International Journal of Refractory Metals & Hard Materials 79 (2019) 185–196

Contents lists available at ScienceDirect

International Journal of Refractory Metals

& Hard Materials
journal homepage: www.elsevier.com/locate/IJRMHM

Development of wear resistant hammer heads for coal crushing application T

through experimental studies and field trials
⁎
Kaushal Kishore , Manashi Adhikary, Goutam Mukhopadhyay, Sandip Bhattacharyya
R&D and Scientific Services, Tata Steel, Jamshedpur 831004, India

A R T I C LE I N FO A B S T R A C T

Keywords: Coke is one of the most important raw materials for iron making through blast furnace route. Strength and
Coal crushing reactivity of coke plays a huge role in efficiency of the counter-current reactor. In order to attain the desired
Hammer heads quality of coke, large lumps of coals are crushed in to smaller size fraction in a crushing mill using rotating
Abrasive wear hammers. However, the heads of these hammers fail prematurely during service that requires their frequent
Refractory alloy carbides
replacements along with interruption in production. This paper presents failure analysis of a coal crushing
Tungsten carbide
Electron probe micro-analyzer
hammer head with its detailed metallurgical characterization. Analysis revealed that hammer heads fail in
abrasive wear mode due to lean chemistry of the alloy used and lower hardness that manifests as higher abrasion
rate. 6Cre1Mo steels were supplied in quenched and tempered conditions to a hardness of around 52 HRC. There
was presence of only iron chromium carbides that is not sufficient to withstand an application involving extreme
wear.
The second part of this paper presents detailed chemistry-microstructure-wear resistance correlation for four
different alloys; 6Cre1Mo, 20Cre1Mo, complex refractory alloy carbides and tungsten carbide weld deposited
hard-facing. Microstructural analysis and phase identification is carried out using scanning electron microscope
coupled with electron probe micro-analyzer, x-ray diffraction and Vickers hardness tester. Dry sand abrasion
tests were carried out for the existing 6Cr-1 Mo steel and proposed trial specimens. Study shows that the abrasion
resistance is strongly a function of type of carbides and their volume fraction. Niobium carbide and tungsten
carbides are much more effective in improving the abrasion resistance of alloys compared to primary chromium
carbides. Tungsten carbide hard-facing demonstrated the best abrasion resistance. Based on the study, a new
design for hammer head with tungsten carbide hard-facing is developed and field trial revealed an improvement
in service life greater than three times compared to existing 6Cre1Mo quenched and tempered hammer heads.

1. Introduction the hammer that is subjected to high wear and impact of falling lumps
of coal is made up of expensive wear resistant material whereas its arm
Despite the inventions and developments in alternative routes of which is subjected to rotational fatigue, reactive impact but minimal
iron making processes like COREX and MIDREX, Blast Furnaces still wear is made up of low alloy steels in quenched and tempered condi-
account for over 50% of the liquid iron produced all over the world [1]. tion.
Coke is one of the most important raw materials for iron making as it One of the biggest challenges in uninterrupted running of mill is the
provides permeability to the bed for counter-current reactions. It is also frequent failures of the hammer heads. On an average, hammer heads
the primary source of reducing agent and heat [2,3]. Metallurgical coal give a service life of around 2–3 months. In contrast, the average service
is converted to coke by a destructive distillation process. Prior to the life of hammer arms is around 1 year. This study is aimed at analyzing
coking process, lumps of coal needs to be reduced to finer size fraction mode of failure of hammer heads and its root cause. It is further aimed
in a crushing mill consisting of a set of rotating hammers [4]. at extending the service life of these hammer heads to around 1 year to
Hammers of coal crushing mill are essentially made of two distinct synchronize the life cycles of hammer arm and head. This would result
components; hammer arm and hammer head. The arm and the head are in planned annual shut-down instead of multiple repetitive delays and
joined together using a locking nut as shown in Fig. 1. The basis for this interruption in production causing severe loss of money and man hours.
design is the judicious selection of material and economy. The head of

⁎
Corresponding author.
E-mail address: kaushal.kishore3@tatasteel.com (K. Kishore).

https://doi.org/10.1016/j.ijrmhm.2018.12.009
Received 23 October 2018; Received in revised form 9 December 2018; Accepted 10 December 2018
Available online 12 December 2018
0263-4368/ © 2018 Elsevier Ltd. All rights reserved.
K. Kishore et al. International Journal of Refractory Metals & Hard Materials 79 (2019) 185–196

Table 1
Locking Pin Measurement of wear at different location.
Location Wear (in mm)

1 63
Hammer arm 2 39
3 22
4 0
5 38
6 50
7 69

Hammer Head
study of three different alloy system, namely, a high chromium cast iron
Fig. 1. Schematic of a flux crushing hammer.
with 20 wt% Cr- 1 wt% Mo, hard-facing of complex alloy carbides on
mild steel and hard-facing of tungsten carbide on mild steel.
Microstructural characterization of these systems was carried out using
scanning electron microscope coupled with electron probe micro-ana-
lyzer, x-ray diffraction and Vickers hardness tester. To understand the
effect of chemical composition, type of carbides and hardness on
abrasion resistance, dry sand/rubber wheel abrasion test as per ASTM:
G65–16 standard [5] was carried out. Specimens were prepared to di-
mension conforming 25 mm × 76 mm with 12.5 mm thickness. These
were ground to a surface roughness (Ra) of 1.1 ± 0.1 μm. Abrasion
tests were carried out at applied load of 13 kg, abrasive sand flow rate
of 683.5 g/min and for 30 min. These parameters were selected based
on the work of H. Durmus et al. [6]. Three tests were conducted for
each specimen. After tests, specimens were cleaned using acetone for
5 min and dried using compressed air. Samples were weighed prior to
Fig. 2. On-site image of a coal crushing mill. and after completion of the abrasion tests using weighing balance with
an accuracy of 0.001 g. Average value of volume loss along with stan-
dard deviation is reported for comparison and ranking of different al-
2. Experimental procedure
loys. It should be noted that, lower the volume loss, higher is the
abrasion resistance.
The first part of this paper presents failure analysis of the hammer
head whereas the second part consists of development of abrasion re-
sistant hammer heads for extended service life. Failure analysis is car- 3. Failure analysis of coal crushing hammer head
ried out using macroscopic observations, comparison of failed hammer
head with the unused one to determine the nature and extent of wear at 3.1. On-site and visual observations
different locations. It is proceeded by its chemical analysis using optical
emission spectroscopy and x-ray fluorescence spectroscopy. Fig. 2 shows on-site image of an interior of a coal crushing mill. A
Metallography samples were prepared using hot mounting followed by number of hammers are arranged in both series and parallel. The as-
polishing on silicon carbide and diamond polishing cloth to obtain sembly can rotate 360° about its axis, though for practical purposes it is
scratch free surface. Microstructural analysis was carried out using restricted to around 270°. As shown in the schematic of hammer in
optical microscope (Leica, DMR, Germany). Characterization of pre- Fig. 1, it can be seen that hammer heads and arms are fixed together
cipitate was done using scanning electron microscope coupled with with the help of locking pins. Lumpy coal fall from the top and are
electron probe micro-analyzer. crushed between hammer heads and wear resistant liner plates. This
After failure analysis, improvement phase consisted of detailed crushing action results in wear of hammer heads.

Fig. 3. Visual image of failed and new hammer heads: (a) overall view, (b) measurement of extent of wear at different locations: failed hammer head superimposed
over new hammer head.

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Table 2
Chemical analysis of failed and new hammer heads.
Sample C Mn S P Si Cr Ni Mo Cu V Ti

Failed 1.14 0.33 0.038 0.025 0.56 6.90 0.015 1.17 0.055 0.024 –
New 0.96 0.38 0.033 0.024 0.48 6.95 0.14 1.10 0.05 0.025 0.002

Fig. 4. Optical micrographs at 500×: (a) failed hammer head, (b) new hammer head.

Fig. 5. SEM-EPMA micrographs of existing 6Cre1Mo hammer heads: (a) micrograph showing tempered martensite and carbides, elemetal distribution of (b) Fe, (c)
Cr, (d) Mo, (e) Mn, (f) C.

Fig. 3 (a) shows visual image of failed and new hammer heads. As termed as predominantly abrasive wear. Fig. 3 (b) shows the method of
evident from the photograph, mode of failure is “wear”. Worn out quantifying the extent of wear in failed hammer head. Failed hammer
surface is highly smooth and symmetric about its center. There is no head was placed over the new one keeping their center at the same
material chip off. Based on visual observations, mode of failure can be position and the extent of wear was measured at different locations. It

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Table 3
Scheme of trial materials for hammer heads.
Trial Base material Hard-facing

1 High Chromium alloy –

2 Mild Steel Complex Alloy Carbides
3 Mild Steel Tungsten based alloy carbides

Fig. 6. Schematic of weld hard-facing process.

was observed that at the centre, there was no or minimal wear, whereas
the extent of wear increases on either side of it. Wear was found to be to periphery.
slightly more skewed towards the right side of the hammer head but the
nature of wear was similar on both side of the central axis. It is evident 3.4. Hardness measurements
that the extent of wear is quite severe as the maximum worn out region
corresponds to 69 mm and this results in inefficient crushing of raw Average hardness value of failed hammer head was measured to be
materials (see Table 1). around 51 HRC, whereas it was around 50.2 HRC for new hammer
head. Since the mode of failure is abrasive wear, a higher hardness is
3.2. Chemical analysis expected to increase wear resistance [10,11]. However, it should not
have an adverse affect on toughness, otherwise material may fail in
Chemical analysis of failed and new hammer heads are summarized brittle mode by chipping-off [12]. Micro-hardness values of matrix and
in Table 2. It is close to conventional 6 Cr-1 Moe1C material. These are carbide were measured to be 440 HV 0.1 and between 780 and 815 HV
generally supplied in quenched and tempered condition. However, for 0.1 respectively.
such a high stress wear application this grade might not be best suited.
3.5. Concluding remark on failure analysis of hammer heads
3.3. Microstructural analysis
Existing hammer heads failed in “abrasive wear” mode.
Fig. 4 shows optical micrographs of failed and new hammer heads. Metallurgical analysis revealed that these were made up of conven-
Their microstructure consists of tempered martensitic phase with car- tional 6 Cr-1 Moe1C steels and were used in quenched and tempered
bide precipitates. The volume percentage of primary carbides was condition. A lower wear resistance can be attributed to leaner chemistry
measured to be 7% and 3% in failed and new hammer heads respec- that resulted in lower volume fraction of carbides.
tively. Failed hammer head has coarser carbides compared to the new
hammer head. Such a small fraction of carbide is insufficient for wear 4. Alloy development for enhanced wear resistance of hammer
resistance for such an extreme application [7]. heads
SEM micrograph of the existing beater head is shown in Fig. 5 (a). It
consists of tempered martensite with fine distribution of precipitates. 4.1. Consideration for design and development of hammer heads
Distribution of different elements in the microstructure is shown in
Fig. 5. As indicated in Fig. 5 (b), matrix is rich in iron and at precipitates As discussed in Section 1, it is aimed at extending the service life of
iron concentration is relatively lower. In contrast, matrix is depleted in hammer heads from existing 2–3 months to around 1 year so as to
Cr whereas precipitates are chromium rich phase. Fine spherical pre- synchronize the life cycles of hammer arm and head. This would help to
cipitates have lower chromium content (23–27 wt%) compared to run the crushing mill for a year without any major interruption and
coarser precipitates (30–50 wt%). This suggests finer precipitates are then take a planned annual shut-down to replace the entire hammer at
Cr7C3 where as the coarser precipitates are Cr23C6 based on CreC phase once. This will undoubtedly have huge financial benefits for any mill.
diagrams [8,9]. Likewise, molybdenum is also depleted in matrix and Failure analysis presented in Section 3 provides the guideline and
preferentially present in chromium carbides. Fig. 5 (e) shows the pre- direction for designing hammer heads with targeted life cycle. Since the
sence of manganese sulphide inclusion in the area rich in Mn but de- mode of failure is rapid abrasive wear, all effort should be concentrated
pleted in Fe, Cr and C. It should be noted that there is segregation on enhancing the wear resistance but not at the expense of toughness as
within the precipitates with greater solute content at the core compared it would otherwise result in material chip off. There is a direct

Table 4
Detail of phases identified in different trials using XRD [18].
Phase Chemical Formula Crystal Structure Space Group Lattice parameters (Å) Lattice angles

α- ferrite Fe BCC I m −3 m a = b = c = 2.842 α = β = γ = 90°

Austenite Fe FCC F m −3 m a = b = c = 3.610 α = β = γ = 90°
Chromium Carbide (7/3) Cr7C3 Orthorhombic Pnma a = 4.526 α = β = γ = 90°
b = 7.010
c = 12.142
Chromium Carbide (3/1) Cr3C Orthorhombic Pnma a = 5.120 α = β = γ = 90°
b = 6.800
c = 4.580
Cementite Fe3C Orthorhombic Pnma a = 5.087 α = β = γ = 90°
b = 6.779
c = 4.526
Niobium Carbide NbC Cubic F m −3 m a = b = c = 4.430 α = β = γ = 90°
Molybdenum Niobium Carbide MoNbC2 Cubic F m −3 m a = b = c = 4.400 α = β = γ = 90°
Tungsten carbide WC Hexagonal P −6 m 2 a = b = 2.907 α = β = 90°
c = 2.837 γ = 120°
Iron Tungsten Carbide (3/3/1) Fe3W3C Cubic F d −3 m a = b = c = 11.060 α = β = γ = 90°

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Fig. 7. Visual images of trial samples: (a) Trial #2: Complex alloy carbide hardfacing over mild steel, and (b) Trial #3: Tungsten carbide hardfacing over mild steel.

Fig. 8. SEM micrographs of trial materials: High chromium alloy: (a) 1000×, (b) 4000×, Complex alloy carbides: (c) 1000×, (d) 4000×, tungsten carbide alloy: (e)
40×, (f) 4000×.

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Fig. 9. X-ray diffraction plots of three trials: (a) Trial #1 (high chromium cast alloy), (b) Trial #2 (hard-facing of complex alloy carbides), (c) Trial #3 (hard-facing of
tungsten carbide.

proportionality between hardness and abrasive wear resistance [13]. optimizing the composition. It is aimed to increase the volume per-
However, the steel with similar composition would not result in desired centage of carbide in a tougher matrix that can increase the abrasion
improvement in life cycle. This is because even if it is used in as resistance and at the same time prevent cracking.
quenched or in quenched and very low temperature tempered state to
yield higher hardness, it would be extremely brittle because of un-
tampered martensitic microstructure. Thus, the focus is shifted towards

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Fig. 10. SEM-EPMA micrographs of Trial #1 (High chromium cast alloy): (a) SEM micrograph, elemental distribution of (b) Fe, (c) Cr, (d) C, (e) Mn, (f) Mo.

4.2. Materials and manufacturing process 4.3. Microstructural analysis

Three different schemes of hammer heads are developed and their 4.3.1. Scanning electron microscopy
microstructure and wear properties are to be compared with the ex- Microstructure of Trial #1 (High Chromium cast alloy) shows the
isting 6 Cr-1 Moe1C hammer heads (see Table 3). Table 4 summarizes presence of elongated primary eutectic carbides (Ref. Fig. 8 a, b). Their
the detail of trial materials: l/d ratio varied between 8 and 13. In addition to these eutectic car-
First trial was made with volume hardened and tempered high bides, there is uniform distribution of fine secondary carbides having l/
chromium alloy. No additional hard-facing layer was provided since d ratio in the range of 1–2. These secondary carbides are known to
this alloy itself is considered to have superior wear resistance. Second enhance wear resistance of high chromium cast iron [14]. Phase frac-
and third trials were made using the concept that only top surface of the tion of primary and secondary carbides was calculated using image J
hammer head experiences severe wear and it should be hard and wear software and found to be 19% and 17% respectively. Microstructure of
resistant whereas the core (base metal) should be tough to withstand Trial #2 (hard-facing of complex alloy carbides) is shown in Fig. 8 (c, d)
impact loading. Low carbon mild steel was chosen as base material has a network of primary carbides and geometric alloy carbides. These
owing to its superior toughness and weldability. A wear resistant hard- sharp edges of geometric carbides indicates coherency which is desired
facing layer (weld overlay) was applied over mild steel using robotic for impeding the dislocation movement for improved strength [15].
controlled arc welding electrodes. In trial 2, complex alloy carbide is Phase fraction of these carbide networks and geometric carbides was
used as welding electrode whereas tungsten based alloy carbides is used calculated to be 46% and 9% respectively. Such a high percentage of
in case of trial 3. A schematic describing the process adopted for hard- carbide is expected to improve the wear resistance of the hammer head.
facing in case of trails 2 and 3 is shown in Fig. 6. Fig. 8 (e) shows the micrograph of Trial #3 (hard-facing of tungsten
Weld hardfacing process adopted in this study involves an oscil- based alloy carbides). Approximately 62% of the microstructure is oc-
lating welding head that consists of electrodes of desired composition. cupied by spherical carbides. Even in matrix, there are dendritic arms of
Conventional arc welding process is used. The movement of welding carbides as shown in Fig. 8 (f). No severe crack was observed in the
head is robotically controlled in different directions to get a uniform specimen indicating reasonably good toughness of the hard-facing.
deposit of weld overlay over mild steel. No buffer layer is needed owing Such a high fraction of carbides is desirable from point of view of wear
to excellent weldability of mild steel due to its low carbon equivalent. resistance.
Water jets are impinged on the opposite face of the mild steel plate to
achieve faster cooling rate and finer precipitates. Fig. 7 shows the visual 4.3.2. Phase identification using X-ray diffraction
images of hard-faced samples for trial #2 and trail #3. In Trial #1 (high chromium cast alloy), there is a matrix of austenite
and α-ferrite with Cr7C3 and Cr7C3 as the major carbide phases. XRD
analysis of Trial #2 (Hard-facing with complex alloy carbides) revealed

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Fig. 11. SEM-EPMA micrographs of Trial #2 (Complex alloy carbide hard-facing): (a) SEM micrograph, elemental distribution of (b) Fe, (c) Cr, (d) Nb, (e) Mo, (f) C.

five different alloy carbides in austenite and α-ferrite matrix. In addi- appearance and a diffused layer around its periphery. As anticipated,
tion to chromium carbides (Cr7C3 and Cr3C), niobium carbide (NbC), the brighter appearance of inner core is because of the presence of high
tungsten carbide (WC) and complex carbide of molybdenum and nio- concentration of higher atomic number tungsten therein as shown in
bium (MoNbC2) were detected. These refractory carbides are known to Fig. 12 (b). Furthermore, in outer diffused layer, there is a decrease in
have high hardness and is expected to improve the wear resistance of tungsten and carbon content with the simultaneous increase in iron
the alloy [16,17]. In Trial #3, strong peaks of tungsten carbide (WC) content. It should be noted that nickel is present with the spherical
and iron tungsten carbide (Fe3W3C) in austenite matrix were noted. particles of tungsten and acts as binder, where as manganese is present
Small peak of cementite was also present (see Fig. 9). as solid solution in austenite matrix. Based on stoichiometry and XRD
analysis, inner spherical core is determined to be WC (Tungsten car-
bide), outer core as Fe3W3C (Iron Tungsten Carbide) with austenite
4.3.3. Electron probe micro analysis
being the matrix phase. Within the austenite matrix, there is a variation
SEM micrograph of Trial #1 shows lamellar eutectic mixture of
of iron and tungsten content which prompted for further analysis.
chromium carbide and austenite in the microstructure. As evident from
Within the spherical particles, distribution of elements is shown in
elemental distribution of Cr and C, eutectic carbides is metastable Cr3C.
Fig. 13. It shows WC has triangular and rhombus shaped grains in the
These are accompanied by spheroidal carbides uniformly distributed in
size range of 1–3 μm. Although some of these grains are overlapping,
the matrix is identified to be Cr7C3. These observations corroborates
predominantly, these are seperated by nickel‑iron based filler material
with the XRD analysis in which Cr3C and Cr7C3 were identified. Mn and
which provides toughness to the hard-facing. Within the austenite
Mo are richer in secondary carbides compared to the matrix (see
matrix, there is significant gradient of concentration of iron and tung-
Figs. 10 and 11).
sten as revealed by their distribution in Fig. 14. It appears that during
SEM micrograph of Trial #2 shows bright geometric precipitates
solidification of molten pool of alloy, there is dilution of tungsten that
along with chain like connected precipitates. These are found to be
resulted in formation of alternate lamellar structure consisting of aus-
extremely niobium rich and iron depleted phase. Based on stoichio-
tenite and Fe3W3C (Iron Tungsten Carbide).
metry, it is determined to be cubic NbC precipitate. Additionally, there
are finer elongated precipitates identified to be Cr3C and Cr7C3 phases.
Moreover, there are fine carbides rich in both Nb and Mo and these are 4.4. Hardness measurements
MoNbC2. The presence of these refractory carbides are expected to
significantly improve the wear resistance of the hammer heads. Table 5 summarizes the hardness values of different trials. Clearly,
Fig. 12 (a) shows the distribution of spherical particles in the ma- there is an increase in hardness of Trial #1 compared to the existing
trix. These spherical particles have an inner core with brighter hammer head. Further improvement in hardness values was observed in

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Fig. 12. SEM-EPMA micrographs of Trial #3 (Tungsten carbide hard-facing): (a) SEM micrograph, elemental distribution of (b) Fe, (c) W, (d) C, (e) Ni, (f) Mn.

Fig. 13. SEM-EPMA micrographs of within the spherical particles in Trial #3 (Tungsten carbide hard-facing): (a) SEM micrograph, elemental distribution of (b) Fe,
(c) W, (d) Ni.

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Fig. 14. SEM-EPMA micrographs between the spherical particles in Trial #3 (Tungsten carbide hard-facing): (a) SEM micrograph, elemental distribution of (b) Fe, (c)
W, (d) Ni.

Table 5 case of Trial #2 and #3 owing to carbide type and their fraction. Micro-
Summary of rockwell hardness of diferent trials. hardness measurement showed tungsten carbide is the hardest phase
Location / Phase Hardness (HRC)
(> 1450 VHN). Hardness drop was observed in diffused spherical layer
(iron tungsten carbide) to around 1054 VHN. Indentation did not create
Trial #1 56.3 ± 1.3 any crack at the interface suggesting adequate toughness. Hardness of
Trial #2 62.3 ± 2.1 matrix of tungsten carbides hard-facing is measured to be around 475
Trial #3 68.7 ± 1.4
VHN. This is the resultant of austenite matrix and dispersed dendritic
carbides in it (see Table 6).
Table 6 In case of complex alloy carbides hard-facing, hardness of geometric
Summary of hardness of different phases. niobium rich carbide phase was measured to be in excess of 1335 VHN
and the matrix was having a hardness of 418 VHN. In contrast to ex-
Location / Phase Hadness (VHN 0.1)
tremely hard tunsgten carbide and niobium carbide, hardness of chro-
Tungsten carbide 1451 ± 21 mium carbide is relatively lower (around 800–900 VHN). In addition,
Iron tungsten carbide 1054 ± 17 matrix of high chromium cast alloy is softer (around 400 VHN) than
Matrix of tungsten carbide hard-facing 476 ± 29 than the matrices of hard-facing alloys.
Niobium carbides 1335 ± 31
Matrix of complex carbide hard-facing 418 ± 15
Chromium carbides 845 ± 53 4.5. Abrasion tests
Martix of high chromium cast alloy 397 ± 13
Although hardness values are good indicator of wear properties, to
gauge actual improvement in abrasion resistance of different trials with
120
respect to existing hammer head material, abrasion tests was carried
Equivalent Volume loss (mm3)

out. Abrasion volume loss followed the following trend: Existing

100
hammer head (6Cre1Mo steel) > Trial #1 (high chromium alloy
80 steel) > Trial #2 (Complex alloy carbides hard-facing) > Trial #3
(Tungsten carbides hard-facing). This confirms that tungsten carbide
60 hard-facing is most abrasion resistant among all trials. There is a re-
duction in abrasion volume loss by approximately 5.9 times in case of
40 Trial #3 compared to the existing hammer head. Compared to complex-
alloy carbides hard-facing, tungsten carbide-hard-facing shows a 1.62
20
times lower volume loss. This suggests that tungsten carbide hard-fa-
cing is expected to outperform its next nearest competitor (complex
0
Exisng Trial #1 Trial #2 Trial #3
alloy carbide hard-facing) by at least a factor of 1.5. (Fig. 15)
Sample Detail
5. Field trial
Fig. 15. Equivalent material volume loss of different samples in dry sand/
rubber wheel abrasion tests. Based on the promising microstructure, hardness values and high
abrasion reistance among the tested alloys, Trial#2 (Complex alloy
carbides hard-facing) and Trial #3 (Tungsten carbide hard-facing) were

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Fig. 16. On-site images of hammer heads used in trial: (a) during installation, (b) after 1 month of service life, (c) after 4 months of service life, (d) Trial #3 after
10 months of service life showing minimal damage to the hard-facing layer.

chosen for field trial in a coal crushing mill. Fig. 16(a) shows an in- presence of finer and harder alloy carbides like NbC, WC and
stallation image of the hammer head inside the coal crusher. Condition MoNbC2, in addition to chromium carbides namely Cr3C and
of the hammer head was regularly monitored (almost every month). Cr7C3. Presence of these carbides are confirmed by a combition of
Fig. 16 (b) shows the hammer heads after 1 month of service. It is EPMA and XRD techniques.
evident that wear has started from the edges in case of complex alloy (iv) Tungsten carbide hard-facing (Trial #3) showed highest abrasion
carbide hard-facing. In contrast, no significant wear occurred in tung- resistance. This is probably because of higher hardness of WC
sten carbide hard-facing. Condition of these hammer heads after (1450 HV) compared to NbC (1335 HV) and chromium carbides
4 months of service life is shown in Fig. 16 (c). It is clear that no pro- (800–910 HV). This has also resulted in higher bulk hardness of
nounced wear was observed in WC hard-facing, whereas wear has WC hard-facing (around 68–69 HRC) compared to other trials.
progressed from edges to the centre of hammer heads in case of com- Furthermore, the presence of spherical tungsten carbides is ex-
plex alloy carbide hard-facing. These hammer heads had to be even- pected to reduce the stress concentration and thus has lower cut-
tually replaced after 6 months of service life to maintain the efficiency ting or ploughing effect during abrasion test. In addition to WC,
of coal crushing. This manifests as 100% improvement compared to microstructure consitututed of iron tungsten carbide Fe3W3C en-
6Cre1Mo quenched and tempered hammer heads. WC hard-facing was circling WC and eutectic Fe3W3C in austenite matrix.
observed to be intact even after 10 months of service life. No significant (v) Based on microstructural and abrasion properties, Complex alloy
wear or chipping off of the hard-facing layer was observed. This means carbides (Trial #2) and WC hard-facing (Trial #3) over mild steel
an increase in service life to > 3 times that of the conventional substrate were chosen for field trial for coke crushing application.
6Cre1Mo hammer heads is achieved. In contrast to 3 months of service life obtained by existing hammer
head (6Cre1Mo steel), 6 months of service life was obtained using
6. Conclusion Trial #2. No significant degradation (wear or chipping off) of
tungsten carbide hard-facing was observed even after 10 months of
Based on overall studies, following conclusions are made: service life. This corroborates with the experimental results where
multi-fold improvement in wear resistance was achieved with
(i) Existing hammer heads fail prematurely in predominantly abrasive tungsten carbide hard-facing.
wear mode. This premature failure can be attributed to sub-op-
timal alloy design that resulted in lesser fraction of carbides Acknowledgement
(< 10% by volume) and thus lower hardness (50–51 HRC). Such a
combination of microstructure and hardness is manifested as Authors express their sincere gratitude to Tata Steel Limited,
higher material volume loss in abrasion tests and in service as well. Jamshedpur for allowing us to publish this work. Authors are thankful
(ii) Compared to existing hammer head material, high chromium cast to Mr. Brikesh Kumar for arranging for field trial and assisting in con-
alloy (Trial #1) had significantly higher fraction of carbides. These dition monitoring of hammers. Mrs. Samvedana and Ms. Ankita Roy is
were identified to be non-equilibrium Cr3C carbides and spherical acknowledged for their help in x-ray diffraction analysis of complex
Cr7C3 using EPMA and XRD analysis. This resulted in an increase in phases.
carbide fraction, higher hardness and an improvement in abrasion
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