Use the matrix for toughness and load support, with wear-resistant material in the wear zones. Applications include composite jaw plates, mantles, concaves, blow bars, teeth, hammers and heavy-wear liners. Validate the matrix, wear phase, interface and loading direction together.
Bimetallic and metal matrix wear parts use tough steel, manganese steel or another metal matrix to carry impact and overall loads. High-chromium iron, hard particles, ceramic or cemented carbide inserts resist localized wear. Effective reinforcement requires correct placement along the wear path and a reliable interface.
Composite materials address concentrated wear where a single material cannot readily provide both toughness and wear resistance.
Locate inserts from actual wear scans. Incorrect placement can increase interface stress without improving service life.
Feed size, rotor speed, tramp metal and impact direction determine material placement. Keep hard phases from extending through critical load-bearing sections.
Use cushioning or tougher materials in severe direct-impact zones. Brittle wear layers require support against bending.
| Part | Candidate Composite Designs | Material Functions | Pre-manufacturing Checks |
|---|---|---|---|
| Jaw Plate | Manganese steel matrix with localized wear inserts. | The matrix carries compression and impact; inserts at tooth peaks and wear zones retain the profile. | Jaw profile, wear map, feed, CSS, insert positions and safe removal. |
| Cone / Gyratory Crusher Mantles and Concaves | Manganese steel or tough alloy matrix with reinforcement in high-wear chamber zones. | The matrix retains overall toughness; reinforcement controls uneven wear and profile loss. | Chamber profile, feed distribution, power, liner thickness, heat treatment and interfaces. |
| Impact Crusher Blow Bars | Martensitic or tough steel matrix with ceramic/MMC wear faces, or a controlled bimetallic design. | The mounting zone carries centrifugal and bending loads; the working face resists high-speed wear. | Rotor speed, blow bar mass balance, feed size, tramp metal and impact direction. |
| Mineral Sizer Teeth / Tooth Caps | Alloy steel matrix with high-chromium or hard inserts, or hardfaced wear zones. | The root resists fracture; the tip and face resist abrasive cutting and compressive wear. | Feed material, speed, tooth profile, connection design, repairability and maximum impact. |
| Composite Chute / Hopper Liners | Steel backing with high-chromium iron, ceramic, hard particles or a rubber cushioning layer. | Backing provides support and mounting, the wear layer resists abrasion, and the buffer absorbs impact. | Drop height, flow direction, impact angle, supports, module size, joints and fastening. |
Composite parts add interface risks beyond those of a single material. Acceptable hardness does not establish correct insert placement, metallurgical bonding or residual stress.
Check matrix grade, reinforcement material, dimensions, batches and preparation separately, ensuring compatible thermal expansion and subsequent heat treatment.
Use traceable tooling to control insert depth, spacing and orientation. Validate process limits for pouring, casting infiltration, brazing or mechanical joining.
Select section checks, metallography, UT/CT, other flaw detection or destructive procedure qualification for the design. Assess debonding, porosity, cracks and reinforcement displacement.
Check mass and dynamic/static balance for rotating parts such as blow bars. For crusher liners, also assess removal, welding and cutting, and exposed-insert hazards.
Related Material Families: Explore Cemented Carbides and Ceramics for tungsten carbide studs, cutting tips and small hard inserts; Rubber and Polyurethane for rubber-metal mill liners; and Hardfacing and Surface Engineering for overlay plate and in-situ repairs. This page covers integrated or assembled load-bearing matrices and wear zones.
Material References: Metso MX Hybrid Wear Parts; Metso Metallic and MMC Liners. Published examples do not authorize reproduction of proprietary designs. Manufacture to an independent design or confirmed drawings.
Provide the equipment model, part drawing or drawing number, current material, wear distribution, impact direction, failure photographs, quantity, target life and acceptable manufacturing or repair methods.
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