Impact Crusher plate hammer: Material and Wear Resistance analysis

The impact crusher is a highly efficient crushing equipment widely used in industries such as mining, building materials, and chemicals. As a key component of the impact crusher, the material and wear resistance of the plate hammer directly affect the crushing efficiency and service life of the equipment. This article will delve into the common materials of plate hammers, such as high manganese steel and high chromium cast iron, and analyze the wear resistance of these materials and their performance in practical applications.

First, the material selection of the hammer
1.High manganese steel
High manganese steel is a commonly used material for plate hammers, featuring excellent toughness and wear resistance. High manganese steel undergoes work hardening when subjected to impact, significantly increasing its surface hardness and thereby enhancing its wear resistance. This material is suitable for working conditions with high impact and high wear, and can effectively withstand the impact and friction of materials.
Advantages:
High toughness: High manganese steel has excellent toughness, capable of withstanding significant impact forces and is not prone to breakage.
Work hardening: When subjected to impact, the surface of high manganese steel undergoes work hardening, significantly increasing its hardness and enhancing its wear resistance.
Wide adaptability: It is suitable for crushing various materials, especially performing well when crushing materials with high hardness.
Disadvantage:
Low initial hardness: The initial hardness of high manganese steel is relatively low and it needs to gradually harden during use.
High processing difficulty: The processing performance of high manganese steel is poor and the processing cost is relatively high.

2. High-chromium cast iron
High-chromium cast iron is a high-performance wear-resistant material, featuring high hardness and excellent wear resistance. The hardness of high-chromium cast iron is usually between HRC 58 and 65, which can effectively resist the wear of materials. This material is suitable for working conditions with high wear and low impact, and can significantly extend the service life of the plate hammer.
Advantages:
High hardness: High-chromium cast iron has a high hardness, which can effectively resist the wear of materials and extend its service life.
Good wear resistance: It performs well under high-wear conditions and can significantly reduce wear and replacement frequency.
Strong adaptability: It is suitable for crushing various materials, especially when crushing materials with strong abrasiveness, the effect is remarkable.
Disadvantage:
High brittleness: High-chromium cast iron has relatively high brittleness and poor impact resistance, and is prone to fracture under high-impact conditions.
High processing difficulty: The processing performance of high-chromium cast iron is poor and the processing cost is relatively high.

Second, wear resistance analysis
1.The wear resistance of high manganese steel
The wear resistance of high manganese steel mainly depends on its work hardening characteristics. During the usage process, the surface of high manganese steel will gradually harden, and the hardness will increase from about HB 220 initially to above HB 450. This work hardening property enables high manganese steel to perform well under high-impact conditions, effectively resisting the impact and wear of materials. However, the initial hardness of high manganese steel is relatively low, and it may exhibit poor wear resistance under low-impact conditions.

2. Wear resistance of high-chromium cast iron
The wear resistance of high-chromium cast iron mainly depends on its high hardness. The hardness of high-chromium cast iron is usually between HRC 58 and 65, which can effectively resist the wear of materials. Under high-wear conditions, the wear resistance of high-chromium cast iron is significantly better than that of high-manganese steel, which can significantly extend the service life of the plate hammer. However, high-chromium cast iron is relatively brittle and prone to fracture under high-impact conditions, with relatively poor impact resistance.

Third, practical application cases
1.Ore crushing
In ore crushing, high manganese steel plate hammers are widely used due to their excellent toughness and wear resistance. When a certain mining enterprise was using high-manganese steel plate hammers, it was found that they performed well in crushing ores with high hardness and could effectively withstand the impact and wear of materials. Although the initial hardness of high manganese steel is relatively low, through work hardening, its surface hardness gradually increases, significantly enhancing its wear resistance. The enterprise reported that the service life of high manganese steel plate hammers has been increased by more than 30% compared with that of ordinary materials.

2. Construction waste treatment
In the treatment of construction waste, high-chromium cast iron plate hammers are widely used due to their high hardness and good wear resistance. A certain construction waste processing enterprise found that when using high-chromium cast iron plate hammers, they performed well in crushing highly abrasive materials such as concrete blocks and bricks, significantly reducing wear and the frequency of replacement. Although high-chromium cast iron is more brittle, its wear resistance is significantly better than that of high manganese steel under low-impact conditions. The enterprise reported that the service life of high-chromium cast iron plate hammers has increased by more than 50% compared with high-manganese steel plate hammers.

Fourth, select the appropriate material for the hammer
The selection of the appropriate material for the plate hammer requires a comprehensive consideration based on specific working conditions and requirements. The following are some selection suggestions:
1. Working condition analysis
High-impact working conditions: If the crusher mainly processes materials with high hardness and there is a significant impact force in the working conditions, it is recommended to choose a high-manganese steel plate hammer. The toughness and work hardening characteristics of high manganese steel can effectively withstand impact forces and reduce the risk of fracture.
High wear conditions: If the crusher mainly processes highly abrasive materials and the wear is significant in the working conditions, it is recommended to choose high-chromium cast iron plate hammers. The high hardness and good wear resistance of high-chromium cast iron can significantly extend the service life of the plate hammer.

2. Cost considerations
Initial cost: The processing cost of high manganese steel and high chromium cast iron is relatively high, and the initial investment is large. However, in long-term use, High-Quality Plate hammers can significantly reduce the frequency of replacement and lower maintenance costs.
Maintenance cost: The maintenance cost of high manganese steel plate hammers is relatively low, but they need to be inspected and replaced regularly. The maintenance cost of high-chromium cast iron plate hammers is relatively high, but they have a long service life and a low replacement frequency.

3. Service life
High manganese steel: Under high impact conditions, the service life of high manganese steel plate hammers is usually 3 to 6 months.
High-chromium cast iron: Under high-wear conditions, the service life of high-chromium cast iron plate hammers is typically 6 to 12 months.

Fifth, Conclusion
The material selection of the plate hammer is crucial to the performance and service life of the impact crusher. High manganese steel and high chromium cast iron are two common materials for plate hammers, each with its own advantages and disadvantages. High manganese steel has excellent toughness and work hardening properties, and is suitable for high-impact working conditions. High-chromium cast iron features high hardness and excellent wear resistance, making it suitable for high-wear working conditions. When choosing the material of the plate hammer, a comprehensive consideration should be made based on the specific working conditions and requirements to ensure the efficient operation and long-term stable use of the crusher. By rationally choosing and using high-quality plate hammers, the crushing efficiency can be significantly improved, maintenance costs can be reduced, and the service life of the equipment can be prolonged.