At a customer site in China, an Nordberg HP300 cone crusher was suffering repeated trips: lubrication and hydraulic unit and PLC-cabinet temperatures were climbing above safe limits and destabilising the machine.
Our factory-trained service team carried out a full maintenance intervention, replacing needed critical components with ONA-made parts. The HP300 crusher is now operating normally.
Note: Metso® and HP300® are registered trademarks of Metso Corporation. The units serviced were rebuilt using aftermarket parts produced, supplied and warranted solely by ONA in China; they are not OEM originals and have no OEM affiliation, endorsement or warranty.
Choosing the wrong crusher blow bars material will have a series of serious negative impacts on the operation and economic benefits of an impact crusher. So, how should we choose the correct material for impact crusher parts?
1. High-manganese steels: MN13CR2, MN18R2, and MN22CR2.
Mn steel offers advantages in wear resistance and toughness, but its wear resistance is not as good as high-chromium steels.
2. High-chromium steels: CR22 or Cr26.
Cr steel offers advantages in wear resistance, but its disadvantage is that it makes the blow hammer brittle (poor toughness), unable to absorb impact energy during crushing and prone to breakage.
Impacts:
Secondary Equipment Damage: Broken hammer fragments fly at high speed, potentially damaging the crusher liner, impact frame, and even the rotor, resulting in high repair costs and extended downtime.
Safety Hazards: Flying fragments pose a serious safety hazard, potentially harming equipment and personnel.
3. Materials with added Mo include: CR27MO0.5, CR27MO1, and CR27MO2.
The advantage of Mo is that it increases microstructure and toughness, but it comes at a high price.
4. Other Materials: Depending on the application environment and requirements, titanium carbide, ceramics, and other materials can also be added to extend service life. Although relatively expensive, the overall cost-effectiveness is significant.
Different Heat Treatment:
How to interpret the material report provided by the manufacturer?
In addition to ensuring that the main material components, such as Mn and Cr, match the quoted value, the lower the P and S values, the better; these are considered impurities.
Common Misconception: Higher hardness is not always better. For applications involving high impact and hard materials (such as granite crushing), sufficient toughness (e.g., using high-toughness alloy steel) is crucial. For applications involving high abrasiveness but low impact (e.g., limestone crushing), a higher hardness (e.g., using high-chromium cast iron) is recommended.
The correct selection method:
Provide accurate information: Provide ONA Casting with the crusher model, material type, hardness, feed size, and expected output. ONA's professional engineers can recommend the most suitable material, such as high-chromium cast iron, high-manganese steel, and alloy steel.
If price is the only consideration, the savings in blow bars purchase costs may far outweigh the significant losses caused by frequent downtime, equipment damage, and reduced production.
Therefore, choosing the right material is crucial.
Metso C80 Jaw crusher are widely used in mining. Their main wear-resistant component is the jaw plate. However, many users lack dedicated engineers or, due to purchasing older, secondhand machines, cannot find relevant information and have little understanding of the materials used for the jaw plates and their heat treatment processes. Today, we will provide a detailed introduction to the practical applications of crusher jaw plates.
The jaw crusher operates on a reciprocating compression principle: the motor drives the belt and pulley, which in turn moves the moving jaw up and down via an eccentric shaft. When the moving jaw rises, the angle between the jaw crusher toggle plate and the moving jaw increases, pushing the moving jaw plate closer to the fixed jaw plate. Simultaneously, the material is crushed or split, achieving the crushing purpose. When the moving jaw descends, the angle between the jaw crusher toggle plate and the moving jaw decreases, and the moving jaw plate, under the action of the return rod and spring, moves away from the fixed jaw plate. At this point, the crushed material is discharged from the bottom of the crushing chamber. With the continuous rotation of the motor, the moving jaw of the crusher performs periodic movements to crush and discharge materials, achieving mass production.
Jaw crusher wear plates are divided into moving jaw plates and stationary jaw plates(Some regions call it mantle concave). Depending on the model of the jaw crusher, there are various tooth profile sizes, generally made of high-manganese steel, i.e., high-manganese steel jaw plates. High-manganese steel has a history of over 100 years. Under conditions of strong impact abrasive wear, high-manganese steel has excellent wear resistance and is therefore commonly used in machinery and equipment in mining, building materials, and thermal power plants. Applicable materials include coal gangue, feldspar, barite, and basalt. Under low-impact conditions, the work hardening effect is not significant, and high-manganese steel cannot fully utilize its material properties.
Research has found that three major factors affect the wear resistance of high-manganese steel jaw plates during the casting process: material, purity of raw materials, and heat treatment process. Material is the fundamental element determining the wear resistance of high-manganese steel jaw plates. Adding chromium to high-manganese steel (Mn18Cr2) directly increases its wear resistance. Some manufacturers use recycled high-manganese steel as raw material, or mixed in the new raw material, which introduces harmful sulfur and phosphorus elements into the newly cast jaw plates, affecting their service life. Finally, regarding the heat treatment process of high-manganese steel jaw plates, rapid heating at low temperatures can cause cracking. Therefore, the correct procedure is to maintain a heating rate of <80℃/h below 350℃ and <100℃ above 750℃, when the casting is in a plastic state and can be rapidly heated. At 1050℃, determine the holding time based on the casting thickness (usually 1 hour/25mm); then rapidly raise the temperature to approximately 1100℃ and hold for half an hour before removing from the furnace. The casting must be immersed in water as soon as possible after removal from the furnace; the time between removal and immersion should not exceed 45 seconds, and even shorter in winter. Slow heating at high temperatures, insufficient holding time, and excessively long intervals between removal and immersion (not exceeding 0.5 minutes) all negatively impact the quality of the high-manganese steel jaw plates.
Striving for greater wear resistance in jaw plates does not necessarily require continuously increasing the proportion of high-manganese steel. Mn13Cr2 and Mn18Cr2 are suitable for most jaw plates, while Mn22Cr2 is suitable for extremely cold regions. For regions with suitable temperatures, choosing Mn22Cr2 compared to Mn18Cr2 will not only fail to significantly extend the service life but will also increase procurement costs. For better results, consider inlaying with cemented carbide, which can achieve a service life 1.5-1.8 times that of Mn18Cr2.
If you are unsure which material is best for your needs, please contact us. Tell us about your raw materials being crushed and the desired results. Our professional engineers will recommend the most cost-effective solution for you.
I believe many customers know that when purchasing crusher wear-resistant parts, you can ask suppliers to provide material inspection reports. The material inspection reports provided by different suppliers are slightly different. Even the inspection reports of the same manufacturer may have some differences in different orders. Today we will briefly describe the meaning of each chemical element in the material inspection report.
As the name suggests, Mn13Cr2 means that the high manganese steel content is 13% and the high chromium content is 2%. Therefore, as long as the content values are within the range, there is no problem.
The advantages of high manganese steel are wear resistance and good toughness, but high chromium steel has better wear resistance and is more expensive. The disadvantage of high chromium steel is that it is very brittle and the product is easy to break during use, so the more chromium steel, the better. The life of Cr is 2-2.5 times that of Mn.
P and S stand for phosphorus and sulfur respectively. They are impurities, so the lower their content, the better.
In addition to the above materials, we often encounter Mo. Its function is to increase the fineness of tissue particles and increase toughness, but the price is very high.
Titanium carbide, also known as cemented carbide, is expensive, but its lifespan is 1.5-1.8 times that of Mn.
If you are not sure what material is suitable for you, you can contact us and tell us the raw materials you want to crush, and our engineers will recommend the right material for you.
The jaw crusher is a core piece of crushing equipment in industries like mining and construction. Its stable operation directly impacts production efficiency. Routine maintenance not only reduces downtime due to failures but also significantly extends the equipment's service life.
Pre-Startup Inspection
Check the tension of the V-belt, jaw plate, and the tightness of all bolts.
Inspect the equipment casing and frame for cracks and loose bolts.
Check the oil level in the hydraulic tank to ensure it is between the oil gauge lines. Check the hydraulic quality and verify that the hydraulic pump is operating properly and that there are no leaks in the oil pipes.
Clear any remaining material from the feed inlet to avoid stalling during startup. Check the discharge opening clearance to ensure it meets production requirements to prevent substandard crushing or equipment overload.
Metso's Barmac 840 rotor is the most wear parts of the Barmac B7150se VSI crusher, commonly used in quarries and stone production plants. "840" refers to the rotor's outer diameter, or 840 mm.
Function
The rotor's primary function is to accelerate the feed material and fling it against a fixed material bed ("rock-on-rock" anvils) or a surrounding feed bed. This high-speed impact crushes the rock along its natural fissures, producing high-quality cubic aggregate.
1. Material Acceleration: The raw material enters the crusher through the feed pipe and reaches the center of the rotating rotor.
2. Distribution and Ejection: The rotor's tip captures the material and ejects it outward at high speed through the rotor outlet.
3. Crushing Impact: The ejected material impacts the dense material layer accumulated on the surrounding feed ring and cascade rings, causing the material to break.
The "rotor" isn't a single component; it's a rotor assembly consisting of a rotor body and wear parts for Barmac B7150se vsi. Key components of the Barmac 840 rotor include:
Rotor body: The primary cast iron or steel structure that supports all other components. It serves as the backbone of the entire assembly.
Rotor tip (wear parts): These are replaceable tungsten carbide components bolted to the rotor body. They are the primary wear parts that directly contact and propel the feed material. They require periodic replacement.
Rotor outlet: The open passage between the rotor tips through which the accelerated material exits the rotor.
Shaft and bearings: The rotor assembly is mounted on a heavy shaft supported by large bearings for Metso Barmac B7150se vsi, enabling high-speed rotation (typically around 1,500-2,000 RPM).
When do wear parts need to be replaced?
Decreased output/capacity: The crusher is not processing as much material as before.
Poor product shape: An increase in flaky or elongated particles.
Excessive vibration: This may be due to uneven wear on the rotor tip tips, leading to imbalance.
Increased operating noise
The following is a list of the main components of the Barmac 840 DTR and STD:
840 DTR
№
Part Number
Description
Qty
Weight. KG Unit
1
B90334105N
Bare Rotor
1
370
2
B96394049O
Rotor Tip Set
3
5.2
3
B90394060A
Short Backup Tip Set
1
1.6
4
B90394055B
Trial Plate
1
1.5
5
B96394060B
Long Backup Tip Set
1
3.2
6
B96334170C
Top wear plate lipped
1
55
7
B96334180A
Bottom wear plate lipped
1
58
8
B96394150O/B
Bolt Set
3
0.15
9
B963940425A
Bolt
1
0.2
10
B96394150N
Cavity Wear Plate Outer
4
7.5
11
B96394150O
Cavity Wear Plate Middle
2
7.5
12
B96334030E
Feed Eye Ring
1
21
13
B96334135A
Upper Wear Plate
1
19
14
B96334140A
Lower Wear Plate
1
25.2
15
B962S7040B
Feed Tube
1
14
16
B96394120E
Distributor Plate
1
33
840 STD
№
Part Number
Description
Qty
Weight. KG Unit
1
B96334105L
Bare Rotor
1
253
2
B96394049O
Rotor Tip Set
2
5.2
3
B96394055B
Trial plate set
1
3.5
4
B96394060B
Long Backup Tip Set
1
3.2
5
B96334170C
Top wear plate lipped
1
55
6
B96334180A
Bottom wear plate lipped
1
58
7
B96394150O/B
Bolt Set
3
0.15
8
B963940425A
Bolt
1
0.2
9
B96394150N
Cavity Wear Plate Outer
4
2.5
10
B96334135A
Upper Wear Plate
1
19
11
B96334140A
Lower Wear Plate
1
25.2
12
B96334030E
Feed Eye Ring
1
21
13
B962S7040B
Feed Tube
1
14
14
B96394120E
Distributor Plate
1
33
If you have any needs, you can contact us at any time.
All names, marks, models, symbols and descriptions are used for reference purposes only and it is not implied that any of the parts/brands listed are the product of any company other than ONA. We are not agents or distributors for any of the above mentioned brands nor do we have any commercial relationship or association with them.
Sand making machines are generally only used in stone mines and stone factories. Rotor assembly is the complete spinning-rotor assembly that fits inside VSI (Vertical Shaft Impact) crusher.
Which mian parts in the Sandvik cv229 rotor assembly?
A high-strength welded plate hub that carries the tungsten-carbide-tipped wear parts (rotor tips, back up tip sets, trial plate etc.) and accelerates the feed rock to high speed so the particles shatter against the anvils and produce cubical sand or aggregates.
Other components（feed tube, feed eye ring, distributor plate, cavity wear plate, upper/lower wear plate）are made of high chromium alloy Cr26Mo0.5. Top/bottom wear plate are made of high-strength wear-resistant plate.
Penetrant testing, also known as liquid penetrant testing, is a non-destructive testing method widely used in industrial fields such as casting and forging. Its main function is to detect surface defects in mantle and concave, and other wear liners.
Its core principle is very simple and intuitive: it utilizes the capillary action of liquids to detect discontinuous defects with openings on the material surface, such as cracks, pores, and porosity.
The penetrant testing process is similar to blotting away spilled liquid with a paper towel. The basic steps are as follows:
1. Cleaning: Thoroughly clean the surface of the bowl liner and mantle to be tested, removing any oil, iron filings, paint, etc., ensuring that defect pathways are open.
2. Applying the penetrant: Spray or brush a special liquid (penetrant) containing colored or fluorescent dye onto the working surface and allow sufficient "residence time" (usually a few minutes to tens of minutes). During this time, the penetrant will penetrate into even the smallest surface opening defects through capillary action.
3. Removing excess penetrant: After the residence time, carefully wipe or rinse off any excess penetrant from the working surface. The key point is that the penetrant trapped inside the defect will not be washed away.
4. Applying the developer: Apply a thin layer of developer to the working surface. It is usually a white powder suspension or dry powder, acting like blotting paper, using capillary action to "draw back" the penetrant from the defect to the surface.
5. Observation: After sufficient development time, observe the surface.
Staining method: Under sufficient white light, the defect will show a clear red (or other colored) mark.
Fluorescence method: Under ultraviolet light (black light), the defect will emit a bright yellow-green fluorescence.
Main advantages
High sensitivity: Capable of detecting extremely fine, invisible surface opening defects.
Wide application: Applicable to almost any non-porous material (metals, ceramics, plastics, etc.).
Here is a detailed breakdown of the typical production process:
Step 1: Pattern/Mold Making
· Process: A physical model (pattern) of the part is created, typically from wood.
· Purpose: This pattern or mold defines the exact shape and dimensions of the final cast part. Its accuracy is critical.
Step 2: Molding and Casting
1. Mold Creation: Sand molds are commonly used. The pattern is packed in special foundry sand mixed with a binder (like clay or resin) to create a firm mold cavity in the shape of the part. The mold is typically made in two halves (cope and drag).
2. Melting: Raw materials (scrap steel, pig iron, and specific alloys like chromium, molybdenum, and manganese) are melted in a large furnace (e.g., electric arc furnace or induction furnace) at temperatures exceeding 1500°C (2732°F).
3. Pouring: The molten metal is poured into the prepared mold cavity and left to solidify.
Step 3: Shakeout and Cleaning
· Shakeout: Once the casting has cooled and solidified, the sand mold is broken apart, and the raw casting (called a "casting with gates and risers") is removed.
· Cleaning: The casting is then cleaned to remove all residual sand and the excess metal from the pouring channels (gates) and feeders (risers). This is often done using shot blasting (propelling small metal beads at high velocity) or arc air gouging.
Step 4: Heat Treatment
This is a crucial step that determines the final mechanical properties of the part, such as hardness, strength, and toughness.
· Process: The casting is subjected to a carefully controlled sequence of heating and cooling.
· Typical Cycle:
· Quenching: The part is heated to a very high temperature and then rapidly cooled (quenched) in oil or air. This creates a very hard, but brittle, microstructure.
· Tempering: The quenched part is reheated to a lower temperature and held for a specific time before cooling. This reduces brittleness and relieves internal stresses, achieving the perfect balance of hardness and toughness required to withstand impact and abrasion in a crusher.
Step 5: Machining and Finishing
· Process: The heat-treated casting is machined to achieve precise final dimensions and tolerances. This is typically done on CNC (Computer Numerical Control) machines like lathes, milling machines, and drills.
· Purpose: To ensure the part fits perfectly into the crusher. Key contact surfaces, bolt holes, and mating features are machined to exact specifications.
Step 6: Quality Control and Inspection
Quality checks are performed throughout the entire process.
· Chemical Analysis: A sample of the molten metal is analyzed via spectrometry to ensure the alloy composition is correct.
· Dimensional Inspection: Finished parts are measured with calipers, micrometers, and CMMs (Coordinate Measuring Machines) to verify they match the engineering drawings.
· Hardness Testing: The surface hardness is checked at multiple points using a Brinell or Rockwell hardness tester to ensure it meets the required standard.
· Non-Destructive Testing (NDT): Methods like Magnetic Particle Inspection (MPI) or Dye Penetrant Inspection (DPI) are used to detect surface or sub-surface defects like cracks or inclusions that are not visible to the naked eye.
Step 7: Painting and Marking
· The finished part is often painted with a rust-preventative primer for protection during storage and shipping. We can customized color as your needs.
· Important information (part number, heat number, brand) is stamped or painted on the part for identification.
Step 8: Packaging and Shipping
The parts are securely packaged, usually in wooden pallet or iron pallet, to prevent damage during transportation to the customer.
Summary of Key Materials Used:
The specific material chosen depends on the application (e.g., crushing granite vs. recycling concrete).
· High Manganese Steel (Mn14, Mn18, Mn22): The classic material that work-hardens under impact, becoming harder as it is used.
· High Chromium Steel (Cr26): Excellent abrasion resistance but lower impact toughness. Used for highly abrasive conditions with less impact.
· Alloy Steel: A combination of various elements (like Cr, Mo, Ni) to create a balance of properties for specific crushing challenges.
ONA Casting manufacture compoments suit to Trio crusher parts as follows:
1. Wear Parts
These are the parts that directly interact with the rock and undergo constant abrasion and impact. They determine the crusher's product size, capacity, and are crucial for maintaining efficiency.
Mantle (Get China cone crusher parts mantle price): The moving cone-shaped part that gyrates against the concave to crush rock. It's the primary wear surface.
Concave (or Bowl Liner): The stationary outer surface that the mantle crushes the rock against. Mantles and concaves are always replaced as a matched set to ensure optimal crushing performance and product shape.
Feed Plate (Get high manganese crusher parts quotes): Mounted at the top of the crusher, the function is distribute incoming feed material evenly around the crushing chamber. This prevents uneven wear and maximizes crusher efficiency and liner life.
: This refers to the *combination* of the mantle and concave, and their specific profile (e.g., coarse, medium, fine). According to the chamber of concave, we can find the correct mantle for you.
There also has spare parts, know more as follows parts list:
No
Part Number
Description
1
14/12G-AHPP - OD
14/12G-AHPP OUTLINE DRAWING
2
14/12G-AHPP - OD
14/12G-AHPP OUTLINE DRAWING
3
A482242
GENERAL ARRANGEMENT FOR 75NPCWBH ZVH1 DRIVE
4
A482293
ARRANGEMENT OF 100 DD-HRM WITH 110KW MOTOR
5
A482654
8/6 E-AH WITH 45kW MOTOR ZV1 LEVERLINK GENERAL ARRANGEMENT
