HX900
cast-in-carbide
Cast-in-carbide for the
toughest conditions
HX900 is a unique wear material combining the wear resistance
of cemented carbide with the shock resistance, ductility and
forming capability of nodular iron. This is an ideal combination
resulting in a hard material that stands well in tough environments and has a long wear life.
Used in a wide range of applications, HX900 is implemented
in the mining and mineral handling industries, steel works,
concrete plants and in road maintenance. It has found use
most readily in crushing, fragmentation and grinding operations.
In such applications HX900 can easily replace conventional
wear resistant steels, castings and hardfacing on wear parts
subjected to severe stresses.
The high wear resistance of HX900 makes it a material that
contributes to new opportunities for improved product quality,
reduced down-time and increased productivity.
HARD, DURABLE AND FLEXIBLE
A typical HX900 product has a wear resistance that is comparable
with cemented carbide and a strength that is 80-90% of the
strength of pure nodular iron. The wear resistance is generally
3-15 times higher than with common structural steel, nodular
iron, welded material or ceramics. HX900 can be produced
in various shapes and sizes and can be used in many different
types of applications. The composition of the material can be
optimized to meet the specific requirements for each application.
That makes it a flexible and durable material.
COMPARABLE WEAR RESISTANCE
Ni-hard 1
HX900 3-7
Manganese steel 1
HX900 4-10
High chromium cast iron 1
HX900 4-8
Hardened steel 1
HX900 5-15
Hardfacing 1
HX900 3-6
Material
description
HX900 is produced in the form of composite or clad. The
casting method used in both cases provides a metallurgical
bond between the cemented carbide granules or tiles in the
wear zone and the nodular iron in the base metal. It is also
possible to have a mixture of composite and clad.
HX900 COMPOSITE
To create the composite of HX900, granules of cemented
carbide are added to the nodular iron surface. Composite is
ideal to use in products that will be exposed to heavy impact.
Approximately 50% of the composite wear zone consist of
granules. The granules have a size of 1 to 6 mm (0.04-0,24”),
depending on the application and thickness of 5 to 20 mm
(0.2-0.79”).
HX900 CLAD
HX900 clad products consist of cemented carbide tiles
embedded in the nodular iron surface. The tiles form an almost
continuous surface and provide the best protection against
wear due to abrasion and erosion. The tiles can be of various
shapes and sizes but are usually rectangular with a length and
width of 10 to 50 mm (0.39-1.97”) and thickness of 2 to 10
mm (0.08-0.39”).
2-10 mm
00
HX9
Clad
e
posit
om
00 C
5-20 mm
(0.2-0.79”)
HX9
(0.08-0.39”)
r iron
la
Nodu
n
ar iro
ul
Nod
Versatility leads to
various applications
There are well proven uses for HX900 within fragmentation, materials handling,
surface mining and civil engineering. It can be found in hammers, crusher arms,
chutes, liners, mixer paddles, bucket lips and teeth, grader blades etc. Thanks to its
high wear resistance, HX900 can replace conventional wear materials at a total lower
cost. It can be delivered in various standard shapes or made-to-measure shapes according
to the chosen requirements. The examples below are just a few of the
applications that are improved with HX900.
SLIDING
In ducts, troughs, pipes and chutes carrying and guiding flows of material, the
curved and restrictive areas are often
subjected to heavy impact and abrasive
wear. In such applications HX900 gives
many times the life of Ni-hard, hardfacing, hardened steel, etc.
CRUSHING
When sinter is crushed, the crusher
arms, breaker bars and crush deck are
subjected to heavy wear. HX900 crusher parts last 3-5 times longer than conventional materials such as hard facing,
Ni-hard and Cr-steel. A more uniform
particle size of the crushed sinter is obtained which facilitates the rest of the
process.
MILLING
In hammer mills, the hammer suffers
the greatest wear. In order to increase
service life the hammers are often hard
faced. Hammers made of HX900 will
last 3-8 times longer than conventional
materials.
MIXING
Many types of concrete mixes contain
mixing paddles and scraper blades. For
optimum mixing efficiency these components are designed to operate with a
minimum clearance between the sides
and the bottom of the mixer. HX900
composite paddles and scraper blades
with cemented carbide tiles embedded
in the leading edge have a service life
several times longer than competing
designs in Ni-hard and brazed carbide
tiles. HX900 paddles and blades also
require less frequent adjustments due to
wear.
CUTTING
In surface mining operations, large
quantities of overburden are often removed with bucket wheel escavators.
The buckets are fitted with teeth or cutting lips. In both cases it is important
that the original cutting geometry of
the teeth or cutting lips is retained in
order to maintain power requirements
at a constant low level. HX900 cutting
teeth have a higher wear resistance than
conventional materials and they retain
a sharp cutting edge throughout the service life. HX900 liners for wear protection inside and outside the bucket last
several times that of conventional steel
and reduce downtime.
SCRAPING
Snowplowing on roads and highways is
often undertaken at high speed. Plowing exposes base asphalt, subjecting the
blades and shoes to heavy abrasive and
impact wear. HX900 plough blades and
shoes last up to 40 times longer than
conventional steel blades and shoes.
GRINDING
At coal-fired power stations coal is
ground to powder in impact mills by
a rotor which accelerates the lumps of
coal and throws them against the armored periphery of the mill. The rotor
blades and the breaker blades are subjected to rapid wear. By using HX900 in
these parts, service life can be increased
by 4-6 times compared with Ni-hard,
Cr- and Mn-steel, etc.
Mixing
Sliding
Scraping
Crushing
Cutting
Milling
Grinding
FIELD TEST WITH HX900 WEAR PLATES
The charts below show the results from field tests in a belt
conveyor transfer station for iron ore sinter. Liners in different types of material were tested including the HX900.
HX900 proved to be both the most cost efficient and the long
lasting of the materials tested.
Material flow speed: 4 m/s
Angle of impact: 15 degrees
COST
HX900 Wear plates
(Granules)
HX900 Wear plates
(Tiles)
Hardfacing
AW5 2x6 mm
Material
Personnel
Hardfacing
AW6 2x6 mm
Rubber
Ceramic rubber
Chilled cast iron
Mild steel BS 436-40C
Manganese steel
1000
2000
3000
Cost (USD) for 100,000 t/m² used surface
Cost: The wear cost in USD for the liners at a 100,000
tonnes/m2 material flow. The total cost refers to the material
cost ( purchase price for the liners ) and the personnel. ( assembly, and exchanging worn-out liners )
TONNAGE
HX900 Wear plates
(Granules)
HX900 Wear plates
(Tiles)
Hardfacing
AW5 2x6 mm
Hardfacing
AW6 2x6 mm
Rubber
Ceramic rubber
Chilled cast iron
Mild steel BS 436-40C
Manganese steel
5
10
15
20
25
Output in 100,000 t
Tonnage: The amount of material that has been dropped on
the liners before they are considered worn-out.
HX900 liners in a chute
HX900 is used on snow plowblades
A bucket wheel reclaimer with cutting lips of HX900
HX900 crusher arms of a sinter cusher
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