Wear resistant materials
ABRASIVE WEAR
Abrasive wear is the loss of material from a surface that
results from the motion of a hard material across this
surface.
There are several types of abrasive wear. Since the
properties required of a wear-resistant material will
depend on the type of wear the material has to withstand,
a brief mention of these types of wear may be useful.
There are three main types of wear generally.considered:
gouging abrasion (impact), Figure 18.1; high-stress abrasion
crushing),Figure 18.2; and low-stressabrasion (sliding),Figure
18.3. This classificationis made more on the basis of operating
3rressesthan on the actual abrading action.
Gouging abrasion
This is wear that occurs when coarse material tears off
sizeable particles from wearing surfaces. This normally
im-olves high imposed stresses and is most often encoun-
tered when handling large lumps.
DEFORMATION AND
SUBSEQUENT REMOVAL
OF PROTRUSIONS
Figure 18.1 Types of gouging abrasion
18
High-stress abrasion
This is encountered when two working surfaces rub
together to crush granular abrasive materials. Gross loads
may be low, while localised stresses are high. Moderate
metal toughness is required; medium abrasion resistance
is attainable.
Rubber now competes with metals as rod and ball mill
linings with some success. Main advantages claimed are
longer lifer at a given cost, with no reduction III throughput,
lower noise level, reduced driving power consumption, less
load on mill bearings and more uniform wear on rods.
Low-stress abrasion
This occurs mainly where an abrasive material slides
freely over a surface, such as in chutes, bunkers, hoppers,
skip cars, or in erosive conditions. Toughness require-
ments are low, and the attainable abrasion resistance is
high.
(b)
Figure 18.2 Types of high-stress abrasion: (a) rod and
ball mills; (b) roll crushing
Figure 18.3 Low-stress abrasion
18 Wear resistant materials

MATERIAL SELECTION
Very generally speaking the property required of a
wear-resistant material is the right combination of hardness
and toughness. Since these are often conflicting require-
ments, the selection of the best material will always be
a compromise. Apart from the two properties mentioned
above, there are few general properties. Usually the right
material for a given wear-resistant application can only
be selected after taking into consideration other factors
that determine the rate of wear. Of these the most im-
portant are:
Ambient temperature, or temperature of material in
contact with the wear surface.
Size distribution of particles flowing over the wear
surface.
Abrasiveness of these particles.
Type of wear to which wear surface is subjected (i.e.
gouging, sliding, impact, etc.).
Velocity of flow of material in contact with wear
surface.
Moisture content or level of corrosive conditions.
General conditions (e.g. design of equipment, head-
room available, accessibility, acceptable periods
of non-availability of equipment).
Tables 18.1 and 18.2 give some general guidance on
material selection and methods of attaching replaceable
components.
Table 18.3 gives examples of actual wear rates of various
materials when handling abrasive materials.
The subsequent tables give more detailed information on
the various wear resistant materials.

Table 18.1 Suggested materials for various operating conditions

Operating conditions Properties required Material

High stress, impact Great toughness; work-hardening Austenitic manganese steel, rubber of
properties adequate thickness

Low stress, sliding I, Great hardness; 2, toughness less Hardened and/or heat-treated
important; 3, quick replacement metals, hardfacing, ceramics

I, Cheapness of basic material; 2, re- Ceramics, quarry tiles, concretes

placing time less important

1, Maximum wear resistance; cost is Tungsten carbide

immaterial

Gouging wear High toughness Usually metals, i.e. irons and steels,
hard facing
Wet and corrosive conditions Corrosion resistance Stainless metals, ceramics,
rubbers, plastics

Low stress; contact of fine particles; Low coefficient offriction Polyurethane, PTFE, smooth metal
low abrasiveness surfaces

High temperature Resistance to cracking, spallillg, ther- Chromium-containing alloys of iron

mal shocks; general resistance to and steel; some ceramics
elevated temperawres

Minimum periods of shut-down of Ease of replacement Any material that can be bolted in
plant position and/or does not require
cunng

Curved, non-uniform irregular sur- Anyone or a combination ofthe above Hardfacing weld metal; most trowell-
face and shapes properties able materials

Arduous and hot conditions Hardfacing weld metal

 Wear resistant materials 18

Table 18.2 Methods of attachment of replaceable wear-resistant components

Method oj fixing Suitable jar:

Bolting, nuts, or Metals, ceramics,

nuts and bolts rubbers, plastics

2 Sticking, adhesives Ceramics, concretes,

or cement mortar plastics, rubbers
WEAR - RESISTANT MATER lAL

3 Filled fabricated Concretes, pastes,

metal trays,
provided with
I I poured plastics

studs, then fixed

as I above

4 Cast-in bolts or Cast irons, ceramics,

studs concretes

5 Fabricated panels
l= Ceramics

L
~. J-CERAMIC
__-_-_-_-_-_-_-_-_-_-_-~_-_-_-~-_-_-_-_-_-~_-_-_-_-_~_ METAL

J-STUD
6 'T' bars Rubbers, plastics

~I ~ ~
rRCBBEe
~'T'-BOLT

,
Welded studs

I
Metal plates previously
SURFACE
plasticoated or coated
with weld or spray
WCAR
-R'"'' "T "-J metal

BACKING PLATE

8 Tack-welding Mainly for steel or steel-

based components
CTACK WELDS
~// ~ ~ \ J
'/~
~///,'
-' ' '/'
/// />/
/
/>/ / / '
~/, ~/~, ~
/>;::/<:;':;;>: :>/~;;
'III

~
Table 18.3 Typical performance of some wear-resistant materials as a guide to selection
0.53
4.0-4.4
0.06
0.91
0.33
00
Type Some typical materials
0.19
0.87
0.81
0.15
0.17
0.22
0.43
0.12
0.32 -Sliding wear-rate*
0.12
0.13
0.31
0.44
0.43
0.22
2.2-3.4
by coke
6.5
0.11-0.14
0.30-0.84
0.63
0.11
0.09
1.27
0.05-0.14
Iy sinter Temperature
limitations
Ease and convenience qf replacement General comments

0.17
0.05
0.11 0.42
Cast irons 0.09-0.16
2.13.2
Ni-hard type martensitic white iron Yes The most versatile of the materials which,
High chrome martensitic white irons now, by varying alloying elements, method
Spheroidal graphite-based cast iron of manufacture and application are able to
High phosphorus pig iron give a wide range of properties. Their main
Low alloy cast iron advantage is the obtainable combination of
strength, i.e. toughness and hardness, which
Cast steels 3 i Cr-Mo cast sleel accommodates a certain amount of abuse.
13 Mn austenitic cast steel Other products are sintered metal and metal
1~ Cr-Mo cast steel coatings

Rolled stccls Armour plate

Work-hardened Mn steel
Low alloy steel platc, qucnched and ~
tempered CO
EN8 steel Q)
...,
Hard facings High chrome hardfacing welds, various No Could be difficult if applied in situ
...,
CO
Ceramics Fusion-cast alunUna-zirconia-silica
Slagceram
Fusion-cast basalt
Yes, if bolted. Not so convenient if fixed by Great range of hardness. Most suitable for
adhesive or cement mortar, as long curing low-stress abrasion by low-density
times may be unacceptable materials, and powders. Disadvantage:
-.
en
en
c.o Acid-resisting ceramic tile brittleness r-+
I') Plate glass Q)
Quarry floor tiles
:::J
r-+
Concretes Aluminous cement concrete. Could be messy. Might be difficult under Advantages: cheapness, castability.
Quartz-granite aggregate-based concrete dirty conditions Disadvantage: long curing or drying-out
times 3
Q)
Rubbers Rubbers, various Bonded and bolted. Stuck with adhesive, Main advantage is resilience and low
r-+
could be difficult under dirty conditions density, with a corresponding loss in bulk CO
hardness. The most useful materials where ...,
fulladvantage at the design stage can be Q)
taken of their resilience and anti-sticking
properties en
Rubber-like plastics 2.3 Yes polyethylene
6.4
Resin-bonded
8.2
2.3
2.3-5.4
Polyurethanes,
High-density clacined
various bauxite

In sheet form it is difficult to stick Low coefficient of friction, good antisticking

properties. Best for low-stress abrasion by
fine particles

Trowelled; could be messy. Difficult in These materials are only as strong as their
dirty and inaccessible situations bonding matrix and therefore find more
application where low-stress wear by powders
or small particles (grain, rice) takes place

*\Vear rate is expressed in in3 of material worn away per 1000 tons of the given bulk materials per ft2 of area in contact with the abrading material. The results were obtained from field trials in a chute feeding a conveyor belt.
This data is provided as examples of the relative wear rates of the various materials when handling abrasive bulk materials.
 Wear resistant materials 18

:~:Jllo\\ing tables give more detailed information on the materials listed in Table 13.3 with examples of some typical
3.pplications in which they have been used successfully.
\Vhen selecting the materials for other applications, it is important to identify the wear mechanism involved as this is a major
factor in the choice of an optimum material. Further guidance on this is given in Table 13.1.

Table 18.4 Cast irons

Type 1.5-10%
Various
Meehanite
470-650
250-700
3.5%C
3-6%
3%C
150-300
to 2%Cr
Hardness Ni
2.8-3.5%C,
7-9%
Up
Nominal Cr,
650 Cr
2.0%PWSH2
I %Ni Ni,
Brinell
5-6.5%
composition Characteristics Typical application
4-7% Mn
Spheroidal graphite Graphite gives lubrication Brake blocks and drums,
pumps

Heat-treatable. Can be Many engineering parts,

lined with glass, rubber, crusher cones, gears, wear
enamels plates

Brittle, can be reinforced Sliding wear

with steel mesh.

Sliding wear, grate bars,

cement handling plant, heat-
treatment

High abrasion
Ore handling, sand and
gravel

More toughness.
Resists fracture and
corrOSIon

Cr:'loNi Martensitic irons 14--22% Cr, 1.5% Ni, 500-850 Ball and rod mills, wear
3.0% Mo plates for fans, chutes, ete.
Typical examples:
Paraboloy

High Chromium iro,?-s 22-28% Cr 425-800 Cast as austenite Crushing and grinding
Heat-treated to martensite Plant
Typical examples: Ball and Rod mills
BF 253 Shot blast equipment,
HC 250 pumps
 18 Wear resistant materials

Table 18.5 Cast steels

TYpe Nominal composition Hardness Characteristics TYpical applications

Carbon steel Up to 250 Use as backing for coatings

BS 3100 Grade A

Low alloy steels Additions of Ni, Cr, Mo 370-550 For engineering 'lubricated'
BS 3100 Grade B up to 5% wear conditions

Austenitic 11% Mn min. 200 soft For heavy impact wear,

BS 3100 BWlO Up to 600 when Jaw and Cone crushers,
work-hardened Hammer mills

High alloy steels 30% Cr 500 Special alloys for wear at

BS 3100 Grade C 65% Ni + Mo, Nb etc. high temperature and
corrosive media

Tool steels 17% Cr, 4% Ni, 9% Mo, Up to 1000 Very special applications,
Many individual 22% W, 10% Co usually as brazed-on plates.
specifications

Austenitic
BS
321
(En8
20
---
manganese
Diamond
1449
30, &Wp
and
Creusabro
450,
and
Cyclops
ARQ
Typical 30014
Grade
Red
500,
11/14
Grades, 40
Grades,
Diamond
and
OXAR
examples:
plate)
21, Abrazo
Compass Mn,
TenborAbro
500, 320
Red
60
B55525
250-500
I%Mo
1.7%
Heat
Stainless
160-260
etc.
200
1]/16%
in
Quenched
Up to
TYpical
Nominal Mn
andassteels
soft
10% +corrosion
Mn
Characteristics
Hardness
26%
22% Cr,
Ni,
.06/1.0%
For use
coatings
Higher
Use for condition
C,
backing
carbon
hopper
3.5%
600 Nb,
and
Mn,
application
composition Ti
Cr,for
tempered./ hardTable
600
forNi,
liners,
4%low chutes, medium 18.6
resistant
Are wear Rolled
skin weldable
hardened with care steels
by rolling

Low
High alloy
alloy steels
and stainless
18 Wear resistant materials

Table 18.8 Some typical wear resistant hardfacing rods and electrodes
Material type Name Typical application

Low alloy steels Vodex 6013, Fortrex 7018, Saffire Range. Tenosoudo Build-up, and alternate layering in laminated surfaces
50, Tenosoudo 75, Eutectic 2010

Low alloy steels
Brinal Dymal range. Deloro Multipass range. EASB Punches, dies, gear teeth, railway points
Chromtrode and Hardmat. Metrode Met-Hard 250,
350, 450. Eutectic N6200, N6256. Murex Hardex 350,
450, 650, Bostrand S3Mo. Filarc 350, Filarc PZ6152/
PZ6352. Suodometal Soudokay 242-0, 252-0, 258-0,
Tenosoudo 105, Soudodur 400/600, Abrasoduril.
Welding Alloys WAF50 range Welding Rods Hardrod
250, 350, 650

Martensitic chromium Brinal Chromal 3, ESAB Wearod, Metrode Met-Hard Metal to metal wear at up to 600C. High C types for shear
steels 650. Murex Muraloy SI3Cr. Filarc PZ6162. Oelikon blades, hot work dies and punches, etc.
Citochrom 11113. Soudometal Soudokay 420, Welding
Rods Serno 420FM. Welding Alloys WAF420

High speed steels Brinal Dyma H. ESAB OK Harmet HS. Metrode Hot work dies, punches, shear blades, ingot tongs
Methard 750TS. Murex-Hardex 800, Oerlikon
Fontargen 715. Soudometal Duroterm 8, 12,20,
Soudostell, 12,21. Soudodur MR

Austenitic stainless steels Murex Nicrex E316, Hardex MnP, Duroid II, Bostrand Ductile buttering layer for High Mn steels on to carbon
309. Metrode Met-Max 20.9.3, Met-Max 307, Met- steel base. Furnace parts, chemical plant
Max 29.9 Soudometal Soudocrom D

Austenitic manganese Brinal Mangal 2. Murex Hardex MnNi Metrode Hammer and cone crushers, railway points and crossings
steels Workhard 13 Mn, Workhard 17 MnMo, Workhard
12MnCrMo. Soudometal Soudomanganese, Filarc
PZ6358

Austenitic chromium Metrode Workhard IICr9Mn, Workhard 14Crl4Mn. As above but can be deposited on to carbon steels. More
manganese steels Soudometal Comet MC, Comet 624S abrasion resistant than Mn steels

Austenitic irons Soudometal Abrasodur 44. Deloro Stellite Delcrome II Buttering layer on chrome irons, crushing equipment,
pump casings and impellors

Martensitic irons Murex Hardex 800. Soudometal Abrasodur 16. Eutectic For adhesive wear, forming tools, scrapers, cutting tools
Eutectdur N700

High chromium austenitic Murex Cobalarc lA, Soudometal Abrasodur 35, 38. Shovel teeth, screen plate, grizzly bars, bucket tips
irons Oerlikon Hardfacing 100, Wear Resistance WRC.
Deloro Stellite Delcrome 91

High chromium Metrode Met-hard 850, Deloro Stellite Delcrome 90 Ball mill liners, scrapers, screens, impellors
martensitic irons

High complex irons Brinal Nioba!. Metrode Met-hard 950, Met-Hard 1050. Hot wear applications, sinter breakers and screens
Soudometal Abrasodur 40, 43, 45, 46

Nickel alloys Metrode 14.75Nb, Soudonel BS, Incoloy 600. Metrode Valve seats, pump shafts, chemical plant
14.75MnNb, Soudonel C, Incoloy 800. Metrode HAS
C, Comet 95, 97, Hastelloy types

Cobalt alloys EutecTrode 90, EutecRod 91 Involving hot hardness requirement: Valve seats, hot shear
blades

Copper alloys Saffire AI Bronze 90/10, Citobronze, Soudobronze Bearings, slideways, shafts, propellers

Tungsten carbide Cobalarc 4, Diadur range Extreme abrasion: fan impellors, scrapers
 Bexane
Scandurathane
-~ curved and Xawkward
" -
'ti
:;:::!

thick minimum.
temperatures
needs
impact,
grain,
high strong
Fusion-cast
Zac
alsoetc.
temperature
rice
Supron
!soden
Various
7-8Moh
9Moh
Tivarthane
Hardness
resistant
materials
Fairly
1681
support
at high Wear
Alumina
Rubber
balls
Alumina
Process
rubber
natural
materials
resistant
for
Polytetra-
90%AlzOg
50%AlzOg
aggregates
For
particles
Very
Best
soft
Mainly
Various
Particularly
Polyurethane
High
pipe fine
In-situ
conveyors,
7}pical
95(Slater)
(Scandura)
Solidor)
Therefore
filled
limits
basalt
with
silico-aluminates
like
(Polyhi-
Remelted
Low fine
vanous coke
suited wear
materials
materials
Resin-based
stress
wear-
Characteristics
Nominal
32.5%ZrOz
96%AlzOg
Boors,
based,
40%A12Og
Resilient,
95%A12Og
2,4%Si02 powders
brittle
density
linings, size
abrasion.
rubber-
chute
flexible
walls, liners
chutes,
chutes,
for
calcium
grades
repairs wharves,
chutes
application Low
to
alsoEnhanced
surfaces
friction
chemical
stress
lumpy
screens
light,
fine
suitable
usually Can Xcoefficient
resistance
Glass
100
Brittle
Can be
atslurry
vessels.
bunker,
small
powders,
material.be 300
stress
cost
and
18
applications
for
blocks
50
high nun
Specially borne
trowelled.
butwear
produced
to High
any
temperatures50
suitable of
mm.
abrasion
flow
not forof
for
wear-resistant
resistance
medium
materials in
heat
shape. materials
thick
and
Low Low stress wear, also at surfaces
Suitable for lining
round particles, curved
water

Sintered Alumina Duplex PTFE