Material Analysis Suggestions

As a professional manufacturer of wear-resistant parts for crushers, ONA has extremely stringent requirements for materials: controlling the alloy ratio and purity from the source, scientifically matching high-manganese steel, high-chromium cast iron, or ceramic composite materials according to working conditions, and combining precision casting and heat treatment processes to ensure stable performance, resulting in long service life and high reliability under high impact and high wear conditions.

Crusher liners are key wear parts that protect the casing and transmit crushing force. The following is a comprehensive analysis of commonly used liner materials and key factors in their selection.

Manganese steel 

Features：

• Work Hardening: Increases surface hardness under impact, enhances wear resistance, and maintains core toughness.
• High Toughness: Excellent crack resistance, absorbs impact energy, and ensures stable equipment operation.
• Initial Softening: Lower initial hardness, slightly faster wear during the break-in period, but significantly improved wear resistance after hardening.

Variations:

• Mn13cr2: Good toughness, moderate work hardening, high cost-effectiveness, suitable for general working conditions and soft rock crushing.
• Mn18r2: Standard grade manganese steel, balanced toughness and wear resistance, suitable for most aggregates and medium-hardness rocks.
• Mn22cr2: Fast work hardening, high surface hardness, excellent wear resistance, suitable for highly abrasive hard rocks (such as granite, basalt, and iron ore).

 High chromium cast iron

Features:

Excellent wear resistance: Contains high-hardness chromium carbide, with wear resistance far exceeding that of manganese steel, suitable for highly abrasive materials such as quartz sand and granite.

High hardness: Maintains high wear resistance for extended periods without work hardening, ensuring stable operation.

Relatively brittle: Poor impact toughness, unsuitable for high-impact conditions, but suitable for low-impact, stable feed environments.

Applications:

Best suited for: Suitable for secondary/tertiary crushing, low-impact, high-wear conditions.

Typical components: Impact crusher blow bar, cone crusher distribution plate, VSI rotor, wear-resistant parts for plate feeders.

Alloy Steels

Features:

Excellent wear resistance: Significantly superior to manganese steel in fine crushing and highly abrasive conditions.

Balance of strength and toughness: Optimized alloying and heat treatment balance wear resistance and impact resistance.

High resistance to deformation: Resistant to deformation under extremely high pressure, maintaining cavity stability.

Applications:

Widely applicable to various crushing scenarios, especially suitable for fine crushing of highly abrasive materials, such as cone crusher mantle, cone crusher bowl liner, jaw plates for crusher, jaw crusher side plate and other parts.

 

 

Embedded alloys

Features:

Ultra-high wear resistance: Tungsten carbide alloy hardness HRA 88-92, improving wear resistance by 1.5-1.8 times.

Combination of rigidity and flexibility: High-toughness matrix resists impact, alloy layer provides wear-resistant protection.

Precise reinforcement: Inlay only in high-wear areas, optimizing material utilization.

Self-sharpening effect: Continuous alloy protrusion maintains high-efficiency crushing performance.

Applications:

VSI Rotor tip set, Impact crusher blow bars and processing scenarios involving highly abrasive materials such as river pebble sand making, granite crushing, iron ore crushing, and high-silica ore.

 

 

 

 

Factors Influencing Material Selection

The core factors influencing material selection mainly include:

• Material characteristics: The type, abrasiveness, hardness, particle size, and moisture content of the feed determine the basic requirements for wear resistance and toughness.
• Equipment type: Jaw crushers require high toughness and impact resistance; cone crushers require a balance between wear resistance and toughness; impact crushers prioritize the wear resistance of the hammer plates.
• Operating environment: High temperatures accelerate wear, high humidity easily leads to corrosion, and high dust levels exacerbate wear, all affecting the lifespan of the liner plates.
• Cost budget: A comprehensive assessment of procurement costs and operating costs incurred due to downtime replacements is conducted to achieve the optimal cost per ton.