Quality Nickel Alloy Casting & Cobalt Alloy Castings factory

.gtr-container-a1b2c3d4 { font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif; color: #333; line-height: 1.6; padding: 15px; max-width: 960px; margin: 0 auto; box-sizing: border-box; } .gtr-container-a1b2c3d4 p { margin-bottom: 1em; text-align: left !important; font-size: 14px; } .gtr-container-a1b2c3d4-heading-2 { font-size: 18px; font-weight: bold; margin-top: 1.5em; margin-bottom: 0.8em; color: #0056b3; text-align: left; } .gtr-container-a1b2c3d4-heading-3 { font-size: 16px; font-weight: bold; margin-top: 1.2em; margin-bottom: 0.6em; color: #0056b3; text-align: left; } .gtr-container-a1b2c3d4 figure { margin: 1em 0; text-align: center; } .gtr-container-a1b2c3d4 figure img { height: auto; display: block; margin: 0 auto; } .gtr-container-a1b2c3d4 figcaption { font-size: 12px; color: #666; margin-top: 0.5em; text-align: center; } .gtr-container-a1b2c3d4 figcaption a { color: #0056b3; text-decoration: none; } .gtr-container-a1b2c3d4 figcaption a:hover { text-decoration: underline; } .gtr-container-a1b2c3d4 blockquote { border-left: 4px solid #0056b3; margin: 1.5em 0; padding: 0.5em 1em; background-color: #f0f8ff; color: #333; font-style: italic; font-size: 14px; text-align: left; } .gtr-container-a1b2c3d4 blockquote strong { font-style: normal; } .gtr-container-a1b2c3d4 ul, .gtr-container-a1b2c3d4 ol { margin: 1em 0; padding-left: 25px; list-style: none !important; } .gtr-container-a1b2c3d4 ul li, .gtr-container-a1b2c3d4 ol li { position: relative; margin-bottom: 0.5em; padding-left: 15px; font-size: 14px; text-align: left; list-style: none !important; } .gtr-container-a1b2c3d4 ul li::before { content: "•" !important; position: absolute !important; left: 0 !important; color: #0056b3; font-size: 1.2em; line-height: 1; } .gtr-container-a1b2c3d4 ol { counter-reset: list-item; } .gtr-container-a1b2c3d4 ol li::before { content: counter(list-item) "." !important; position: absolute !important; left: 0 !important; color: #0056b3; font-weight: bold; width: 20px; text-align: right; } .gtr-container-a1b2c3d4 table { width: 100%; border-collapse: collapse !important; margin: 1.5em 0; font-size: 14px; border: 1px solid #ccc !important; } .gtr-container-a1b2c3d4 th, .gtr-container-a1b2c3d4 td { border: 1px solid #ccc !important; padding: 10px !important; text-align: left !important; vertical-align: top !important; word-break: normal !important; overflow-wrap: normal !important; } .gtr-container-a1b2c3d4 th { background-color: #e9ecef; font-weight: bold !important; color: #333; } .gtr-container-a1b2c3d4 tbody tr:nth-child(even) { background-color: #f8f9fa; } .gtr-container-a1b2c3d4 .gtr-table-wrapper { overflow-x: auto; margin: 1.5em 0; } .gtr-container-a1b2c3d4 .gtr-divider { border-bottom: 1px solid #d1d1d1; margin: 2em 0; } .gtr-container-a1b2c3d4 .gtr-alert { background-color: #fff3cd; border-left: 4px solid #ffc107; padding: 1em; margin: 1.5em 0; color: #856404; font-size: 14px; text-align: left; } .gtr-container-a1b2c3d4 .gtr-alert strong { color: #856404; } @media (min-width: 768px) { .gtr-container-a1b2c3d4 { padding: 20px; } .gtr-container-a1b2c3d4-heading-2 { font-size: 20px; } .gtr-container-a1b2c3d4-heading-3 { font-size: 18px; } } To choose the right crusher liner, you need to match the liner type and material to your operation. This decision affects how efficiently your equipment runs, how long it lasts, and how often you must maintain it. For example, using a jaw crusher with the proper liner for extremely hard rocks brings high efficiency, but the wrong choice may raise maintenance costs. The table below shows how matching liners to crusher types influences performance and cost: Crusher Type Best Material Match Efficiency & Maintenance Impact Jaw Crusher Extremely hard rocks High efficiency, possible higher maintenance Cone Crusher Hard rocks Longer wear life, lower maintenance Shear Crushers Sticky materials Optimized production for specific needs Multi-cylinder Cone Concrete aggregates Better particle control, higher efficiency Gyratory Crushers Large-scale mining High efficiency for big operations High-pressure Roller Energy-saving applications May lower costs, but needs cost analysis You should always consider your crusher type, feed size, material properties, and the output you want. Key Takeaways Choose the right liner material based on the hardness and abrasiveness of the material you crush. Manganese steel is ideal for high-impact jobs. Match the crusher type with the appropriate liner profile to enhance performance and wear life. Each crusher has specific liner requirements. Monitor feed size and gradation to select liners that prevent premature wear and improve crushing efficiency. A consistent feed size is crucial. Regularly inspect liners for wear indicators like production drops or thickness. Proactive replacement can save costs and avoid downtime. Implement smart feeding techniques and routine maintenance to extend liner life. Proper lubrication and inspections are key to keeping your operation running smoothly. Crusher Liner Selection Factors Material Types & Properties When you select a crusher liner, you must consider the material type and its mechanical properties. Each material offers unique benefits for different crushing environments. The table below compares common liner materials: Property Manganese Steel High Chrome Iron Medium Chrome Alloy Steel Hardness Low (work hardens) Very High Medium Variable Toughness Excellent Low Medium Good Wear Resistance Good Excellent Moderate Variable Impact Resistance Excellent Poor Fair Good Manganese steel stands out for its toughness and ability to work harden during operation. High chrome iron provides excellent wear resistance but lacks toughness. Alloy steel offers high strength and durability in extreme conditions. You should match the liner material to the abrasiveness and hardness of the material you crush. In mining and aggregate applications, manganese steel and alloy steel have shown superior performance due to their toughness and wear resistance. Tip: Choose manganese steel for high-impact jobs and alloy steel for extreme wear environments. Crusher Types & Applications The type of crusher you use determines the best liner for your operation. Each crusher has specific liner requirements based on its design and application. The table below outlines common crushers and their liner needs: Type of Crusher Applications Liner Requirements Jaw Crushers Quarries, demolition recycling, portable setups Manganese wear parts for durability Gyratory Crushers Primary crushing for hard rock and aggregates Concave bowl liner for compression Cone Crushers Asphalt production, road base, concrete aggregates Mantle and bowl liner for shape control Impact Crushers Recycling, tertiary crushing, sand manufacturing Impact plates for high-speed material handling Roll Crushers Secondary and tertiary stages in mineral processing Manganese-lined cylinders for wear resistance You must match the crusher liner profile and material to the crusher type. For example, jaw crushers need tough manganese liners to handle high-impact forces. Cone crushers require liners that help control product shape. Impact crushers use plates designed for fast-moving material. The type of crusher affects the choice of liner profile and material. Different materials and designs cater to specific operational conditions and material characteristics. Proper selection enhances performance and wear life. Feed Size & Gradation Feed size and gradation play a major role in liner selection. Large feed sizes demand thicker and tougher liners to absorb impact and resist wear. If you process fine or well-graded material, you can use liners with less thickness and more focus on shape control. You should always check the maximum feed size your crusher can handle and choose a liner that matches this requirement. This step helps prevent premature wear and improves crushing efficiency. Note: Oversized feed can damage liners and reduce their lifespan. Desired Output Your desired product size and shape influence the choice of crusher liner profile and material. A flat liner profile creates a symmetrical crushing chamber, which produces consistent product size. A toothed liner profile works better for harder materials and aggressive crushing. You should select the liner material based on the characteristics of the material you crush. Manganese steel and high chromium iron offer durability and efficiency for different output needs. If you want uniform product size, choose a liner profile that matches your output goals. For example, use a symmetrical profile for even gradation or a more aggressive profile for tough materials. Tip: Always align your liner selection with your production targets to maximize efficiency and wear life. Performance & Lifespan Impact Wear Rate & Durability You need to understand how the choice of crusher liner affects wear rate and durability. The material you select plays a major role in how long your liner lasts and how often you need to replace it. Some materials resist impact and abrasion better than others. For example, chromium steel offers high hardness and abrasion resistance, which can extend the service life of jaw crusher liners. High manganese steel stands out for its impact resistance, making it ideal for tough, abrasive conditions. Advanced alloys balance hardness and toughness, so they resist wear without becoming brittle. Material Type Benefits Impact on Wear Rate and Durability Chromium Steel Hardness and abrasion resistance Significantly extends service life of jaw crusher liners. High Manganese Steel Exceptional impact resistance, ideal for heavy impacts and abrasive forces Ensures durability and consistent performance in harsh conditions. Advanced Alloys Balance of hardness and toughness Resists wear without becoming brittle, enhancing durability. Innovative designs and advanced alloys can increase uptime and reduce shutdowns. Metal Matrix Composites (MMC) use ceramic inserts to resist micro-cutting and erosive wear, which leads to longer wear life. Manganese steel with titanium-carbide (TiC) provides extra toughness and wear resistance. These technologies can improve service life by two to four times compared to standard alloys. You will notice fewer interventions and steadier gradation in your output. Technology Impact on Service Life Metal Matrix Composites (MMC) Engineered ceramic inserts resist micro-cutting and erosive wear, leading to longer wear life. Manganese steel with Titanium-Carbide (TiC) Provides structural support while enhancing toughness and wear resistance, resulting in improved durability. Typical Results 2–4× life improvement over mono-alloys, fewer interventions, and steadier gradation. Tip: Choosing the right material and design for your crusher liner can help you avoid frequent replacements and keep your operation running smoothly. Throughput & Efficiency The wear rate of your crusher liner directly affects throughput and efficiency. If you optimize the feed stream into your crushing circuit, you can boost productivity and lower energy costs. A steady feed size prevents blockages and keeps material flowing, which is important for maintaining throughput. When you extend the life of wear parts by selecting the right liner, you lower operational costs and reduce downtime. Optimizing the feed stream into crushing circuits enhances productivity and reduces energy costs. A consistent feed size prevents blockages and promotes steady material flow, which is crucial for maintaining throughput. Extending the life of wear parts through optimized feed leads to lower operational costs and reduced downtime. You should monitor your feed and adjust your liner selection to match your material. This approach helps you maintain high efficiency and steady output. Maintenance Considerations Your choice of crusher liner also impacts how often you need to perform maintenance and how much it costs. If you select a liner that matches your operation, you can reduce the frequency of shutdowns and avoid expensive repairs. The table below shows how different wear conditions affect maintenance decisions: Condition Action Rationale Both 70% worn, concave 70% worn, concave >60% Replace both Avoids future mismatches and reduces downtime. Concave >70% worn, mantle

What parameters should be paid attention to when selecting semi-autogenous mill liners? To correctly select the type, size and material of semi-autogenous mill liners, it is necessary to combine the working conditions (such as material hardness, mill specifications, operating parameters) and installation requirements (such as Cylinder body structure, bolt fixing method), and pay attention to the matching of core parameters. The following is a detailed explanation from three dimensions: size determination, tolerance selection, and key parameters: Ⅰ. Size determination: "Mill cylinder parameters + material characteristics" as the core The size of semi-autogenous mill liners must match the mill cylinder (inner diameter, length, bolt hole distribution) and adapt to the material processing characteristics (hardness, particle size, filling rate). The core is to determine the four key parameters of liner type, thickness, length & width, and bolt hole specifications: 1. Liner type: "Position-specific adaptation" to mill structure Semi-autogenous mill liners are divided into different types according to installation positions, and the selection must match the functional requirements of each position: Cylinder liners (main body): Bear direct impact and wear from materials and steel balls, require high wear resistance and impact toughness; Adaptation scenario: General material grinding (ore, limestone), matching mill cylinder length (usually divided into multiple sections for splicing); End liners (front/rear ends): Bear axial impact from materials, need thickened edge design; Adaptation scenario: High filling rate (30-35%) mills, prevent material leakage from end gaps; Lifter bars (integrated with cylinder liners): Responsible for lifting materials and steel balls, require reasonable height and angle; Adaptation scenario: Low-speed mills (14-18 r/min) need higher lifter bars, high-speed mills need moderate height to avoid excessive material throwing; Grid liners (discharge end): Control material discharge speed, require precise grid gap; Adaptation scenario: Classification grinding processes, grid gap matching finished product particle size (usually 15-30mm). 2. Thickness (δ): Balance "wear life" and "mill load" The thickness directly affects service life and mill power consumption, determined by material hardness and impact intensity: Soft material (Mohs hardness ≤5, such as coal, gypsum): δ=80-100mm, avoid excessive thickness increasing mill load; Medium-hard material (Mohs hardness 5-7, such as limestone, iron ore): δ=100-120mm, balance wear resistance and load; Hard material (Mohs hardness ≥7, such as granite, basalt): δ=120-150mm, thickened design to resist high impact wear; Special note: For large-diameter mills (Φ≥5m), thickness can be increased by 10-20% on the basis of the above ranges, and the liner weight per unit area should not exceed 30kg/m² to avoid overloading the mill drive system. 3. Length & Width (L×W): "Modular splicing" matching mill cylinder Width (W): Consistent with the mill cylinder section division (usually 500-1200mm), the width of adjacent liners must be the same to ensure tight splicing; Length (L): For cylinder liners, L=(1/4-1/6)×mill circumference (modular design, easy to install and replace); for end liners, L matches the mill end cover radius (sector-shaped structure, usually 8-12 pieces spliced into a full circle); Splicing principle: The total length of liners in each circumferential layer is equal to the mill inner circumference (error ≤5mm), and the length of axial adjacent liners is staggered (staggered joint design) to avoid continuous gaps. 4. Bolt hole parameters: "Fixed reliability" as the core Bolt holes are used to fix the liner to the mill cylinder, and parameters include hole diameter (d₀), hole depth (h), and hole pitch (P): Hole diameter (d₀): Matching with fixing bolts (usually M24-M42 high-strength bolts), d₀=bolt diameter + 2-4mm (reserve installation adjustment space); Hole depth (h): h=bolt head height + 5-10mm (ensure bolt head is completely embedded in the liner, avoid collision with materials), and a counterbore design is required (counterbore diameter = d₀ + 8-12mm) to protect the bolt head; Hole pitch (P): P=300-500mm, determined by liner size (the larger the liner area, the smaller the hole pitch), ensure that the maximum distance between adjacent bolts does not exceed 500mm to prevent liner deformation under impact. Ⅱ. Tolerance selection: Ensure "splicing tightness" and "fixed stability" Semi-autogenous mill liners work under high impact and vibration, so tolerance control must avoid gaps, loosening or excessive interference: 1. Liner splicing tolerance: Control "gap size" to prevent material leakage and impact Circumferential splicing (between adjacent liners in the same layer): Clearance ≤3mm, avoid material entering gaps and causing liner loosening or wear; Axial splicing (between liners in different axial layers): Clearance ≤5mm, allow slight thermal expansion space (mill operation will generate heat, liner thermal expansion coefficient ~11×10⁻⁶/°C), prevent jamming due to thermal expansion; Flatness tolerance: The splicing surface flatness ≤0.5mm/m (using a straightedge inspection), avoid uneven splicing leading to local stress concentration. 2. Liner-cylinder fitting tolerance: Ensure "close contact" The back of the liner (fitting with the mill cylinder) must be closely attached to the cylinder surface: Fitting gap: ≤0.5mm (measured with a feeler gauge), avoid gaps causing liner vibration under impact (leading to bolt loosening or liner cracking); Perpendicularity tolerance: The liner working surface (contact with materials) is perpendicular to the back surface, tolerance ≤1mm/m, ensure uniform force on the liner. 3. Bolt hole tolerance: Guarantee "bolt matching" Hole diameter tolerance: H12 (e.g., d₀=30mm, tolerance range 0~+0.18mm), ensure bolt can pass through smoothly while avoiding excessive clearance; Hole pitch tolerance: ±2mm, ensure bolt holes align with the cylinder bolt holes (cylinder bolt hole tolerance H10), avoid installation difficulties; Counterbore tolerance: Counterbore depth tolerance ±1mm, counterbore diameter tolerance H10, ensure bolt head is flush with the liner working surface. Ⅲ. Key parameters: Beyond size and tolerance, determine "service life" and "grinding efficiency" 1. Material performance parameters: Adapt to "wear mechanism" Semi-autogenous mill liners are mainly made of wear-resistant materials, and parameters are selected based on material impact and wear type: Hardness: For abrasive wear (soft material, high filling rate), HRC≥55 (e.g., high-chromium cast iron); for impact wear (hard material, large particle size), HRC=45-50 (e.g., manganese steel Mn13) to balance hardness and toughness; Impact toughness (αₖᵥ): ≥15J/cm² (for high-chromium cast iron) or ≥100J/cm² (for manganese steel), avoid brittle fracture under large material impact (particle size ≥100mm); Wear resistance: Volume wear rate ≤0.15cm³/(kg·m) (tested by ASTM G65), ensure service life ≥8000 hours (medium-hard material working condition). 2. Structural design parameters: Optimize "grinding efficiency" Lifter bar height (h₁): h₁=1.2-1.5×maximum material particle size (e.g., maximum particle size 80mm, h₁=96-120mm), too low cannot lift materials, too high increases power consumption; Lifter bar angle (θ): θ=30°-45°, for low-speed mills (≤16r/min) use 30°-35° (increase lifting height), for high-speed mills (≥18r/min) use 40°-45° (avoid material excessive throwing); Wear-resistant groove design: The working surface of the liner is provided with transverse or longitudinal wear-resistant grooves (depth 5-8mm, spacing 50-80mm), which can store materials to form a "material wear-resistant layer" and reduce direct wear of the liner. 3. Working condition adaptation parameters: Match "mill operation parameters" Filling rate adaptation: When mill filling rate is 30-35% (high filling), select thicker liners (δ+10-20mm) and higher lifter bars (h₁+10-15mm); when filling rate is 25-30% (low filling), use standard thickness and lifter bar height; Rotational speed adaptation: Low speed (≤14r/min) → emphasize wear resistance (high-chromium cast iron); high speed (≥18r/min) → emphasize impact toughness (manganese steel or composite materials); Corrosion adaptation: For wet grinding (material contains water or corrosive media), select corrosion-resistant alloy liners (e.g., high-chromium nickel alloy) or add corrosion-resistant coating (thickness ≥0.3mm) on the liner surface.

.gtr-container-p9q2r5 * { box-sizing: border-box; -webkit-font-smoothing: antialiased; -webkit-tap-highlight-color: rgba(0, 0, 0, 0); outline: none; } .gtr-container-p9q2r5 { font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif; color: #333; line-height: 1.6; padding: 20px; margin: 0 auto; max-width: 960px; border: none; } .gtr-container-p9q2r5 .gtr-title { font-size: 22px; font-weight: bold; margin-bottom: 20px; color: #0056b3; text-align: left; } .gtr-container-p9q2r5 .gtr-subtitle { font-size: 18px; font-weight: bold; margin-top: 30px; margin-bottom: 15px; color: #0056b3; text-align: left; } .gtr-container-p9q2r5 p { font-size: 14px; margin-bottom: 15px; text-align: left !important; word-break: normal; overflow-wrap: normal; } .gtr-container-p9q2r5 strong { font-weight: bold; } .gtr-container-p9q2r5 ul { list-style: none !important; padding-left: 0; margin-left: 0; margin-bottom: 15px; } .gtr-container-p9q2r5 ul li { list-style: none !important; position: relative; padding-left: 20px; margin-bottom: 8px; font-size: 14px; text-align: left; } .gtr-container-p9q2r5 ul li::before { content: "•" !important; position: absolute !important; left: 0 !important; color: #0056b3; font-size: 1.2em; line-height: 1; } .gtr-container-p9q2r5 ol { list-style: none !important; padding-left: 0; margin-left: 0; margin-bottom: 15px; counter-reset: list-item; } .gtr-container-p9q2r5 ol li { list-style: none !important; position: relative; padding-left: 30px; margin-bottom: 8px; font-size: 14px; text-align: left; display: list-item; } .gtr-container-p9q2r5 ol li::before { content: counter(list-item) "." !important; position: absolute !important; left: 0 !important; color: #0056b3; font-weight: bold; width: 25px; text-align: right; } .gtr-container-p9q2r5 .gtr-table-wrapper { overflow-x: auto; margin-top: 20px; margin-bottom: 20px; } .gtr-container-p9q2r5 table { width: 100%; border-collapse: collapse !important; border-spacing: 0 !important; border: 1px solid #ccc !important; min-width: 600px; } .gtr-container-p9q2r5 th, .gtr-container-p9q2r5 td { border: 1px solid #ccc !important; padding: 10px !important; text-align: left !important; vertical-align: top !important; font-size: 14px; word-break: normal; overflow-wrap: normal; } .gtr-container-p9q2r5 th { font-weight: bold !important; color: #0056b3; } @media (min-width: 768px) { .gtr-container-p9q2r5 { padding: 30px; } .gtr-container-p9q2r5 .gtr-title { font-size: 26px; } .gtr-container-p9q2r5 .gtr-subtitle { font-size: 20px; } .gtr-container-p9q2r5 table { min-width: auto; } } Chromoly Alloy Steel Grates: High Wear Resistance + High-Temperature Strength & Toughness, Enabling Stable Material Screening in Cement/Metallurgy/Mining Industries Chromoly Alloy Steel Grates: The core product definition, referring to specialized screening and supporting components (typically bar-type, grid-type, or segmented structures) engineered for high-demand material processing equipment—critical parts that realize screening, supporting, and material diversion in crushers, grate coolers, sintering machines, or vibrating screens. Unlike ordinary carbon steel grates, chromoly alloy steel grates are optimized for the "extreme wear resistance + high-temperature stability + corrosion resistance" demands of cement, metallurgy, mining, and power industries, where harsh working conditions (abrasive materials, high temperatures up to 850°C, and corrosive media) require comprehensive performance. They are primarily manufactured from chromoly alloy steels such as 15CrMo, 35CrMo, 42CrMo, or 12Cr1MoV, tailored to specific temperature, wear, and load requirements. Core Performance: High Wear Resistance The defining wear-resistant capability of chromoly alloy steel grates stems from the synergy of material composition and structural design, addressing the severe abrasive wear caused by hard materials (e.g., limestone, iron ore, clinker) in industrial processes: Hardness enhancement via alloying: Chromium (Cr) in the alloy forms a dense chromium carbide (Cr₃C₂) wear-resistant layer on the surface, with a hardness of HRC 45–55—far exceeding ordinary carbon steel (HRC 15–25) and even outperforming manganese steel (HRC 35–40) in medium-to-heavy wear scenarios. Low wear rate: In cement clinker cooler applications, 35CrMo alloy steel grates exhibit a wear rate of less than 0.2mm/1000 hours, while ordinary carbon steel grates wear at 1.0–1.5mm/1000 hours. This translates to 3–5x longer wear life. Wear-resistant structural optimization: Key contact surfaces (e.g., grate bars, edges) are thickened or adopt a streamlined design. Bar-type grates feature a tapered cross-section (thickness 15–30mm) to reduce material impact and sliding friction, avoiding localized excessive wear. Core Performance: High-Temperature Strength & Toughness Chromoly alloy steel grates excel in high-temperature environments (500–850°C) common in cement kilns, metallurgical sintering machines, and power plant boilers, thanks to molybdenum (Mo) that enhances high-temperature strength and thermal stability: High-temperature strength retention: Molybdenum refines the alloy’s grain structure, maintaining significant tensile strength at elevated temperatures. For example, 12Cr1MoV alloy has a tensile strength of ~470MPa at room temperature and retains ~320MPa at 600°C—avoiding deformation or bending under high-temperature material loads (e.g., 50–100kg/m² clinker pressure in grate coolers). Excellent thermal fatigue resistance: The alloy’s balanced strength and toughness withstand repeated cycles of high-temperature heating (e.g., 800°C) and cooling (e.g., 100°C air cooling). 42CrMo grates endure 800+ thermal cycles without cracking, unlike carbon steel grates that brittle fracture after 200–300 cycles. Impact resistance at high temperatures: Even at 700°C, chromoly alloy steel maintains sufficient toughness (impact energy ≥45J/cm²), resisting sudden impact from large material lumps (e.g., 5–10kg clinker blocks) without breaking. Enabling Stable Material Processing in Harsh Industrial Environments The synergy of high wear resistance and high-temperature strength & toughness solves three core pain points of cement, metallurgy, and mining industries: Reducing unplanned downtime: Ordinary carbon steel grates require replacement every 3–6 months due to wear or high-temperature deformation, disrupting continuous production. Chromoly alloy steel grates extend service life to 12–24 months, cutting replacement frequency by 70% and saving 100+ hours of annual downtime. Ensuring consistent screening efficiency: Worn or deformed grates cause material blockage (e.g., clinker bridging in grate coolers) or uneven screening (oversized particles entering subsequent processes). Chromoly alloy steel grates’ stable structure maintains uniform grate bar spacing (5–20mm, customizable), ensuring screening accuracy and material processing efficiency. Adapting to corrosive working conditions: In mining wet screening (e.g., acidic ore pulp) or cement kiln alkaline environments, chromium in the alloy forms a passive oxide film, resisting corrosion from acids, alkalis, or moisture. This avoids grate surface pitting or rust, which would compromise structural integrity. Common Chromoly Alloy Steel Grades Different grades are selected based on process temperature, material abrasiveness, and load requirements: Alloy Grade Key Properties Advantages Typical Application Scenarios 15CrMo Heat resistance ≤600°C, good corrosion resistance Excellent high-temperature stability, cost-effective Cement kiln grate coolers, power plant boiler grates 35CrMo High hardness (HRC 48–52), balanced strength & toughness Versatile, suitable for medium wear/medium temperature Mining crusher grates, vibrating screen grates 42CrMo High wear resistance (HRC 50–55), high tensile strength (~1080MPa) Ideal for heavy wear scenarios Metallurgical sintering machine grates, large crusher grates 12Cr1MoV Thermal fatigue resistance, heat resistance ≤750°C Resists cyclic high temperatures, no cracking Large cement clinker grate coolers, blast furnace grates Additional Advantages for Target Industries Beyond core wear and high-temperature performance, chromoly alloy steel grates offer industry-specific benefits: Corrosion resistance: The chromium-rich oxide film resists acidic ore pulp (mining), alkaline clinker (cement), and high-humidity environments (sintering), avoiding premature failure from corrosion. Structural durability: Manufactured via integral forging or precision casting, the grates have no weak welding seams. This prevents grate bar detachment under heavy material loads, a common issue with welded carbon steel grates. Customizable design: Grate bar spacing (5–20mm), thickness (10–30mm), and structure (bar-type, grid-type, segmented) can be tailored to equipment models (e.g., Φ1200 crusher, 3×12m grate cooler), improving compatibility and processing efficiency by 20–30%. Total cost savings: While initial costs are 2–4x higher than carbon steel, their 3–5x longer service life (15–20 months for 35CrMo) reduces total ownership costs by 60% over 2 years, considering replacement labor and downtime losses. Typical Application Scenarios Chromoly alloy steel grates are indispensable in harsh material processing processes: Cement Industry: Grate cooler grates (supporting and cooling clinker at 800–1000°C), rotary kiln secondary air grates (resisting high-temperature corrosion), and cement mill classifier grates (screening cement particles). Metallurgy Industry: Sintering machine grates (transporting and sintering iron ore at 700–850°C), blast furnace feeding grates (screening coke and iron ore), and steelmaking converter skimmer grates (resisting high-temperature molten steel splashes). Mining Industry: Jaw crusher grates (crushing and screening limestone, granite), vibrating screen grates (wet screening of copper ore, coal), and cone crusher grates (processing abrasive mineral aggregates). Power Industry: Boiler furnace grates (supporting coal combustion at 600–750°C), flue gas desulfurization system grates (resisting acidic flue gas corrosion), and ash handling system grates (screening coal ash). In these scenarios, chromoly alloy steel grates directly address the dual demands of wear resistance (for long service life) and high-temperature reliability (for stable operation), making them the preferred component for critical material screening and supporting systems in cement, metallurgy, mining, and power industries. Email: cast@ebcastings.com

Heat Treatment Baskets: High-Temperature Resistance + Structural Strength, Enabling Stable Workpiece Handling in Automotive/Aerospace Heat Treatment Processes Heat Treatment Baskets: The core product definition, referring to specialized load-bearing containers (typically grid-type, frame-type, or mesh-type structures) engineered for heat treatment operations—critical components that hold, transport, and protect workpieces during heating, quenching, annealing, carburizing, or tempering cycles. Unlike ordinary carbon steel baskets, heat treatment baskets are optimized for the "high-temperature stability + heavy load-bearing" demands of automotive, aerospace, and mold industries, where resistance to thermal deformation and long service life are equally critical. They are primarily manufactured from heat-resistant alloys, such as 2520 (Cr25Ni20), 304 (1Cr18Ni9Ti), or ZG35Cr24Ni7SiN, tailored to different temperature and load requirements. Core Performance: High-Temperature Resistance Heat treatment baskets’ defining capability lies in withstanding extreme thermal environments, a key requirement for processes where temperatures often exceed 800°C. Their high-temperature resistance is driven by material composition and microstructural stability: Wide temperature adaptability: Different materials cover a broad operating range. For example, 2520 (Cr25Ni20) alloy withstands continuous temperatures up to 1200°C, while 304 stainless steel handles up to 800°C—far exceeding ordinary carbon steel (which softens and deforms above 600°C). Strong oxidation resistance: Heat-resistant alloys form a dense, adherent oxide film (e.g., Cr₂O₃, Al₂O₃) on the surface. This film prevents internal metal oxidation even in high-temperature air or controlled atmospheres, with an oxide loss rate of less than 0.1mm/year for 2520 baskets under 1000°C cyclic heating (vs. 0.5mm/year for low-alloy steel baskets). Thermal deformation resistance: High nickel-chromium content maintains the basket’s structural rigidity at high temperatures. For instance, 2520 baskets exhibit less than 2% permanent deformation after 500+ heat cycles, avoiding workpiece collision or misalignment caused by warping. Core Performance: Structural Strength & Load-Bearing Capacity To safely carry workpieces (often weighing 100–500kg per basket), heat treatment baskets combine robust material strength with optimized structural design: High-temperature strength retention: Heat-resistant alloys retain significant tensile strength at elevated temperatures. 2520 alloy, for example, has a tensile strength of ~520MPa at room temperature and maintains ~300MPa at 1000°C—enough to support heavy workpieces like automotive crankshafts or mold blocks without bending. Reinforced structural design: Key stress points (e.g., edges, corners, bottom supports) are reinforced with thickened plates or crossbars. Mesh-type baskets use hexagonal or square grids (aperture 5–20mm) to balance load-bearing capacity and heat penetration, preventing small workpieces from slipping while ensuring uniform heating. Long cyclic service life: Unlike ordinary welded carbon steel baskets (which crack after 50–100 heat cycles), heat-resistant alloy baskets endure 500–1000 cycles. This reduces the frequency of basket replacement, critical for continuous production lines in automotive factories. Solving Core Pain Points in Heat Treatment Industry The synergy of high-temperature resistance and structural strength addresses two major challenges in heat treatment operations: Avoiding workpiece quality defects: Ordinary baskets deform at high temperatures, causing workpieces to collide, scratch, or shift—leading to dimensional errors (e.g., 0.1–0.5mm deviations in automotive gears). Heat treatment baskets’ stable structure ensures workpiece positioning accuracy, reducing defect rates by 30–50%. Minimizing production downtime: Frequent replacement of low-quality baskets disrupts continuous heat treatment processes (e.g., a car parts factory may shut down 4–6 times yearly for carbon steel basket changes). Heat-resistant alloy baskets cut replacement frequency to 1–2 times yearly, saving 80+ hours of downtime annually. Ensuring uniform heat treatment: Mesh and frame designs enable unobstructed airflow and heat circulation around workpieces, reducing temperature differences across the basket to less than 5°C (vs. 10–15°C for solid-bottom baskets). This ensures consistent hardness and microstructure in batch-processed workpieces. Common Materials for Heat Treatment Baskets Different materials are selected based on the process temperature, workpiece weight, and environmental conditions: Material Grade Key Properties Advantages Typical Application Scenarios 2520 (Cr25Ni20) Heat resistance≤1200°C, excellent oxidation resistance Handles ultra-high temperatures, long life Automotive crankshaft quenching, large mold annealing 304 (1Cr18Ni9Ti) Heat resistance≤800°C, good corrosion resistance Cost-effective, suitable for medium temps Small part carburizing, stainless steel workpiece tempering ZG35Cr24Ni7SiN Heat resistance≤1100°C, high thermal shock resistance Resists rapid cooling/heating, high strength Aerospace part aging, hot-work mold quenching Additional Advantages for Heat Treatment Industries Beyond core thermal and structural performance, heat treatment baskets offer industry-specific benefits: Cold-heat fatigue resistance: They withstand repeated cycles of high-temperature heating (e.g., 1000°C) and rapid quenching (e.g., 20°C water), avoiding cracking caused by thermal stress. 304 baskets, for example, endure 500+ cold-heat cycles without damage. Easy cleanability: Their smooth surface (polished or shot-blasted) prevents adhesion of workpiece oxide scale. Scale can be removed with simple high-pressure water washing, eliminating the need for frequent manual grinding and reducing maintenance labor by 40%. Customizable design: Baskets can be tailored to workpiece shapes—e.g., long strip-shaped holes for automotive axles (preventing rolling), or closed frames for fragile aerospace components (avoiding collision). This improves loading efficiency by 20–30% compared to standard baskets. Total cost efficiency: While initial material costs are 2–3 times higher than carbon steel, their 3–5x longer service life (15–20 years for 2520 baskets) lowers total ownership costs by 50% over 10 years. Typical Application Scenarios Heat treatment baskets are indispensable in high-demand heat treatment processes: Automotive Industry: Grid-type baskets for gear/crankshaft carburizing and quenching; frame-type baskets for bearing ring tempering (ensuring uniform hardness); customized baskets for electric vehicle motor cores (avoiding insulation layer damage). Aerospace Industry: High-strength ZG35Cr24Ni7SiN baskets for titanium alloy part high-temperature aging (resisting 1100°C); corrosion-resistant 304 baskets for aluminum alloy component solid solution treatment (preventing surface contamination). Mold Industry: Heavy-duty 2520 baskets for hot-work mold 调质 (quenching and tempering), supporting 500kg mold blocks without deformation; mesh baskets for cold-work mold annealing (ensuring uniform cooling). General Machinery: Small-aperture mesh baskets for fastener batch quenching; large-frame baskets for steel pipe/bar annealing (maximizing loading volume). In these scenarios, heat treatment baskets directly address the dual demands of thermal stability (high-temperature resistance) and operational reliability (structural strength), making them the preferred component for ensuring consistent quality and efficiency in critical heat treatment processes across automotive, aerospace, and mold industries. Email: cast@ebcastings.com

Universal Ball Mill Liners for Dry and Wet Grinding: High Manganese Steel for Enhanced Wear Resistance, Suitable for Cement/Ore Grinding Scenarios, Reduced Downtime and Higher Efficiency Universal Ball Mill Liners for Dry and Wet Grinding: The core product definition, referring to liners designed to work efficiently in both dry grinding (e.g., cement clinker, dry ore) and wet grinding (e.g., ore slurry, wet cement raw materials) environments. Unlike specialized liners that perform well in only one condition, these liners balance wear resistance, corrosion resistance, and impact toughness to adapt to the distinct challenges of dry (abrasive particle wear) and wet (abrasive + corrosive slurry) grinding. High Manganese Steel for Enhanced Wear Resistance: The liners are typically made of high manganese steel (e.g., ZGMn13) treated with water toughening, which gives them unique wear-resistant properties: Work hardening effect: In dry grinding, when hard particles (e.g., cement clinker, ore) impact and rub against the liner surface, the austenitic structure of high manganese steel undergoes plastic deformation, rapidly increasing surface hardness from ~200 HB to 500-800 HB, forming a hard wear-resistant layer while maintaining the toughness of the inner matrix. Impact wear resistance: In wet grinding, the liner not only bears the wear of ore particles but also the impact of grinding media (steel balls). High manganese steel has excellent impact toughness (≥150 J/cm²), which can absorb impact energy without cracking or breaking, far exceeding the performance of brittle materials like high chromium cast iron in high-impact scenarios. Corrosion mitigation in wet conditions: Although not as corrosion-resistant as stainless steel, the dense surface of water-toughened high manganese steel reduces the penetration of slurry, and its work-hardened layer slows down corrosive wear in wet grinding (e.g., ore slurry containing sulfuric acid or chloride ions). Suitable for Cement/Ore Grinding Scenarios: These liners are tailored to the specific demands of two key industries: Cement grinding: In dry grinding of cement clinker (hardness up to Mohs 6-7), the liner withstands high-speed impacts from clinker particles and steel balls, with work hardening ensuring long-term wear resistance; in wet grinding of raw cement slurry, it resists both abrasive wear and mild corrosion from the slurry. Ore grinding: For dry grinding of ores (e.g., iron ore, copper ore), it handles the abrasive wear of hard gangue minerals; for wet grinding of ore slurries, it balances impact resistance (from large ore chunks) and resistance to slurry erosion. Reduced Downtime and Higher Efficiency: The performance advantages translate directly to operational benefits: Extended service life: Compared with ordinary carbon steel liners (service life 1-3 months) or single-condition specialized liners, universal high manganese steel liners last 6-12 months in cement/ore grinding, reducing the frequency of liner replacement. Less unplanned shutdowns: Their toughness and wear resistance minimize sudden failures (e.g., liner cracking, falling off) that cause unexpected downtime, ensuring continuous operation of the ball mill. Stable grinding efficiency: The liners maintain their original shape and surface properties for longer, ensuring consistent contact between the grinding media and materials, avoiding efficiency drops caused by uneven liner wear (e.g., reduced grinding fineness, increased energy consumption). Design optimization for dry and wet universality To achieve true versatility in both dry and wet conditions, the liners incorporate targeted design features: Surface structure: Adopts a wave or corrugated design—enhances material lifting and mixing in dry grinding (improving grinding efficiency), while the curved surface reduces slurry adhesion in wet grinding (minimizing corrosive wear from stagnant slurry). Thickness gradient: Thicker in high-wear areas (e.g., the impact zone near the mill inlet) to withstand intense impact, and appropriately thinner in low-wear areas to reduce weight and energy consumption—balancing durability and operational efficiency. Edge treatment: Smooth, burr-free edges prevent material accumulation (critical in wet grinding to avoid localized corrosion) and reduce particle entrapment (which causes excessive wear in dry grinding). Typical application scenarios Universal high manganese steel ball mill liners are widely used in: Cement plants: Both dry ball mills (for clinker grinding) and wet ball mills (for raw material slurry preparation), adapting to the shift between dry and wet processes in multi-purpose mills. Mining industry: Comminution circuits for iron ore, copper ore, and gold ore—handling dry grinding of run-of-mine ore and wet grinding of ore slurries in flotation circuits. Building materials industry: Grinding of limestone, gypsum, and other minerals, where production may switch between dry (for powder products) and wet (for slurry products) modes. In these scenarios, the liners' ability to perform reliably in both dry and wet conditions eliminates the need for frequent liner changes when switching grinding modes, significantly improving operational flexibility and reducing overall production costs. Email: cast@ebcastings.com