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    Failure Analysis of Hammer Premature Wear During Barite Rocks Crushing

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    Mouna Kallel
    The document summarizes the failure analysis of premature wear of hammers during barite rock crushing. It found that after one week of operation, hammers experienced over 20% material loss due to severe wear. Characterization showed the hammers were made of high chromium cast iron with carbides, while the barite rocks were abrasive with sharp edges. Analysis of the worn surfaces found microcracks, scratches, and carbide fragmentation due to impacts from the rocks. The wear mechanism involved both impact and abrasive wear, with surface chromium migration from damaged to undamaged areas.

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    Failure Analysis of Hammer Premature Wear During Barite Rocks Crushing

    Uploaded by

    Mouna Kallel
    17 views20 pages
    The document summarizes the failure analysis of premature wear of hammers during barite rock crushing. It found that after one week of operation, hammers experienced over 20% material loss due to severe wear. Characterization showed the hammers were made of high chromium cast iron with carbides, while the barite rocks were abrasive with sharp edges. Analysis of the worn surfaces found microcracks, scratches, and carbide fragmentation due to impacts from the rocks. The wear mechanism involved both impact and abrasive wear, with surface chromium migration from damaged to undamaged areas.

    Original Description:

    an expertise study of hammer premature wear

    Original Title

    CMSC 2017

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    The document summarizes the failure analysis of premature wear of hammers during barite rock crushing. It found that after one week of operation, hammers experienced over 20% material loss due to severe wear. Characterization showed the hammers were made of high chromium cast iron with carbides, while the barite rocks were abrasive with sharp edges. Analysis of the worn surfaces found microcracks, scratches, and carbide fragmentation due to impacts from the rocks. The wear mechanism involved both impact and abrasive wear, with surface chromium migration from damaged to undamaged areas.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    17 views20 pages

    Failure Analysis of Hammer Premature Wear During Barite Rocks Crushing

    Uploaded by

    Mouna Kallel
    The document summarizes the failure analysis of premature wear of hammers during barite rock crushing. It found that after one week of operation, hammers experienced over 20% material loss due to severe wear. Characterization showed the hammers were made of high chromium cast iron with carbides, while the barite rocks were abrasive with sharp edges. Analysis of the worn surfaces found microcracks, scratches, and carbide fragmentation due to impacts from the rocks. The wear mechanism involved both impact and abrasive wear, with surface chromium migration from damaged to undamaged areas.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 20

    National Engineering School of Sfax University of Ottawa

    Laboratory of Materials Engineering & 29 Canadian Materials Science


    th

    Environment (LMEE) Conference (CMSC 2017)

    Failure analysis of hammer premature


    wear during barite rocks crushing

    Presented by: Mouna KALLEL (PhD student)

    Supervised by: Pr. Khaled ELLEUCH


    Plan

    1 Context and problematic

    2 Materials characterization

    3 Worn surface analysis

    4 Wear mechanism

    5 Conclusion
    2
    Context and problematic

    Crushing process is the basic operation in the mineral industry.


    However, the continuous service of crushers under severe
    operating conditions provokes heavy wear. Statistics show
    that wear and the consumption of crushing media account for
    roughly 50% of the crushing cost.

    3
    Context and problematic
    Problematic: Hammer wear

    Hammer crusher has undergone a great material loss from hammers leading to the
    interruption of the barite rock crushing process after one week of service

    Worn
    hammer

    Unworn
    hammer
    Material loss

    4
    Context and problematic
    Feeding
    Barite rock before crushing (<100mm)
    Crushing chamber

    rotor

    Maximum radial force: 138 N


    Hammer
    Rotating speed: 1400 rpm
    Feeding rate :18 tons/h Sizing grate

    Crushed rock
    (<5mm)
    Barite rocks are broken by hammer shock

    The particles, with dimension < 5mm, pass through the sizing grate

    The rest of particles with higher dimensions remain trapped between the
    hammers in rotation and the sizing grate to be crushed again 5
    Plan

    1 Context and problematic

    2 Materials characterization

    3 Worn surface analysis

    4 Wear mechanism

    5 Conclusion
    6
    Materials characterization: Hammer
    Hammer material: chemical composition and microstructure
    Sharp edges
    Chemical composition: 3%wt C ; 25wt%
    Eutectic carbide
    M7C3
    Cr
    Microstructure: Eutectic carbides M7C3 +
    Martensitic matrrix with secondary carbides

    Martensitic matrix with


    secondary carbides High chromium cast iron thermally
    treated
    15 kv X 500 50µm

    Hammer material: Mechanical properties

    Bulk hardness HV30 690

    Young’s modulus E 172 GPa


    Compressive strength σR 2460 MPa

    Yield strength σY 2051 MPa


    7
    Strain hardening rate e 8%
    Materials characterization: Barite rocks
    Barite rocks before crushing

    Sharp edges
    Sharp edges

    Large
    particles
    Small particles 20 mm

    Chemical composition: BaSO4 + impurities:


    Pb, Al , Ca et Si (abrasive element)
    Properties: - different particle size
    - irregular shape
    - sharp angles
    Micro-hardness: 158 HV0,05
    8
    Plan

    1 Context and problematic

    2 Materials characterization

    3 Worn surface analysis

    4 Wear mechanism

    5 Conclusion
    9
    Worn surface analysis: Hammer damage view
     Comparison in dimensions and mass between an unworn hammer and a worn hammer

    Unworn Worn
    hammer hammer
    Li=206 mm

    Lf=186 mm
    Length (mm) 206 186
    Thickness (mm) 45 40
    Mass (kg) 5.375 4.240
    24mm
    Material loss: 1,135 Kg (21% of the hammer bulk
    mass)

    Grooves
    Craters Active
    Surface

    Upper
    Surface

    10
    Worn surface analysis: SEM observation
    Upper surface

    Removed material

    Microscratches
    Crack-network

    15 kv 5000Χ 5 µm 15 kv 5000Χ 5 µm

    Active surface
    Removed material

    microscratch
    Ridges
    Grooves
    Microcracks

    15 kv 200Χ 200 µm 15 kv 2000Χ 10 µm 11


    Worn surface analysis: EDS analysis

    Broken carbides Wear


    fragmentation
    debris
    Displaced
    material 2
    1 craters 4

    15 kv 1000Χ 20 µm 15 kv 1000Χ 20 µm

    Surface chromium percentage in different damaged areas


    Area 1 Area 2 Area 3 Area 4
    (Undammaged) (fragmentation) (displaced (wear debris)
    material)
    Cr (%at) 25.250 14.221 4.289 2.770
    Cr (%wt) 30.734 21.280 11.122 9.046

    The more severe the surface damage is, the lower the chromium content is.

    Surface chromium migration occurs from ‘damaged ’to undamaged surfaces 12


    Worn surface analysis: Cross section

    Resin Resin

    Longitudinal Detached eutectic


    microcracks carbide particle
    Finer
    Coarser
    carbide
    carbide
    specimen specimen
    15 kv 2000Χ 10 µm 15 kv 2000Χ 10 µm

    Longitudinal
    microcracks + Radial
    microcracks
    Eutectic carbide
    fracture

    13
    Plan

    1 Context and problematic

    2 Materials characterization

    3 Worn surface analysis

    4 Wear mechanism

    5 Conclusion
    14
    Wear mechanism

    Wear mechanism

    Impact wear Abrasive wear

    Surface chromium
    migration

    15
    Wear mechanism
    Impact
    Barite rock
    Sliding
    Impact Sliding

    Hammer

    Angular tip Impact site Microscratch

    Microcracks initiation Microscratches formation by


    sharp edges of barite rock
    Fragmented carbide
    particles
    Groove

    Carbides microcracking Grooves formation


    Wear debris

    Surface chromium
    16
    migration Material removal
    Plan

    1 Context and problematic

    2 Materials characterization

    3 Worn surface analysis

    4 Wear mechanism

    5 Conclusion
    17
    Conclusion

    From this failure hammer study, it can be concluded that:


    The hammer material loss is caused mainly by the following factors:
    -the hammer fragility;
    -the size, the shape, the angularity and the silicon amount of barite
    rocks.
    Regarding the failure analysis of worn surfaces, it was found that the
    hammer material loss is caused mainly by microcracking and
    microcutting mechanisms associated with surface chromium
    migration;

    18
    This presentation is a part of work, which has recently published in
    ‘Tribology International’ journal

    19
    Thank you for
    your attention

    20

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