manganese with resitant insert for mining and quarries applivat

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The History of Manganese Steel February 24, 2016

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Mangalloy

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MANGALLOY STEEL

11-14 % manganese steel that

performs best in

extreme impact

applications

3x Initial surface rigidity

increases up to 3x &

retains interior

durability

Ideal Material for heavy impact and

abrasive service

Non- Magnetic

for electrical transformer

assemblies & industrial

lifting magnets.

As the surface work-hardens, takes a mirror-like finish, and retains its original underneath toughness. An example is wear strips under conveyor chains.

The compressive abrasion of metal-to-metal contact deforms the surface structure of Manganal and therefore, work-hardens it rapidly. The polish that it

develops and its low coefficient of friction not only reduces the wear on the conveyor chain, but usually results in reduced power requirements for

operating the equipment, because of reduced friction.

The high impact and grinding abrasion destroys most other steels rapidly. Mangalloy Steel withstands the punishing abuse, without breaking or quickly

eroding. Other typical uses are shovel buckets, teeth and loaders working in earth and stone where there is a general mixture of impact/compressive

abrasion. Depending on deformation of the surface crystalline structure, it can work-harden up to more than 500 Brinell. When originally put into service

it is about 200 Brinell.

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HISTORY In 1816, a German researcher Carl J. B. Karsten noted that adding fairly large amounts of manganese to iron would increase its hardness without affecting its malleability and toughness, but the mix was not homogeneous and the results of the experiment were not considered to be reliable. "and no one understood that the real reason why the iron mined in Noricum produced such superb steel lay in the fact that it contained a small amount of manganese uncontaminated by phosphorus, arsenic, or sulfur, and so was the raw material of manganese steel.”

In 1860, Sir Henry Bessemer, trying to perfect the Bessemer process of steel making, found that adding manganese and carbon to the steel after it was blown helped to remove excess sulfur and oxygen. Sulfur combines with iron to form a sulfide that has a lower melting point than steel, causing weak spots, which prevented hot rolling. Manganese is usually alloyed with most modern steels because of its powerful ability to remove sulfur, phosphorus and oxygen, which are all common impurities in steel.

Mangalloy was the first alloy created from carbon steel, also called Hadfield steel after its British inventor, Sir Robert Hadfield, in 1882, and was first produced in the US.

1816

1860

1882

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REINFORCED MANGANESE STEEL

NEW PRODUCTS PORTFOLIO PRESENTATION

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REINFORCED MANGANESE STEEL

MANGANESE STEEL: NEW GENERATION

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REINFORCED MANGANESE STEEL SB® & GPF ®

Bowl Lines Jaw Liners

New Products Patented technology SUPER BITE & GRIP PLUS

GP®  SB®  

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REINFORCED MANGANESE STEEL SB® & GPF ®

Bowl Lines Jaw Liners

New Products Patented technology SUPER BITE & GRIP PLUS

GP®  SB®  

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NEW PRODUCTS SUPER BITE SB® & GRIP PLUS GP®

FEATURES

The same toughness

We tailor the hard inlay to match the customer needs, according to our know-how to reach the best result. Customer shows us only where he notes maximum wear on the casting.

BENEFITS

Increase the hardness of manganese steel 18% where impact is not enough to work-hardening the surface and reducing wear due to abrasion

Increase the life time in very abrasive application

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SB® FOR JAW Examples of Inlay for Different Thoot Shapes

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SB® CASE HISTORY Application: fixed and mobile jaw with SB

Feed: Granite

PRODUCT INFORMATION

This trial exemplifies the benefit of tailored inlay over std manganese steel. The inlays increase life time about 30% more.

BENEFITS

Minimize shutdowns

Save maintenance hours

Increase equipment up time

Increase life time on field application

+30%

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GP® FOR CONE/MANTLE Example

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GP® CASE HISTORY Swedish site +66%

increase

GP® technology lifetime

STD lifetime

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GP® Increases the life-time of parts almost 100%

on site application

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HSI Castings •  Blow Bars •  Apron Liners •  Monoblocks •  Side Liners

Alloys •  Martensitic:F60, F60

45/47 HRC •  White Iron: FX15,

FX25 •  WRI technology •  MNX Manganese •  MNGP Inserts

Jaws / Cones •  Fixed & Swing Dies •  Cheek Plates •  Wedges

Conveyor Belting •  Wear resistant rubber top coats •  Standard options available as well

(2-220/ 3-330/ 4-440 etc)

Wear Parts Overview HSI/ VSI, Jaw, Cone, Gyratory

Bear Claw

Bohringer

Brown Lenox

CEC

Cedar Rapids

Crush Tek

Eagle

Excel

Extec

Finley

Gator

Hartl

Hazemag

Humbolt Wedag

Inertia

Irock/ Indy

KeesTrack

McCloskey

Metso

Nordberg

Parker

Pegson

Pioneer

Powerscreen

Rubble Master

Sandvick

Stedman

Svedala

Telsmith

Terex

Tesab

Trio

Universal

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Technical Details

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TECHNICAL BULLETIN We have developed new innovative Manganese steel – called MNX. Manganese steel combines excellent wear-resistant characteristics with high durability.

MNX can be utilized as an alternative to all Manganese steels. AmCast uses it mostly to produce jaws and cones. However, the best application for this kind of product is one in which the Manganese Steel with high percentage of Chrome represents a challenge in casting because of the particular shape and thickness or where the resistance to breakage and longer wear ratio needs to be improved.

Our steel grade has performed well in very wet conditions, where normally the wear ratio increases dramatically.

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COMPARISON

Bending test with samples that have the same shape & dimensions

See how MnX bends at a greater angle than Manganese steel because of the high percentage of Chrome.

���Manganese steel with a high Chromium content

���MnX

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WEAR PATTERN Evidence of the MnX steel durability can be seen in these photos of the wear pattern after the campaign.

���Manganese steel high Chromium

���MnX

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WEAR PATTERN Wear pattern of cone (red line) compared with the original pattern.

MNX Microstructure: finely dispersed HARD PHASES,consisting of Titanium Cabonitrides

Manganese Steel High Chromium

���Hardness 2500-3000 HV

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The winning characteristic of this material is joining the typical MnCr18.2 toughness to a homogeneous and very fine dispersion of Hard Phases, with HV hardness values that are generally twice in comparison with typical Chromium carbides.

CONCLUSION After several laboratory and field test our technology department is confident in stating that overall the performance of the MNX is clearly superior than the range of manganese steel used in the production of cones, jaws and blow-bars.

MNX

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REINFORCED SPECIAL MANGANESE STEEL For heavy applications

A patented technology for manganese casting

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This trial exemplifies the benefits of tailored inlay over standard manganese steel. The inlay increases the life time about 30% more.

“The manganese steel reinforced with SB®/ GPF®

tech increases the lifetime of the blow bar by 30-60% in field applications.“

STD SB®

136.000 ton 177.000 ton

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The hard inlay is embedded into the casting and during the entire life of the liner protects the surface from sliding wear.

We tailor the hard inlay to match the customer needs, according to our research results. Customers show us the location of maximum wear on the casting.

The manganese steel has durability similar to Mn12

REINFORCED MANGANESE STEEL

INCREASED THICKNESS

NEW INLAY DESIGN

HARD PINS INSIDE

1 2 3

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Ceramic Inserts

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Our ceramic insert was developed to

increase the lifetime of martensitic & White

Chromium blow bars

CERAMIC INSERT For standard working conditions

Blow Bars

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CERAMIC INSERT For standard working conditions

The ceramic particles have a high hardness to prevent the wear abrasion due to feed material.

The ceramic pad is tailored to guarantee maximum absorption

of the molten steel.

Innovative, exclusive chemical composition and heat

treatment guarantee an increased durability of our steel

grades with respect to our competitor’s alloys.

Honeycomb Structure

Steel Grades

Ceramic Particles

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“The ceramic insert is the key to my success. I reduced downtime, increasing the lifetime of the blow bars, and consequently, the productivity.”

Feedback from our customer

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Our R&D department developed a new ceramic pad with the aim to increase the lifetime of blow bars in applications where reducing production costs is necessary.

MASTER CERAMIC For heavy duty business

AmCast research is focused on global challenges. Our research and development investment was focused on increasing wear life of spare parts.

AmCast research helps drive solutions to these challenges through inclusive innovation.

Our team is working with customers to create solutions that meet the unique needs of people working in quarry, mining and recycling.

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MASTER CERAMIC For heavy duty business

The ceramic particles have a modified shape to

permit an increased wettability.

The new design guarantees keep an optimum wear

profile until the complete end of life.

The thickness of the pad was increased up to 60%.

Increased Thickness

New Inlay Design

New Ceramic Particles

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•  Honeycomb structure

•  30mm deep

MASTER CERAMIC PAD

•  Innovative shape

•  +60% of ceramic

•  Tailored design

SDT  or  STD?  Standard?  

STANDARD vs MASTER

STANDARD CERAMIC PAD MASTER CERAMIC PAD

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Increased life time

Full protection of the

rotor during the entire

life of the bar

Decreased maintenance

time

MASTER CERAMIC Key Benefits

Front View Side View

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NEW SHAPE FOR MASTER CERAMIC We modified also the shape of ceramic pad. Our R&D department developed this pattern to increase the surface covered by the ceramic pad. This texture permits to obtain by many of our customer a significant decreased wear rate

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MASTER POWER A new ceramic material developed with the University of Udine

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DEVELOPMENT & TESTING We have completed tests in field with very satisfactory results. Now we are working on improvements to extend this technology for blow bars of different shapes.

MasterPOWER is a new ceramic pad and it was developed to increase life time of blow bar used in very abrasive application as:

• Asphalt

• Slag

• High Abrasive Natural Rock

•  Iron Ore

• Quartzite

• Basalt

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Let the future tell the truth, & evaluate each one according to his work & accomplishments. The present is theirs; the future, for which I have really worked, is mine.”

“ A  Visit  to  Nikola  Tesla,    by  Dragislav  L.  Petkoviæ    in  Poli=ka  (April  1927)  

COMPANY INTRODUCTION

•  Overview of the International Group and Am Cast’s position

•  International group of foundries and machine manufacturers

•  Our company philosophy •  Performance Wear Parts and Innovation in

Crushing Systems

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Am Cast, Inc. Specializes in the manufacturing of abrasion resistant castings, WRI technology, & sustainable, sand-crushing equipment.

About Us

AmCast, Inc.

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34 Aero Road, Bohemia New York 11716 Toll Free: 888-993-2772

Local: 631-750-1644 Fax: 631-750-1646

Am Cast West 2303 West Oxford Ave, Sheridan, Colorado 80110

Telephone: 303-761-6333 Fax: 303-762-6151

Innovation In Aggregate Systems

Contact Us

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