Industry Overview
The mining industry is one of the most demanding applications for wear parts. Ore hardness varies from soft limestone (Mohs 3) to extremely hard granite and quartzite (Mohs 7+), with high abrasive mineral content and large daily processing volumes. Crushing equipment — jaw crushers, cone crushers, hammer crushers, and gyratory crushers — operates continuously under extreme impact loads and abrasive wear, making wear parts the highest recurring cost item for mining operations.
Zhili has served the global mining industry for over 30 years, partnering with mining companies in 50+ countries. Our advanced metallurgical systems — high-chromium cast iron, composite alloys, and heat-treated wear-resistant steels — deliver 2-5× longer service life compared to conventional materials, significantly reducing downtime, spare parts inventory, and total cost per tonne of ore processed.
Related Products for Mining Industry
Crusher Hammer Heads
High-chromium cast iron and composite alloy hammer heads with superior impact toughness and wear resistance for primary and secondary crushing.
Jaw Plates
Manganese steel and alloy jaw plates engineered for maximum toughness and impact resistance in primary jaw crushing applications.
Crusher Blow Bars
High-chromium blow bars with advanced heat treatment for impact crushers. Optimized chemistry and microstructure for maximum wear life.
Cone Crusher Mantle & Bowl Liner
Precision-cast cone crusher liners with optimized wear profiles for consistent product shape and extended change intervals.
Gyratory Crusher Mantle & Concave
Large gyratory crusher wear parts with superior structural integrity for high-throughput primary crushing applications.
Crusher Grate Plates
High-strength grate plates with optimized bar spacing for precise size classification and superior structural durability.
Core Material System for Mining
High-chromium cast iron is the gold standard for impact-crushing applications. Zhili's proprietary alloy design with Cr 18-28%, Mo, V, and Nb additions creates a refined carbide network that delivers exceptional abrasion resistance while maintaining adequate toughness for impact loading.
| Hardness | HRC 58-63 |
| Carbide Type | M₇C₃ / M₂₃C₆ eutectic network |
| Impact Toughness | ak ≥ 8 J/cm² |
| Application | Hammer heads, blow bars, impact plates |
Austenitic manganese steel (Hadfield steel) undergoes rapid work hardening under impact and compression. The surface hardness increases from initial ~200 HB to 500-550 HB during service, creating a self-protecting wear surface ideal for jaw plates and cone liners processing large, unweathered ore.
| Hardness (initial) | 170-220 HB |
| Work-Hardened Surface | 480-550 HB |
| Impact Toughness | ak ≥ 150 J/cm² |
| Application | Jaw plates, gyratory concaves, cone liners |
Hot-rolled bimetal composite technology bonds a high-chromium white iron wear layer (HRC 60+) to a tough low-alloy steel backing. This combines maximum surface wear resistance with structural toughness, achieving weight savings of 30-50% compared to solid alloy castings.
| Wear Layer Hardness | HRC 58-63 |
| Bond Strength | ≥ 350 MPa (shear) |
| Wear Layer Thickness | 8-20 mm (customizable) |
| Application | Grate plates, screen plates, chute liners |
Quenched and tempered low-alloy steels (e.g., 28CrMo, 35CrMo) offer excellent cost-performance ratio for moderate-abrasion applications. Precise heat treatment control delivers consistent hardness (HRC 44-52) with good toughness across large-section castings.
| Hardness Range | HRC 40-54 |
| Toughness | ak ≥ 25 J/cm² |
| Section Size | Up to 300mm thick sections |
| Application | Hammer shafts, rotor shafts, flywheels |
Typical Application Scenarios
Primary Jaw Crushing
Large-block raw ore (≤1,200mm) processed by jaw crushers. Extremely high compressive loads and severe abrasive wear on jaw plates require maximum toughness with good initial hardness.
Jaw Plates · Mn18Cr2Secondary/tertiary Cone Crushing
Medium to fine crushing of processed ore. Continuous abrasive wear from sliding mineral particles demands high chromium alloys with refined carbide distributions.
Cone Mantles & Bowl Liners · HCrCIHammer Crusher (tertiary/fine)
High-speed rotor with hammer heads impacting ore at 40-70 m/s. Combined impact and abrasive wear demands optimal balance of hardness and toughness.
Hammer Heads · Composite AlloyHPGR (High Pressure Grinding Rolls)
Extremely high inter-particle comminution pressure (50-300 bar). The studded roller surface with tungsten carbide tips delivers maximum wear life in fine grinding circuits.
HPGR Stud Rollers/Tyres · Tungsten CarbideVertical Roller Mill (VRM)
Ore grinding with high-pressure roller loading and high-velocity particle impact. Requires wear-resistant liners and grinding rollers with excellent hot abrasion resistance.
VRM Liners & Grinding RollersOre Transport & Chute Systems
Continuous sliding abrasion from high-volume ore flow. Chute liners, bin linings, and feed hoppers experience severe wear requiring replaceable wear-resistant panels.
Wear Liner Plates · Bimetal CompositeMaterial Selection Guide
| Material | Hardness | Wear Resistance | Impact Toughness | Best For |
|---|---|---|---|---|
| HCrCI (Cr 18-28%) | HRC 58-63 | ★★★★★ | ★★★ | Hammer heads, blow bars, impact plates |
| Mn18Cr2 Austenitic | 170→550 HB (work-hardened) | ★★★★ | ★★★★★ | Jaw plates, gyratory concaves |
| Bimetal Composite | HRC 58-63 (wear layer) | ★★★★★ | ★★★★ | Grate plates, chute liners, screen plates |
| Cr-Mo Low-Alloy Q&T | HRC 40-54 | ★★★ | ★★★★ | Rotor shafts, flywheels, structural parts |
| Tungsten Carbide Studs | HRA 88-92 | ★★★★★ | ★★ | HPGR rollers, ultra-abrasive applications |
Successful Cases
Primary Crusher Hammer Replacement — 10,000 tpd Operation
HPGR Stud Roller Upgrade — Fine Grinding Circuit
Crusher Blow Bars for Impact Crusher — 50 Mtpa Operation
Vertical Roller Mill Grinding Rollers — 3,000 tpd Concentrator
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