Cemented carbide, wear ceramics and ceramic-metal composites address different wear problems. Review properties, attachment methods and impact limits for HPGR studs, VSI tips, hydrocyclones, chutes and composite wear parts.
Cemented tungsten carbide resists concentrated wear in studs, rotor tips and cutting inserts. Wear ceramics suit slurry erosion and suitably supported low- to moderate-impact linings. Ceramic-metal composites place hard phases in wear zones and retain a tough matrix in load-bearing areas. Their manufacturing, attachment and failure mechanisms differ.
Material names define candidates. Confirm grade, grain size, binder, ceramic type, purity and composite structure against part drawings and operating conditions.
Unsuitable as a complete structure subject to large deformation. Select carbide grades together with retention, brazing, interference-fit requirements and impact limits.
Specify ceramic type, thickness, tile shape, purity, attachment and substrate. Uncushioned ceramic is unsuitable for direct impact from large lumps.
“Composite” does not identify a single grade. Define interface bonding, hard-phase location, edge protection and impact direction in the drawing.
One machine can contain carbide, ceramic, rubber, steel and hardfacing materials. The relationships below are typical candidates for individual parts.
| Equipment / part | Operating Conditions | Candidate materials and structures | Key checks |
|---|---|---|---|
| HPGR Roll Studs | Severe abrasion in a high-pressure material bed, local impact and stud bending risk. | WC-Co carbide studs working with the roll substrate and hardfaced protection layer. | Stud dimensions, grade, binder, insertion depth, layout, substrate support and roll surface repair plan. |
| VSI rotor tips / backup tips | High-velocity particle impact, cutting and edge wear. | Tungsten carbide inserts, composite tips or hard phases specified for the OEM structure. | Rotor speed, feed, impact angle, insert shape, brazed/mechanical attachment and dynamic balance. |
| Crushing and cutting teeth | High contact stress, gouging abrasion and cyclic impact. | Carbide tooth tips or inserts combined with a tough steel body. | Tooth-body strength, carbide grade, interface, braze quality, holder fit and tramp-metal risk. |
| Hydrocyclone spigots, vortex finders and cone liners | High-velocity slurry erosion, particle abrasion, corrosion and local blockages. | Ceramics such as alumina, ZTA and silicon carbide; rubber or PU may also be options, subject to duty comparison. | Particle size/concentration, flow velocity, pH, bore size, replaceable structure, ceramic joints and support. |
| Chute, bin and slurry pipe liners | Sliding abrasion, erosion, sticky material and local falling-feed impact. | Ceramic tiles, ceramic-rubber composite liners and steel-backed ceramics; use tougher materials in high-impact zones. | Drop height, particle size, impact angle, temperature, adhesive, stud/weld attachment and edge protection. |
| Vertical mill tyres and grinding tables | Compressive grinding, abrasion, cyclic thermal stresses and loading of large sections. | Ceramic/MMC composites, high-chromium cast iron or hardfacing systems, according to the original design. | OEM structure, matrix, hard-phase distribution, interface, repair method and worn profile. |
| Composite blow bars, hammers and impact liners | Combined impact and abrasion, with a risk of local hard-phase detachment or crack initiation. | Ceramic-metal composites or MMC, with a tough metal matrix carrying impact loads. | Feed size, impact direction, ceramic layout, matrix material, interface and edge buffer zones. |
Hard-material failures often originate at interfaces and attachments rather than within the material itself.
Check grade, hard-phase grain size, binder, density, dimensions, visible cracks and interface quality after brazing or pressing.
Check ceramic type, purity, density/porosity, thickness, dimensions, cracks, joints and adhesive or mechanical attachment.
Inspect hard-phase location, metal matrix, interface continuity, edge protection and residual stresses from thermal expansion mismatch.
Check installation using drawings, templates and interface dimensions. For rotating parts, also assess weight distribution, dynamic balance and consistency between replacements.
Open the relevant part page to continue technical checks using OEM drawing numbers, applicable models, part numbers and drawings.
Material selection limits for large-lump, high-impact liners: Do not assume that cone crusher mantles and concaves, jaw plates or other large high-impact liners can use ceramic or carbide merely because they are wear parts. Material selection requires a validated composite structure and a defined hard-phase layout.
Provide the equipment model, part name/drawing number, existing material, feed, particle size, impact conditions, attachment structure, failure photographs, quantity and target service life.
ANRANST provides customers worldwide with coordinated consulting, supplier sourcing, quality control and finished-part delivery for custom parts, wear parts and industrial spares from China, with scope to support other custom industrial parts.
Equipment and part identification, drawing review, material selection and manufacturing feasibility assessment.
Match requirements with suitable manufacturers in China and coordinate the exchange of technical information.
Drawing confirmation, material and process control, production tracking, inspection and acceptance coordination.
Coordinate manufacturing, quality confirmation, packaging and delivery of complete finished parts.
Provide the existing model, drawings, drawing or part numbers, materials or operating conditions so we can identify the appropriate technical review and supply route.
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