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Vol.9 No.2
Abstract: Liners in wet ball mill for mineral processing industry must bear abrasive wear and corrosive wear,
and consequently, the service life of the liner made from traditional materials, such as Hadfield steel and alloyed
steels, is typically less than ten months. Bimetal liner, made from high Cr white cast iron and carbon steel, has
been successfully developed by using liquid-liquid composite lost foam casting process. The microstructure and
interface of the composite were analyzed using optical microscope, SEM, EDX and XRD. Micrographs indicate that
the boundary of bimetal combination regions is staggered like dogtooth, two liquid metals are not mixed, and the
interface presents excellent metallurgical bonding state. After heat treatment, the composite liner specimens have
shown excellent properties, including hardness > 61 HRC, fracture toughness k >16.5 Jcm-2 and bending strength
>1,600 MPa. Wear comparison was made between the bimetal composite liner and alloyed steel liner in an industrial
hematite ball mill of WISCO, and the results of eight-month test in wet grinding environment have proved that the
service life of the bimetal composite liner is three times as long as that of the alloyed steel liner.
Key words: bimetal liner; liquid-liquid composite process; lost foam casting; high Cr white cast iron
CLC numbers: TG249.5/252
Document code: A
Article ID: 1672-6421(2012)02-136-07
Received: 2011-09-04;
136
Accepted: 2012-03-01
May 2012
1 Experimental details
(1)
HCWCI
Carbon steel
Si
Mn
Cr
Mo
2.9-3.1
<0.8
0.8-1.1
<0.04
<0.04
21-23
0.4-0.6
0.4-0.6
<0.035
<0.035
(a)(a)
Runner
Runnersystem
system
Vacuum
Vacuum
(c)
Flask
Flask
(b) (b)
Molten
Cr Cr
white
cast cast
iron
Moltenhigh
high
white
iron
Vacuum
Vacuum
Vacuum
Ni
0.4-0.6
Quartz sand
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CHINA FOUNDRY
Vol.9 No.2
(a)
(b)
HCWCI layer
HCWCI layer
Fig. 3: Bimetal composite liner castings: (a) for 3.6 m ball mill and (b) for 5 m ball mill
Grinding ball
Mineral particles
Composite liner
Alloy steel liner
Ca r bid es a nd ma t r ix of t he HCWCI la ye r a nd t he
microstructure of the carbon steel layer were investigated
by means of SEM-EDS. Relevant elements shown in Fig. 6
have been detected, and their weight percentages are given
quantitively in Table 2. The results prove that the above
microstuctural analysis is reasonable and accurate.
After the destabilization heat treatment, the secondary
carbide precipitation promoted the change of the microstructure
from an austenitic matrix (Fig. 5a) to a mainly martensitic one
(Fig. 7a) with some retained austenite. In addition, the newly
formed matrix was reinforced with secondary carbides of the
type M7C3 (Fig. 7b). In studies on high-Cr white cast irons with
May 2012
(a)
(b)
Carbide
Ferrite
Austenite
Pearlite
50 m
200 m
Fig. 5: Optical photograph of composite microstructure in as cast: (a) HCWCI layer and (b) carbon steel layer
(b)
(a)
(c)
Fig. 6: SEM-EDS analysis: (a) carbide of HCWCI layer, (b) matrix of HCWCI layer and (c) carbon steel layer
wt.%
at.%
wt.%
at.%
wt.%
at.%
10.20
33.50
8.96
31.02
7.54
26.37
2.07
5.42
Si
0.46
0.68
0.27
0.40
Cr
57.60
43.70
15.32
12.25
0.70
0.57
Mn
1.32
1.01
Fe
31.44
22.21
75.26
56.05
88.09
66.22
(a)
Martensite
Carbide
Carbide
Martensite
50 m
Fig. 7: Microstructures of HCWCI layer after heat treatment: (a) optical photograph and (b) SEM photograph
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CHINA FOUNDRY
800
Vol.9 No.2
(a)
500
As-cast
700
Austenite
Austensite
M7 C 3
(b)
Heat treated
400
600
500
300
400
200
300
200
100
100
0
0
30
40
50
60
70
80
90
100
30
40
50
60
70
80
90
100
2 q ()
2 q ()
Fig. 8: XRD traces indicating phases present in HCWCI microstructure: (a) as cast and (b) after heat treatment
(a)
(a)
HCWCI layer
Small
carbide
HCWCI layer
Porosity
50 m
Fig. 9: Microstructure of composite interface after heat treatment: (a) optical photograph and (b) SEM photograph
May 2012
C
O
Si
V
Specimen
No.
Sectional
dimension
10 mm 10 mm
18.8
10 mm 10 mm
20.2
10 mm 10 mm
16.9
a k (Jcm-2)
Cr
Mn
Specimen
No.
dimension
Sectional
Bending
Fe
20 mm 30 mm
1,610
61.8
20 mm 30 mm
1,745
62.3
20 mm 30 mm
1,683
61.2
Hardness
strength (MPa)
(HRC)
(b)
Composite liners
Composite liners
Alloy steel liners
Fig. 11: Wear resistant comparison between liners made from bimetal composite and alloyed steel in industrial hematite
ball mill of WISCO: liners served and disassembled from ball mill for five months (a) and for eight months (b)
Table 5: Weight loss in wet grinding environment
Liner number
Composite
170
133
37
170
138
32
Material
type
Alloyed
185
82
103
steel
185
81
104
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CHINA FOUNDRY
of the alloyed steel liner. Wear resistant difference between
the composite liner and the alloyed steel liner results from
their chemical composition and microstructure, which can be
explained as follows: Microstructure of the alloyed steel after
heat treatment is normally composed of singular martensite,
while the HCWCI layer of the composite after heat treatment
consists of eutectic carbides(M7C3) in a mostly martensitic
matrix.
3 Conclusions
(1) Bimetal composite liner made from HCWCI and carbon
steel has been successfully developed and produced by liquidliquid composite LFC. The composite possesses superior
properties, including high hardness, high corrosive wear
resistance and reasonable fracture toughness.
(2) The obtained micrographs indicate that the boundary
of bimetal combination regions is staggered like dogtooth,
two liquid metals are not mixed, and the interface presents
excellent metallurgical bonding state.
(3) After heat treatment, the composite liner specimens
have shown excellent properties, including hardness > 61
HRC, fracture toughness k >16.5 Jcm-2 and bending strength
>1,600 MPa.
(4) Wear resistant comparison has been made between liners
made from the bimetal composite and the alloyed steel in an
industrial hematite ball mill at WISCO. The result shows that
the service life of the bimetal composite liner is three times as
long as that of the alloyed steel liner.
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This work was financially supported by the National Natural Science Foundation of China under grant No.
50805109, and the Fundamental Research Funds for the Central Universities under grant No. 2011-1a-023.
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