International Symposium on Wear Resistant Alloys for the Mining and Processing Industry

596 Pages·2017·39.68 MB·English

International Symposium on
Wear Resistant Alloys
for the Mining and Processing Industry

International Symposium on
Wear Resistant Alloys
for the Mining and Processing Industry
Proceedings of the International Symposium on Wear Resistant Alloys for the Mining and
Processing Industry. Held in Campinas, São Paulo, Brazil, 4 - 7 May 2015.
Editor-in-Chief
Hardy Mohrbacher, NiobelCon, Belgium
International Editorial Committee
Hardy Mohrbacher, NiobelCon, Belgium
Clovis Antonio de Faria Sousa, CBMM, Brazil
George Krauss, Colorado School of Mines, USA
Mathias Woydt, BAM Federal Institute for Materials Research and Testing, Germany
Mariana Perez de Oliveira, CBMM, Brazil
International Organizing Committee
Hardy Mohrbacher, NiobelCon, Belgium
Pascoal Bordignon, CBMM, Brazil
Mathias Woydt, BAM Federal Institute for Materials Research and Testing, Germany
Mariana Perez de Oliveira, CBMM, Brazil
Jef Vleugels, KU Leuven, Belgium
Copyright © 2018 Companhia Brasileira de Metalurgia e Mineração
(CBMM)
All rights reserved
Published by CBMM
Production work by The Minerals, Metals & Materials Society (TMS)
Editorial support provided by Beta Technology Ltd, UK
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in
any form or by any means - electronic, mechanical, photocopying, recording, scanning, or
otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright
Act, without the prior written permission of CBMM.
Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best
efforts in preparing this book, they make no representations or warranties with respect to the
accuracy or completeness of the contents of this book and specifically disclaim any implied
warranties of merchantability or fitness for a particular purpose. No warranty may be created
or extended by sales representatives or written sales materials. The advice and strategies
contained herein may not be suitable for your situation. You should consult with a professional
where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any
other commercial damages, including but not limited to special, incidental, consequential, or
other damages.
ISBN 978-0-692-05382-9
Printed in the United States of America.
TABLE OF CONTENTS
International Symposium on Wear Resistant
Alloys for the Mining and Processing Industry

Preface ................................................................................................................ ix
Companhia Brasileira de Metalurgia e Mineração (CBMM) .............................. xi

Opportunities for Ferrous Alloys Used in Copper Mining ..................................1
V. Pérez and D. Villaseca

From Monometallic to Composites and Ceramic Wear Resistant Materials:
An Industrial Challenge ..................................................................................... 19
H. François and M. Bonnevie

Development and Application of Advanced High-Strength Steels in
Lightweight Cars for Heavy-Duty Mining Dump Trucks .................................. 47
Linhao Gu, Zhenqiang Wang, Changwen Ma, Deguang Zhou,
Yongqing Zhang and Aimin Guo

Collaboration to Reduce Wear and Corrosion Cost for the Mining
Industry .............................................................................................................. 67
S. Hui

Increasing the Life Cycle of Buckets for Wheel Loaders Using High
Strength and Abrasion Resistant Steels Microalloyed with Niobium ................ 75
H. Rosa, M.K. Ferreira Cardoso, É. França, J.L. Barreto,
L.M. Silvestre and M.A. Stuart Nogueira

Fundamentals and Practical Approaches of Optimizing Martensitic Steels
for Use under Severe Operating Conditions ...................................................... 93
H. Mohrbacher, J.W. Morris and G. Krauss

High Performance Steels for Wear Applications ............................................. 159
A. Dietrich, A. Canpolat, A. Kern and H-J. Tschersich

The Role of Niobium for the Development of Wear Resistant Steels with
Superior Toughness ......................................................................................... 173
A.S. Schneider, J.L. Cayla, C. Just and V. Schwinn

High Performance Abrasion Resistant Steel Plates Using Microalloying
Technology for Grain Refinement ................................................................... 187
N. Takayama, A. Ohmori, Y. Murota and K. Araki

Wear- and Corrosion-Resistant Steels Containing Niobium Carbide .............. 197
M. Seifert, S. Huth, S. Siebert and W. Theisen
v
Modern Pre-Hardened Tool Steels................................................................... 223
P. Hansson

Development of Nb-Bearing Heavy Steel Plates with Ultra High Strength
and Excellent Toughness ................................................................................. 235
Zhao Sixin, Ding Jianhua, Yao Liandeng, Zhang Yongqing
and Guo Aimin

Abrasion Resistant Metallic Alloys for the Mining Industry ........................... 253
E. Albertin and A. Sinatora

Effects of Niobium Additions on the Properties and Life Cycle of Steels
for Hot Working Tools .................................................................................... 277
F. Hippenstiel

The Challenge of Accurate Prediction of Industrial Wear Performance
from Laboratory Tests ..................................................................................... 289
J.D. Gates, P.J. Bennet, L.J. McInnes and B.R. Tunstall

Optimized Gear Performance by Alloy Modification of Carburizing Steels
for Application in Large Gear Boxes ............................................................... 351
Th. Tobie, F. Hippenstiel and H. Mohrbacher

Cutter Rings with Non-Uniform Niobium Carbide Distribution for Tunnel
Boring .............................................................................................................. 385
B. Feistritzer

Influence of Niobium on the Microstructure and Properties of CrMo Cast
Steel for Liner Plate ......................................................................................... 393
Xiangru Chen, Ming You, Aimin Guo, Wei Zhang, Hiacheng Li,
Yang Xu and Qijie Zhai

Development of FeNbC for Wear Resistant Applications ............................... 407
E.B. Cruz and D.P. Fridman

The Tribological Property Profile of Hard Metals and Metal Matrix
Composites Based on Niobium Carbide .......................................................... 427
M. Woydt and H. Mohrbacher

Application of FeNbC as a Hardfacing Material Using Laser Cladding ......... 463
E.T. Galvani, S. Simões, C.H.N. Banov, H.L. Rosa and E.B. Cruz

Mechanical Characterization of Hard Phases by Means of
Nanoindentation ............................................................................................... 487
F. Pöhl, A. Weddeling and W. Theisen
vi
Formation of Niobium Carbide Coating on AISI L2 Steel Using Thermo-
Reactive Diffusion (TRD) Technique .............................................................. 505
M. Azizi and M. Soltanieh

NbC-Based Cermets: Influence of Secondary Carbide Addition and Metal
Binder .............................................................................................................. 521
S.G. Huang, J. Vleugels, H. Mohrbacher and M. Woydt

Comparison of the Life-Span of NbC-Co and WC-Co Inserts during
Different Machining Operations on 100Cr6 (SAE 52100) Bearing Steel ........ 535
G. Le Quilliec, R. Leroy, C. Richard, M. Woydt and A. Morandeau

Wear and Mechanical Properties of Spark Plasma and Liquid Phase
Sintered WC And NbC Based Cemented Carbide Inserts ............................... 547
R.M. Genga, L.A. Cornish, M. Woydt, K. Sobiyi and C. Polese

Common Acronyms and Abbreviations ........................................................... 569
Author Index .................................................................................................... 581
Subject Index ................................................................................................... 583

A DVD containing the papers presented and videos summarizing the main
technical conclusions, along with interviews with the hosts and selected speakers
from the symposium, can be found at the back of this publication.

vii

Preface
Wear is by no means the highest profile area of materials research and technological focus, but
there can be no doubt that it ought to command our utmost attention. There have been
continuous investments and studies on wear mechanisms, as the losses associated with its
complex and varied damaging mechanisms have severe economic consequences through direct
replacement costs, machine downtime and lost production. The challenges of wear are
significant across a broad range of mechanical processing operations, some of which are carried
out at elevated temperatures, and include crushing, drilling, conveying, mixing and separating.
Although of immediate interest to the mining sector, other industries such as iron and steel
production, cement manufacturing, power generation, recycling and environmental protection
are also of significance in this context.
Over 40 years ago a major international symposium took place in Colorado, USA, that
highlighted the importance of wear on materials and its impact on the industry. It is surprising
to note that since then there have been few international events focused on this topic. Abrasive
wear is the dominant issue and this is caused by the materials being handled, which include
mineral species like silica sand, granite, metal ores and coal. Conveyors, ball mills, drills,
chutes and dumper truck bodies are examples of equipment which can be exposed to abrasive
wear when handling such materials. The classic engineer’s rule of thumb states that “the harder
the material, the better the resistance against abrasive wear”. However, research has indicated
that abrasive wear resistance not only correlates with hardness, but also with toughness.
Consequently, substantial efforts have been made over recent decades to optimize steel and
iron-based alloys to better withstand these harsh conditions and thus extend the life of
equipment and components.
Since niobium is one of the key alloying elements that can be used to upgrade the functional
profile of steels and irons against abrasive wear, Companhia Brasileira de Metalurgia e
Mineração (CBMM), the world’s premier supplier of niobium and niobium applications
technology, believed it was timely to host a long overdue international symposium focusing on
wear resistance. Accordingly, “Wear Resistant Alloys for the Mining and Processing Industry”
was held during May 2015 in Campinas, São Paulo, Brazil.
Attended by over 170 delegates from around the world, expert speakers from the entire supply
chain shared their experiences and this publication brings together a selection of papers
presented at the symposium on topics such as abrasion-resistant high strength steels, forgings,
castings, hard facing alternatives and intrinsically hard metals. In essence, the symposium
provided a significant range of practical solutions and identified future opportunities for the
efficient development of improved alloys for the mining and processing industry. These
proceedings summarize the wealth of knowledge presented during the symposium and provide
additional background information. The symposium stimulated a long overdue technical debate
and showcased recent advances in the state of the art in wear resistant alloys. Let us hope the
mining industry will not neglect this important subject for another 40 years!
The International Editorial Committee
ix