wear resistant cast materials for the mining industry
DESCRIPTION
ricardo fuoco wear resistant cast materials for the mining industryTRANSCRIPT
Ricardo Fuoco
METSO Minerals – Brazil
Wear Resistant Cast Materials
for the Mining Industry
© Metso
• 1. Introduction
• 2. Types of wear in the mining industry (comminution)
• 3. Wear resistant cast materials to:
• Crushers
• SAG/AG mill
• Balls mill / Vertimill
• 4. Summary
Outline
2
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
Introduction
3
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
• 1. Drilling
• 2. Blasting
• 3. Comminution
4
Introduction Typical mining operations
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
Introduction Typical mining operation
5
Drilling
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
6
Blasting
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
Introduction Typical mining operation
© Metso
• Comminution:
• 1. Crushing
• 2. Grinding (AG/SAG Mills, Ball Mills and Vertimills)
7
Introduction Typical comminution operation in the mining industry
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
8
1. Crushers
Introduction Typical comminution operation in the mining industry
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
9
2. SAG Mill 1. Crushers
Introduction Typical comminution operation in the mining industry
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
10
3. Ball Mill/Vertimill 1. Crushers 2. SAG Mill
Introduction Typical comminution operation in the mining industry
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
Types of wear in the mining industry
(comminution)
11
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
Vertimill
12
Types of wear in the mining industry
(comminution)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
13
Types of wear in the mining industry
(comminution)
Vertimill
High stress abrasion and impact
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
14
Types of wear in the mining industry
(comminution)
Vertimill
High stress abrasion and impact
High stress grinding abrasion
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
15
Types of wear in the mining industry
(comminution)
Vertimill
High stress abrasion and impact
High stress grinding abrasion
Erosion
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
• Crushers:
• High stress abrasion
• High impact forces
• Gouging abrasion
Wear resistant material with high toughness:
Austenitic Mn steels
16
Types of wear in the mining industry
(comminution)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
• AG/SAG mills and large balls mills:
• High stress grinding abrasion
• Medium impact forces
• Scratching and micro-cracking resistant
Wear resistant material with some toughness:
Cr-Mo low alloy steels
17
Types of wear in the mining industry
(comminution)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
• Small ball mills and Vertimills:
• Erosion
• Low stress scratching abrasion
• Low impact forces
Very high wear resistant material:
High Cr white cast iron
18
Types of wear in the mining industry
(comminution)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
• Hardness (and wear resistance):
19
Types of wear in the mining industry
(comminution)
0
100
200
300
400
500
600
700
Hadfield
Steel (initial)
Hadfield
Steel
(deformed)
Cr-Mo low
alloy steel
(pearlitic)
Cr-Mo low
alloy steel
(martensitic)
Hi Cr White
Cast Iron
Series1
Hardness (HB)
200 HB
450 HB
320 HB
375 HB
600 HB
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
• Charpy Impact test (toughness):
20
Types of wear in the mining industry
(comminution)
0
20
40
60
80
100
120
140
160
180
200
Hadfield Steel
(initial)
Cr-Mo low alloy
steel
(pearlitic)
Cr-Mo low alloy
steel
(martensitic)
Hi Cr White Cast
Iron
Series1
Impact (J)
200 J
10 J 15 J 2 J
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
Wear resistant cast materials Crusher parts
21
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
22
Wear resistant cast materials Types of crushers: Primary gyratory
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
23
Wear resistant cast materials Types of crushers: Jaw crusher
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
24
Wear resistant cast materials Types of crushers: Cone crusher
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
25
Wear resistant cast materials Austenitic Mn steel - Typical castings
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
26
Wear resistant cast materials Austenitic Mn steel - Typical castings
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
27
Wear resistant cast materials Austenitic Mn Steels for Crushers Parts
• Typical Spec described in the ASTM A128 Grades B and C:
• 12 – 14% Mn / 1.1 – 1.25% C
• High Mn special grades:
• 17 - 19% Mn
• 19 - 22% Mn
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
28
Wear resistant cast materials Austenitic Mn Steels for Crushers Parts
High Mn special
grades
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
29
Wear resistant cast materials Austenitic Mn Steels for Crushers Parts – wear mechanisms
Gouging abrasion (deep surface scratching and high energy indentation)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
Surface layer: microstructure
after deformation
Core: original microstructure
400 to 500 HB
200 HB
30
Wear resistant cast materials Austenitic Mn Steels for Crushers Parts
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
31
Wear resistant cast materials Austenitic Mn Steels – Heat treatment
• Critical step in the production: Heat Treatment
• Solution heat treatment at 1050 – 1100°C
• Quench in water
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
32
Wear resistant cast materials Austenitic Mn Steels – Heat treatment
Microstructure in the as cast condition Microstructure after solution HT
Charpy impact energy = 10J Charpy impact energy = 180J
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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• Typical problem in the heat treatment (low toughness).
Wear resistant cast materials Austenitic Mn Steels – Heat treatment
Incomplete solution HT
(low temperature or insufficient time) Complete solution HT but ineffective
quenching (low cooling rate)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
34
TTT curves of carbides re-precipitation during the cooling after solution
of Hadfield austenitic steel
Wear resistant cast materials Austenitic Mn Steels – Heat treatment
• Typical quenching problem
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
35
TTT curves of carbides re-precipitation during the cooling after solution
of Hadfield austenitic steel
Solution Carbide re-precipitation
Wear resistant cast materials Austenitic Mn Steels – Heat treatment
• Typical quenching problem
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
• Typical quenching problem
36
Effect of the grain boundaries coverage by continuous carbide re-precipitation in the
Charpy impact energy of different grades of Hadfield austenitic manganese steels
Wear resistant cast materials Austenitic Mn Steels – Heat treatment
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
37
Wear resistant cast materials Austenitic Mn Steels
• The main problems in austenitic Mn steels production are
related to heat treatment;
• Ineffective heat treatments develops microstructures with
carbides which result in low toughness and possibility of
breakage problems in field.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
Wear resistant cast materials SAG/AG Mills (and large ball mills)
38
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
39
Wear resistant cast materials SAG/AG Mills (and large ball mills)
Feed end side
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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40
Wear resistant cast materials SAG/AG Mills (and large ball mills)
Discharge side (grates)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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41
Wear resistant cast materials SAG/AG Mills (and large ball mills)
Lifting effects of the shell liners illustrated by charge motion simulation
(TCS - Total Critical Speed)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
42
Wear resistant cast materials SAG/AG Mills (and large ball mills)
Lifting effects of the shell liners illustrated by charge motion simulation
(TCS - Total Critical Speed)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
43
Wear resistant cast materials SAG/AG Mills (and large ball mills)
Lifting effects of the shell liners illustrated by charge motion simulation
(TCS - Total Critical Speed)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
44
Wear resistant cast materials SAG/AG Mills (and large ball mills)
Charge motion illustration showing the atriction and the impact grinding
mechanisms.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
45
Wear resistant cast materials SAG/AG Mills – Typical castings
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
46
Wear resistant cast materials SAG/AG Mills – Alloy specification
• Typical Specification: Cr-Mo steels
• Cr-Mo steels (Pearlitic microstructure) - 320 HB
• Cr-Mo steels (Martensitic microstructure) - 375 HB
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
47
Wear resistant cast materials SAG/AG Mills – Heat treatment
• Critical step in the production: Heat Treatment
• Pearlitic – Normalizing and Tempering
• Martensitic – Quenching in blown air and tempering
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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• Schematic TTT curves of Cr-Mo steel showing the formation of Pearlite and Martensite during the heat treatment.
48
Wear resistant cast materials SAG/AG Mills – Heat treatment (TTT curve)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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• Cr-Mo steel (0.6%C) after normalizing and temper heat treatment
49
Wear resistant cast materials SAG/AG Mills – Typical microstructures
400x
Pearlite
Spheroidized
Pearlite
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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• Cr-Mo steel (0.45%C) after quenching and temper heat treatment
50
Wear resistant cast materials SAG/AG Mills – Typical microstructures
200x
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
51
Wear resistant cast materials Cr-Mo steels
• The main problems in Cr-Mo steels production are related to
heat treatment;
• Inadequate microstructures and hardness result in low wear
resistance (premature wear) or low toughness and possibility of
breakage problems in field;
• Improper mill operation frequently promote direct impact of balls
on liners resulting in accelerated wear and risk of breakage.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
52
Wear resistant cast materials Improper mill operation causing direct impact of balls on liners
Charge motion simulation
(< 75% TCS - no impact)
Charge motion simulation
(> 75% TCS - direct impact on liners)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
53
Typical aspect of liner surface after direct impact of balls on liners
promoting accelerated wear and risk of liner breakage.
Wear resistant cast materials Improper mill operation causing direct impact of balls on liners
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
Wear resistant cast materials Balls mills and Vertimills
54
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
55
Wear resistant cast materials Balls mills
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
56
Wear resistant cast materials Vertimills
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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57
Wear resistant cast materials Vertimills – Grinding mechanism
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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58
Wear resistant cast materials Ball mills – Typical wear parts
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
59
Wear resistant cast materials Vertimills – Typical wear parts
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
60
Wear resistant cast materials Balls mills and Vertimills – Alloy specification
• Typical specification: ASTM A532
• Grade II E : 18 – 23% Cr / 2.0 – 3.0% C
• Grade III A : 23 – 28% Cr / 2.5 – 3.5% C
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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61
Wear resistant cast materials Balls mills and Vertimills – Alloy specification
ASTM A532 Grade III A
ASTM A532 Grade II E
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
62
Wear resistant cast materials SAG/AG Mills – Heat treatment
• Critical step in the production: Heat Treatment
• Solution (austenite destabilization) at 950 – 1000°C
• Quenching in calm air / blow air
• Tempering
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
63
Wear resistant cast materials Balls mills and Vertimills - microstructures
1000x SEM, 2000x
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
64
Wear resistant cast materials Balls mills and Vertimills – wear mechanism (erosion)
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
65
Wear resistant cast materials Balls mills and Vertimills – wear mechanism (erosion)
Martensite HV=700
Carbides HV= 1500
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
66
Wear resistant cast materials Balls mills and Vertimills – wear mechanism (erosion)
– Carbides (M7C3) has high hardness > 1500 HV
– Most important abrasive is quartz with 1.000 to 1.300 HV
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
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67
Wear resistant cast materials High Cr white cast irons
• The main problem in high Cr white cast iron production is crack
formation;
• Premature shake out, inadequate handling and thermal shock
are common causes of cracks in high Cr cast iron castings.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
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Summary
68
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012
© Metso
69
Summary
• The most commonly used cast materials in the mining industry
are:
• Austenitic Mn steels – normally used in Crusher
application due to its very high toughness and fairly good
wear resistance;
• Cr-Mo low alloy steels – normally used in SAG/AG
mills application due to its high wear resistance and
reasonable toughness;
• High Cr white cast iron – normally used in ball mills
and vertimills application due to its very high wear
resistance.
WEAR RESISTANT CAST MATERIALS FOR THE MINING INDUSTRY
RICARDO FUOCO - 2ND BRICS FOUNDRY FORUM - CHINA – MAY 8-11, 2012