chute HX900 is used on snow plow blades A bucket wheel reclamer with cutting lips of HX900 HX900 crusher arms of a sinter cusher

HX900 cast-in-carbide standard liners HX900 LINERS - EIGHT TIMES MORE WEAR RESISTANT In ducts, troughs, chutes and pipes, wear liners are often subjected to heavy impact and abressive wear.

8 HX900 cast-in-carbide standard liners HX900 LINERS - EIGHT TIMES MORE WEAR RESISTANT In ducts, troughs, chutes and pipes, wear liners are often subjected to heavy impact and abressive wear. In these environments HX900 cast-in-carbide liners are an excellent choice. When nine HX900 liners were installed in a chute (transporting iron ore and minerals) at Thyssen Krupp Steel AG, Duisburg, they proved to be over eight times more wear resistant than the conventional steel liners in the same chute. With the HX900 liners installed, cost savings of over 40% were achieved. The HX900 lasted for six months, a period with no mainenance needed. HX900 LINERS WITH ONE HOLE Length L mm (in) Width W mm (in) Total thickness T mm (in) Granular thickness t mm (in) Order codes 200 (7.87) 200 (7.87) 30 (1.18) 10 (0.39) SA CS 200 (7.87) 200 (7.87) 20 (0.79) 8 (0.32) SA CS 250 (9.84) 250 (9.84) 30 (1.18) 10 (0.39) SA CS 250 (9.84) 250 (9.84) 20 (0.79) 8 (0.32) SA CS 300 (11.81) 300 (11.81) 30 (1.18) 10 (0.39) SA CS 300 (11.81) 300 (11.81) 20 (0.79) 8 (0.32) SA CS

9 HX900 LINERS WITH ONE BOLT Length L mm (in) Width W mm (in) Total thickness T mm (in) Granular thickness t mm (in) Order codes 200 (7.87) 200 (7.87) 30 (1.18) 10 (0.39) SA CS 200 (7.87) 200 (7.87) 20 (0.79) 8 (0.32) SA CS 250 (9.84) 250 (9.84) 30 (1.18) 10 (0.39) SA CS 250 (9.84) 250 (9.84) 20 (0.79) 8 (0.32) SA CS 300 (11.81) 300 (11.81) 30 (1.18) 10 (0.39) SA CS 300 (11.81) 300 (11.81) 20 (0.79) 8 (0.32) SA CS HX900 LINERS WITH FOUR HOLES Length L mm (in) Width W mm (in) Length, edge to hole l mm (in) Total thickness T mm (in) Granular thickness t mm (in) Order codes 400 (15.75) 300 (11.81) 50 (1.97) 30 (1.18) 10 (0.39) SA CS 400 (15.75) 300 (11.81) 50 (1.97) 20 (0.79) 8 (0.32) SA CS 300 (11.81) 300 (11.81) 50 (1.97) 30 (1.18) 10 (0.39) SA CS 300 (11.81) 300 (11.81) 50 (1.97) 20 (0.79) 8 (0.32) SA CS 300 (11.81) 300 (11.81) 75 (2.95) 30 (1.18) 10 (0.39) SA CS 300 (11.81) 300 (11.81) 75 (2.95) 20 (0.79) 8 (0.32) SA CS HX900LINERS WITH FOUR BOLTS Length L mm (in) Width W mm (in) Length edge to bolt l mm (in) Total thickness T mm (in) Granular thickness t mm (in) Order codes 400 (15.75) 300 (11.81) 50 (1.97) 30 (1.18) 10 (0.39) SA CS 400 (15.75) 300 (11.81) 50 (1.97) 20 (0.79) 8 (0.32) SA CS 300 (11.81) 300 (11.81) 50 (1.97) 30 (1.18) 10 (0.39) SA CS 300 (11.81) 300 (11.81) 50 (1.97) 20 (0.79) 8 (0.32) SA CS 300 (11.81) 300 (11.81) 75 (2.95) 30 (1.18) 10 (0.39) SA CS 300 (11.81) 300 (11.81) 75 (2.95) 20 (0.79) 8 (0.32) SA CS R4 = Edge radius 4 mm R5 = Corner radius 5 mm M20 x 50 bolts are used as standard. Other dimensions can be ordered on request.

10 HX900 cast-in-carbide road maintenance components HX900 SNOW PLOW SHOES HX900 ROUND SHOE Function Rotating SAROA CS Non-rotating SAROA CS HX900 SHOE Function SAROA CS Wear resistant zone

HX900 GRADER BLADES HX900 ROAD GRADER BLADES Length mm (in) 610 (24.02) SAROA 2978 1 CS 915 (36.02) SAROA 2978 2 CS 1220 (48.

02) SAROA 3456 1 CS 915 (36.02) SAROA 3456 2 CS 792 (31.

11 HX900 GRADER BLADES HX900 ROAD GRADER BLADES Length mm (in) 610 (24.02) SAROA CS 915 (36.02) SAROA CS 1220 (48.03) SAROA CS HX900 SNOW PLOW BLADES HX900 DOUBLE SIDED SNOW PLOW BLADES, TYPE 3456 Length mm (in) 610 (24.02) SAROA CS 915 (36.02) SAROA CS 792 (31.18) SAROA CS HX900 DOUBLE SIDED SNOW PLOW BLADES, TYPE 3451 Length mm (in) 610 (24.02) SAROA CS 915 (36.02) SAROA CS 792 (31.18) SAROA CS 610 right (24.02) SAROA CS Wear resistant zone

LIEBHERR TYPE MIXER PADDLES 3427 1030 3428 1031 3571

12 HX900 cast-in-carbide mixer paddles TEKA TYPE MIXER PADDLE FEJMERT TYPE MIXER PADDLES LIEBHERR TYPE MIXER PADDLES Wear resistant zone - tiles Wear resistant zone - granules

13 SONTHOFEN TYPE MIXER PADDLE SKAKO TYPE MIXER PADDLES EIRICH TYPE MIXER PADDLES Wear resistant zone - tiles Wear resistant zone - granules

HX900 cast-in-carbide sinter crusher components When crushing, the crusher arms, breaker bars, chutes and crash-decks are subjected to severe wear due to the high temperature and the abrasive nature

Wear of the wear parts of a crusher takes different forms from one crusher to another, depending particularly on the design of the crusher, the composition and the temperature of the sinter.

14 HX900 cast-in-carbide sinter crusher components When crushing, the crusher arms, breaker bars, chutes and crash-decks are subjected to severe wear due to the high temperature and the abrasive nature of the sinter. HX900 crusher arms, breaker bar caps and liners last several times longer than conventional wear resistant materials, including hard facings. Wear of the wear parts of a crusher takes different forms from one crusher to another, depending particularly on the design of the crusher, the composition and the temperature of the sinter. HX900 sinter crusher components can be adapted to the particular wear situation by varying the location and thickness of the wear protection. When necessary, additional protection can be provided by embedded tiles or preformed inserts of cemented carbide. By reducing wear while preserving optimum dimensions and profiles, HX900 components can improve crusher efficiency and permit the production of more uniformly sized particles, which is advantageous in the subsequent process. Wear resistant zone

HX900 SINTER CRUSHER ARMS Cemented carbide granules Nodular cast iron Weldable steel A HX900 sinter crusher arm can easily be welded since it incorporates a weldable steel segment.

Wear resistant zone HX900 BREAKER BAR WEAR CAPS Cemented carbide granules Nodular cast iron Installed HX900 breaker bars wear caps will considerable minimize production stops due

15 HX900 SINTER CRUSHER ARMS Cemented carbide granules Nodular cast iron Weldable steel A HX900 sinter crusher arm can easily be welded since it incorporates a weldable steel segment. Manufactured in custom made dimensions adjusted to the customers requirements and for each specific application. Wear resistant zone HX900 BREAKER BAR WEAR CAPS Cemented carbide granules Nodular cast iron Installed HX900 breaker bars wear caps will considerable minimize production stops due to maintenance. The HX900 breaker bar wear caps are placed over the breaker bars and are easily replaced when needed. Manufactured in custom made dimensions adjusted to the customers requirements and for each specific application. Wear resistant zone

ESCO Universal Wear Solutions. Mining, Construction, Aggregate & Industrial Applications

ESCO Universal Wear Solutions. Mining, Construction, Aggregate & Industrial Applications ESCO Universal Wear Solutions Mining, Construction, Aggregate & Industrial Applications ESCO Corporation With a history of proprietary products and a reputation for engineering and metallurgical expertise,