Under the harsh working conditions of high load and high wear in cement production, the risk of crusher hammer breakage and insufficient wear resistance are two major pain points that plague companies.
Hammer manufacturer---Zhili New Materials, innovatively launched high manganese steel matrix + alloy bars inlay + hardfacing reinforced triple protection hammer, the comprehensive life is increased by 2 times, and the safety reaches the industry-leading level.
一、 Problems of traditional hammers: the vicious cycle of fracture risk and short life
1. High manganese steel hammer head: good toughness but insufficient hardness, fast wear, frequent replacement increases downtime cost.
2. High chromium cast iron hammer head: high wear resistance but high brittleness, easy to break under impact load, threatening equipment safety.
3. Ordinary composite hammer head: low interface bonding strength, easy to fall off the alloy layer, actual life is less than 60% of the theoretical value.
Real case: A cement plant caused rotor damage due to hammer head fracture, the maintenance cost exceeded 120,000 yuan, and the loss of shutdown reached 300,000 yuan/day.
2. Solution: high manganese steel matrix + alloy bars inlay + hardfacing process
Insert alloy bars hammer head profile design
Hardfacing hammer head diagram
1. Core skeleton: high-toughness high manganese steel matrix
Absorb more than 80% of impact energy to prevent overall brittle fracture.
The matrix hardness is HRC50-55, which meets the crushing needs of medium and high hardness materials.
2. Anti-wear backbone: titanium carbide alloy bars are embedded longitudinally
4-6 alloy bars (8-12mm in diameter) are implanted per square centimeter to form a "wear-resistant skeleton".
The hardness of the alloy bar is HRC63-68, which directly resists material cutting wear and tear, and the service life is increased by 200%.
3. Surface armor: full coverage of wear-resistant surfacing layer
The surfacing thickness is customized according to the working conditions, with a hardness of HRC55+ to resist high-speed impact wear of materials.
The honeycomb weld bead design avoids large-area peeling and continuously protects the substrate.
三、 4 core advantages: perfect balance between safety and wear resistance
四、Customer Testimony: Interview with the Purchasing Director of XX Cement Group
Background: 2500t/d production line, crushing basalt and slag mixture, the original hammer head broke in an average of 15 days.
Solution: Customized alloy bars + hardfacing hammer head, adjusting the crusher speed to 2800rpm.
Effect:
92 days of continuous use without breakage, and a single set of hammer heads processed more than 180,000 tons.
Annual maintenance costs were reduced from 540,000 yuan to 160,000 yuan, and won the group's "Cost Reduction and Efficiency Innovation Award".
五、Get your exclusive optimization plan for free
Submit your working conditions and equipment model, and you can communicate with our experts one-on-one to customize your exclusive optimization plan.
Lear that Our efforts for the local ecology
Learn that how we can make the the products more wear resistant
Help you maximize your business profits
