Metallurgy For Balls and Liners

LUNDIN PRESENTATION SEPTEMBER 2008
METALLURGY FOR BALLS AND LINERS

PALABORA MINING COMPANY
WEAR RESISTANCE
1
CONTENT
1/ GRINDING MEDIA
• 1.1 FORGED BALLS
•1.2 Low Cr MEDIA
• 1.3 HiCr BALLS
2/ ALLOYS FOR LINERS
2
CONTENT
1/ GRINDING MEDIA
•1.2 Low Cr MEDIA
• 1.3 HiCr BALLS
3
METALLURGY FOR BALLS AND LINERS - SF BALLS
METHOD OF PRODUCTION
FORGED BALLS ARE PRODUCED FROM RODS

THE RODS ARE HEATED BEFORE FORGING
TWO MAIN MANUFACTURING PROCESSES:
- UPSET FORGING FOR THE BIGGER BALLS
- ROLLING FOR THE SMALLER BALLS
4
ROD STOCK
FROM ROLLING MILL INDUCTION HEADING ROD
CUTTING OF ROD IN SEGMENTS TO BE FORGED FORGING BALL

IN FORGING DIES
WATER QUENCH
PRODUCT STORAGE
AND SHIPPING
5
CHEMICAL COMPOSITION
IT VARIES WITH THE SUPPLIER
C: 0.7 to 0.9 %
Mn: 0.5 to 0.9 %
Si: 0.5 to 0.8 %
Cr: 0.3 to 0.5 %
THE % OF THE DIFFERENT ELEMENTS (ESPECIALLY % C) IS

LIMITED BY THE PRODUCTION PROCESS OF FORGING
6
Fe-C diagram
7
DIFFERENT POSSIBLE QUENCHED METALLOGRAPHIC

PHASES:
WHEN QUENCHING A STEEL, AUSTENITE CAN TRANSFORM

INTO:
- MARTENSITE: 60 TO 64 Rc
- BAINITE : 50 TO 55 Rc
- PEARLITE : 30 TO 40 Rc
STILL REMAINING SOME RESIDUAL AUSTENITE: 10 TO 20 %
QUENCHING PARAMETERS :
SPEED OF QUENCH >> INFLUENCES PROPERTIES FOR SF
TEMPERATURE >> DOES NOT INFLUENCE PROPERTIES FOR SF
ALLOYING ELEMENTS >> INFLUENCES PROPERTIES FOR SF
8
Bain Curve
9
HEAT TREATMENT
- ONLY ONE HEAT TREATMENT
- QUENCH IN WATER FROM
AUSTENISATION TEMPERATURE
MICROGRAPHY
- ONLY A MATRIX WITHOUT ANY CARBIDES BUT
VARIABLES STRUCTURES DUE TO LOW ALLOYING
ELEMENTS
HARDNESS
- DEPENDING ON CHEMICAL COMPOSITION AND
HEAT TREATMENT >> DIFFERENT PHASES IN
MATRIX >> HARDNESS CAN VARY FROM 55 Rc TO
64 Rc
10
Hardness Profile
Harndess from surface to center in SF 80mm ball
65
60
55
Rc hardness
SF Rc Hardness
50
45
40
0 10 20 30 distance from
40 surface 50 60 70 80
11
EXAMPLES
HIGH HARDNESS LOW HARDNESS
12
HARDNESS OF MINERALS VERSUS GRINDING MEDIA METALLIC PHASES
VICKERS HARDNESS SCALE
QUARTZ
2000
CHROMIUM CARBIDES
(Hi-Cr balls)
PYRITE
1500
CHROMITE
FELDSPAR
OLIVINE
HEMATITE
1000 PYROXENES + AMPHIBOLES
MARTENSITE MAGNETITE
(good forged balls)
CLINKER
500 DOLOMITE - GOETHITE
PYRRHOTITE –CHALCOPYRITE-PENTLANDITE
PEARLITE LIMESTONE - SPHALERITE
GALENA - CUPRITE - CHALCOSITE
MICAS - CLORITES
0
13
HOW TO RECOGNIZE FORGED BALLS VERSUS

HICR IN A MILL CHARGE:
TWO EASY WAYS:
1/ LET THE BALLS DRY IN THE AIR:

- FORGED BALLS ARE RUSTY
- HICR BALLS ARE MORE SHINY
2/ GRINDING WHEEL TEST:

- FORGED BALLS GIVE LONG BRIGHT SPARKS
- HICR BALLS GIVE SHORT DARK SPARKS
14
CONCLUSIONS:
- RESISTANCE TO ABRASION IS MEDIUM:

AS NO CARBIDES AND LESS HARD THAN THE
MINERALS OF THE COMMON ORES
- RESISTANCE TO CORROSION IS LOW AS
VERY LITTLE CR CONTENT
- RESISTANCE TO IMPACTS CAN BE GOOD
15
CONTENT
1/ GRINDING MEDIA
•1.2 Low Cr MEDIA
• 1.3 HiCr BALLS
16
METALLURGY FOR BALLS AND LINERS - HICR
Low chromium white iron media
17
Low chromium white iron media
30-40%iron
carbides
Rest
soft pearlite
18
In the High Carbon fields low chromium,

we find 1 type of carbides.
Kc Cementite: (Fe, Cr)3C

contains ± 6.7-6.9 % of carbon
up to 20 %of chromium
hardness : 840-1100Hv
19
QUARTZ
2000
PYRITE
1500
CHROMITE
FELDSPAR
IRON CARBIDES OLIVINE
(low CR iron balls) HEMATITE
MAGNETITE
CLINKER
PEARLITE
LIMESTONE - SPHALERITE
MICAS - CLORITES
0
20
CONCLUSIONS:
- RESISTANCE TO ABRASION IS MEDIUM :

IRON CARBIDES AND LESS HARD THAN THE
MINERALS
- RESISTANCE TO CORROSION IS LOW AS
VERY LITTLE CR CONTENT
- RESISTANCE TO IMPACTS IS VERY BAD
21
CONTENT
1/ GRINDING MEDIA
•1.2 Low Cr MEDIA
• 1.3 HiCr BALLS
22
METALLURGY
Etapes de la production FOR Usine
BALLS BouletsAND LINERS - HICR
COMPARISON OF THE PRODUCTION PROCESS BETWEEN

SF AND HiCr
– FOR FORGED BALL THE CHEMICAL COMPOSITION IS THE ONE

OF THE ROD :
• STARTING FROM « SOLID METAL »
• TOO HIGH % C >> RISK OF CRACKS
• TOO HIGH ALLOYING ELEMENTS >> LOWER HARDNESS
• NO CARBIDES
– FOR HIGH CHROME BALL THE CHEMICAL COMPOSITION CAN
WIDELY BE ADJUSTED :
• STARTING FROM « MOLTEN METAL »
• PRODUCED FROM SCRAPS AND FECR
• ALLOWING WIDER CHEMICAL COMPOSITION RANGE
• GENERATING HARDER PHASES >> CARBIDES
23
CONTROL
CONTROL
CONTROL
24
CHEMICAL COMPOSITION
QUITE A WIDE RANGE:
C: 2 TO 3.5%
Mn: max 1.5%
Si: max 1%
Cr: 10 to 30%
25
The FeCrC 3D equilibrium diagram
26
FROM Fe-C DIAGRAM TO Fe-Cr-C DIAGRAM
FMk – Karee – 05-2002 – FIG 27

27
STEEL IRON
Equilibrium Fe-C
< 2.1 % of carbon > 2.1 % of carbon
diagram
Carbide presence
No carbide Carbides
at high temperature
Can dissolve all the Cannot dissolve the
Heat treatment
carbides “big” carbides
Can improve by Cannot be improved by
Impact resistance
heat treatment heat treatment
28
Carbides definitions
Eutectic carbides : occur at high temperature, at the end of the

solidification, it is an hypoeutectic structure
Primary carbides : occur at high temperature, at the beginning of the

solidification, it is an hypereutectic structure
Secondary carbides : occur at lower temperature and always in a

solid phase (austenite, ferrite …). Secondary carbides are much
smaller than the eutectic or primary carbides. They can always be
dissolved by heat treatment.
If a structure only contains secondary carbides, the alloy is a steel.
29
Microstructure of low chromium irons:

- Always two phases : matrix and massive iron
carbides
- - Iron carbides are not so hard and badly
dispersed giving some resistance to abrasion and
low toughness
30
Microstructure of High chromium irons:

- Always two phases : matrix and chromium
carbides (primary and secondary Cr carbides)
- Chromium carbides are harder and better
dispersed than iron carbides giving a better
resistance to abrasion and a better toughness
31
The quantity of primary Cr carbides is fixed by the

chemical composition
Exchanges of elements between the carbides and
the matrix as C and Cr happen during heat-treatment.
So, the chemical composition of the matrix can be
changed
32
In the High Carbon fields, we find 3 types of carbides.
We prefer finer and harder”K” so to avoid Kc
Kc Cementite : (Fe, Cr)3C

contains ± 6.7-6.9 % of carbon
up to 20 %of chromium
hardness : 840-1100Hv
K1 Cr carbides : (Fe, Cr)23C6
contains ± 5.5 % of carbon
60 to 84 %of chromium
hardness : 1300 – 1500 Hv
K2 Cr carbides : (Fe, Cr)7C3
contains ± 8.7% of carbon
25 to 70 %of chromium
hardness : 1300 – 1500 HV
33
Heat-Treatment:
Three different heat-treatments are possible:
- Homogenization
- Quench
- Tempering
34
Why heat treatments ?
35
Homogenization
To get a structure with better properties

as abrasion, corrosion and impact resistance
36
37
Quench:
Opposite to the forged balls, the quenching
temperature modifies the matrix composition by
exchange of elements giving a good possibility to
enhance some properties of the alloy
Quench can be made in oil or in blast air
38
H.T. and alloying influence

T°
AUSTENITE
(quenching
temperature)
PEARLITE NOSE
(alloying elements)
BAINITE NOSE
(speed of cooling)
Martensite start
MARTENSITE
time
39
CCT curve on 12%Cr iron from litterature
40
TTT curve on 12%Cr iron from litterature
41
Tempering
This heat-treatment can be made to:
- decrease the residual stresses
- increase the resistance to repeated impacts
by getting a more stable microstructure
42
Strategy to choose an alloy??
43
Fe-Cr-C Diagram: Several areas
•A:
• Higher Cr/C ratio thus a more “quenchable”
(more Cr in matrix)
• Less Carbon into this same matrix thus less
Hardness! But less tendency to crack (less
tensions)
• More Chrome: better corrosion resistance.
Important factor in Wear resistance and
Downstream processing.
• For corrosion resistance quench temperature
can be adjusted.
•B
• Contrary to the A.
• Application where Hardness is the main driver.
• More difficult to master (production side)
•C
• More Carbides (for Cr-C Irons)
• If shape/application allows, it is frequently used.
• Easier to get sound products.
• Usually the Eutectic line is the practical limit.
(4.3%C)
44
A HiCr alloy is not only defined by the % Cr and Hardness
High chromium media

Matrix + carbides = f (% Cr, % C, H.T.)
- % of carbides = f( % C, % Cr )
- type of carbides
- shape and size of carbides
- Martensite + retained austenite
Cr in the matrix
- Hardness
For abrasion → Matrix hardness + %, size and distribution of carbides

For corrosion → % Cr in Matrix = f (% Cr in the alloy, H.T.)
45
Hardness of an Alloy
=
Hardness of the Carbides
+
Hardness of the Matrix
Carbide + Constant
Hardness
may be improved
Matrix significantly by
Hardness heat treatment
« Hardening » or « Quenching »
46
Hardness profile
47
SEGMENTATION OF MILLING CONDITIONS
QUARTZ
2000
CHROMIUM CARBIDES
PYRITE
1500
CHROMITE
FELDSPAR
OLIVINE
HEMATITE
MARTENSITE MAGNETITE
Matrix of high Cr
irons CLINKER
LIMESTONE - SPHALERITE
MICAS - CLORITES
0
48
Conclusions:
- HiCr alloys have a very good abrasion resistance
due to the fair amount of hard chromium carbides
- HiCr alloys have a good corrosion resistance when
Cr content is well chosen
- HiCr alloys have a good resistance to impacts if the
appropriate heat-treatment is chosen
49
CONTENT
1/ GRINDING MEDIA
• 1.2 HiCr BALLS
• 1.3 PARAMETERS INFLUENCING WEAR
50
METALLURGY FOR BALLS AND LINERS -Liners
Different materials are used:
1/ Mn steel
2/ Cr-Moly steel
3/ HiCr white irons
4/ Rubber
5/ Rubber with steel caps
51
1/ Mn steel
Chemistry:
-C: 1.2 %
-Mn: 12 -13%
-Si: max 0.8 %
-Cr: max 0.5 %
52
1/ Mn steel (cont’ed)
Heat –treatment:
Quench in water from very high temperature
Microstructure: austenite without any carbides
Hardness : 10 to 15 Rc but hardness in service can
increase to 35 to 50 Rc
53
1/ Mn steel Typical
microstructure
Microstructure/
properties can be affected by
boundary carbide precipitation
54
Advantages: * very tough
* can be welded if necessary
* non magnetic
Disadvantages: * wears rather fast if no
hardening occurs during operations
* can deform if lot of impacts which
can cause liner bolt breakage
* gives peening of the slots in grate
discharge mills
55
Application :
– crusher parts (gyratory, jaw, cone crushers)
– mill liners (some typical application is grid liner
where balls are filling the pockets and give wear
resistance to the liner )
56
2/ Cr-Moly steel
Chemistry:
-C:0.4 to 0.8 %
-Cr: 2 to 2.5 %
-Mn:1% max
-Si: 1% max
-Mo: 0.2 to 0.6%
57
2/ Cr-Moly steel (cont’ed)

– 3 heat-treatments:
-homogenization
-quench in blast air
-tempering
Microstructure
-pearlitic (mining industry)
58
Typical CrMo
microstructure
Microstructure/ properties
can be affected by
boundary carbide
precipitation
59
2/ Pearlitic Cr-Moly steel (cont’ed)

Hardness: 300 to 400 HB (30 to 40 Rc)
Advantages :
– very though
– can be welded if necessary
– magnetic
– initial hardness higher than Mn steel
– gives less peening of the slots in grate discharge mills
Disadvantages: higher cost than Mn steel
60
2/ Cr-Moly steel (cont’ed)

Application:
– SAG and ROM mills with solid liners (feed end,
shell, discharge grates, pulp lifters)
– Primary ball mills with grate discharge
61
3/ HiCr alloys
Chemistry
-C: 2 to 3%
-Cr: 15 to 27%
-Mn: 0.5 to 1.5%
-Mo: 0 to 1.5%
62
3/ HiCr alloys (cont’ed)

Heat-Treatment
3 heat-treatments:
1.homogenization
2. quench in blast air or liquid bath
3. stress relief or tempering
Microstructure
– Martensite with 22 to 30% Cr carbides
Hardness: 60 to 64 Rc
63
64

Advantages:
– higher wear resistance than manganese or CrMo
steels
Disadvantages:
– less though than Mn and Cr-Moly steels
– can only be welded with care
65

Application:
– AG mill
– Rod Mill
– Primary , secondary and RGD ball mill with
overflow discharge
– Feed chutes, pumps, etc…
66
TOUGHNESS/WEAR RESISTANCE OF THE MOSTLY USED ALLOY TYPES

TOUGHNESS / DUCTILITY
1 Pearlitic Cr Moly steels
WEAR RESISTANT
2 High Mn steels
3 Martensitic Cr steel
4 High Cr irons
1
2
3
FMk – Karee – 05-2002 – FIG 67

67
SUMMARY OF ALLOYS AND WEAR MECHANISMS
Alloys Austenitic Mn steels Pearlitic steels Martensitic HiCr alloys
Composition Mn Cr - Moly 12 - 27 Cr
Matrix + chrome carbides (30 -
Structure Matrix Matrix
35%)
200 - 450 HB after work
Hardness 325 - 400 HB 600 - 650 HB
hardening
Resistance to abrasion low to good low excellent
Resistance to corrosion low low medium to very good
Resistance to repeated
excellent very good good
impacts
68
How to identify the 3 alloys in the yard

If a magnet does not stick : Mn steel
If a magnet does stick: can be either Cr-Moly or HiCr
Use a portable grinder
– if long bright sparks: Cr-Moly
– if short dark sparks: HiCr
69
4/ Rubber
Advantages:
– low weight allowing an easy hand fitting and good safety
– good insulation for noise but unfortunately also for
temperature which could increase corrosion on the grinding
media
– low cost
Disadvantages:
– shape of lifters >> sometimes square lifters used for
increased lifetime but not suitable for grinding efficiency
Application:
– secondary and RGD ball mills because rubber can not resist
to impact of big balls and “cutting effect” by big ore particles
70
5/ Rubber with steel caps

Steel insert is in Cr-Moly steel or White Irons has
been developed for applications where rubber was
not lasting enough
71
Thank you for your attention
72

Metallurgy For Balls and Liners

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Metallurgy For Balls and Liners

Uploaded by

Copyright:

Available Formats

LUNDIN PRESENTATION SEPTEMBER 2008

METALLURGY FOR BALLS AND LINERS

• 1.1 FORGED BALLS

•1.2 Low Cr MEDIA

• 1.3 HiCr BALLS

2/ ALLOYS FOR LINERS

• 1.1 FORGED BALLS

•1.2 Low Cr MEDIA

• 1.3 HiCr BALLS

2/ ALLOYS FOR LINERS

FORGED BALLS ARE PRODUCED FROM RODS

- ROLLING FOR THE SMALLER BALLS

CUTTING OF ROD IN SEGMENTS TO BE FORGED FORGING BALL

IT VARIES WITH THE SUPPLIER

THE % OF THE DIFFERENT ELEMENTS (ESPECIALLY % C) IS

DIFFERENT POSSIBLE QUENCHED METALLOGRAPHIC

WHEN QUENCHING A STEEL, AUSTENITE CAN TRANSFORM

STILL REMAINING SOME RESIDUAL AUSTENITE: 10 TO 20 %

HIGH HARDNESS LOW HARDNESS

HARDNESS OF MINERALS VERSUS GRINDING MEDIA METALLIC PHASES

VICKERS HARDNESS SCALE

HOW TO RECOGNIZE FORGED BALLS VERSUS

1/ LET THE BALLS DRY IN THE AIR:

2/ GRINDING WHEEL TEST:

- RESISTANCE TO ABRASION IS MEDIUM:

• 1.1 FORGED BALLS

•1.2 Low Cr MEDIA

• 1.3 HiCr BALLS

2/ ALLOYS FOR LINERS

Low chromium white iron media

Low chromium white iron media

In the High Carbon fields low chromium,

Kc Cementite: (Fe, Cr)3C

HARDNESS OF MINERALS VERSUS GRINDING MEDIA METALLIC PHASES

VICKERS HARDNESS SCALE

- RESISTANCE TO ABRASION IS MEDIUM :

• 1.1 FORGED BALLS

•1.2 Low Cr MEDIA

• 1.3 HiCr BALLS

2/ ALLOYS FOR LINERS

COMPARISON OF THE PRODUCTION PROCESS BETWEEN

– FOR FORGED BALL THE CHEMICAL COMPOSITION IS THE ONE

The FeCrC 3D equilibrium diagram

FMk – Karee – 05-2002 – FIG 27

Eutectic carbides : occur at high temperature, at the end of the

Primary carbides : occur at high temperature, at the beginning of the

Secondary carbides : occur at lower temperature and always in a

Microstructure of low chromium irons:

Microstructure of High chromium irons:

The quantity of primary Cr carbides is fixed by the

In the High Carbon fields, we find 3 types of carbides.

We prefer finer and harder”K” so to avoid Kc

Kc Cementite : (Fe, Cr)3C

Why heat treatments ?

To get a structure with better properties

H.T. and alloying influence

CCT curve on 12%Cr iron from litterature

TTT curve on 12%Cr iron from litterature

Strategy to choose an alloy??

A HiCr alloy is not only defined by the % Cr and Hardness

High chromium media

For abrasion → Matrix hardness + %, size and distribution of carbides

HARDNESS OF MINERALS VERSUS GRINDING MEDIA METALLIC PHASES