High-manganese steel impact plates (represented by ZGMn13), thanks to the unique properties imparted by the hydro-toughening process, have become core wear-resistant components in equipment used to crush hard rock (such as granite, basalt, and iron ore). Their impact and wear resistance directly doubles their service life. The following provides a detailed analysis of the material properties, process principles, performance advantages, and application value:
I. Core Foundation: The "Performance Binding" of ZGMn13 High-Manganese Steel and Hydro-Toughening
ZGMn13 is a typical austenitic high-manganese steel with a carbon content of 1.0%-1.4% and a manganese content of 11%-14%. This high carbon and manganese ratio is a prerequisite for its impact and wear resistance, but hydro-toughening (solution treatment followed by water quenching) is required to activate these properties.
Hydraulic Toughening Process Principle:
ZGMn13 castings are heated to 1050-1100°C and held for a sufficient period (usually 2-4 hours) to allow the carbides (such as The Fe₃C and Mn₃C) are completely dissolved into the austenite matrix, forming a uniform single-phase austenite structure. The steel is then rapidly cooled in water (water quenching) to inhibit carbide precipitation during the cooling process.
Performance changes after treatment:
Untreated ZGMn13: Carbides are distributed in a network or blocky pattern at the grain boundaries, making the material brittle (hardness approximately 200 HB), easily fractured by impact, and exhibiting poor wear resistance.
After water quenching: A pure austenite structure is obtained, with hardness reduced to 180-220 HB and toughness significantly improved (impact toughness αk ≥ 150 J/cm²). It also exhibits "work hardening" properties—the core mechanism of its impact and wear resistance.
II. Key Performance Advantages: Dual-Core "Impact Resistance + Wear Resistance" for Hard Rock Crushing
During the hard rock crushing process, impact plates must withstand high-frequency, high-energy rock impacts (impact forces reaching thousands of Newtons), as well as sliding friction and compressive wear from the rock. The water-toughened ZGMn13's performance precisely matches this operating condition:
Impact Resistance: "Toughness for Impact Resistance, Preventing Fracture"
The water-toughened single-phase austenite structure is extremely tough, absorbing the energy generated by hard rock impacts without cracking or breaking. Compared to ordinary wear-resistant steels (such as NM450), ZGMn13's impact toughness is 3-5 times greater, enabling it to withstand the "instantaneous impact loads" of hard rock crushing, preventing premature failure of the impact plate, such as edge collapse and cracking. Wear Resistance: "Work Hardening + Dynamic Wear Resistance"
ZGMn13's wear resistance doesn't rely on its initial high hardness, but rather on the "work hardening effect under impact load."
When hard rock impacts or squeezes the impact plate surface, the austenite matrix undergoes plastic deformation, and carbon atoms aggregate at dislocations to form martensite and carbides. The surface hardness rapidly increases from 200HB to 500-800HB, creating a tough, wear-resistant surface layer.
After the surface layer wears away, the unhardened austenite matrix beneath remains exposed, hardening again during subsequent impacts, achieving "dynamic wear resistance." This "hardening with use" property perfectly adapts to the "impact-wear cycle" of hard rock crushing, avoiding the shortcomings of ordinary steels: fixed hardness and irreversible wear. Synergistic Impact and Wear Resistance: Avoiding "Single Performance Weakness"
In hard rock crushing, "purely hard and brittle materials" (such as high-chromium cast iron) have high initial hardness but poor impact resistance and are prone to cracking. "Purely tough materials" (such as ordinary carbon steel) resist impact but have low hardness and are prone to wear and failure. ZGMn13, through water-toughening treatment, achieves a combination of "tough matrix + dynamically hardened surface layer," achieving both impact and wear resistance, resolving the contradiction between "hard but brittle, tough but soft."
III. Application Value: The Core Logic of "Double the Lifespan" in Hard Rock Crushing
In hard rock crushing equipment (such as impact crushers and hammer crushers), the "doubling of the lifespan" of the ZGMn13 water-toughened impact plate is not an exaggeration; it demonstrates performance advantages based on actual operating conditions:
Reducing premature failure and extending effective service life
Ordinary wear-resistant steel (such as Q355 with a welded wear layer) is prone to fracture due to insufficient impact resistance under hard rock impact (typically a failure period of 1-2 months). The ZGMn13 impact plate, with its high toughness, avoids this premature failure. Furthermore, the work-hardening effect slows wear, resulting in an effective service life of 3-6 months, effectively doubling its lifespan.
Reduced O&M costs and improved equipment efficiency.
Reduced replacement frequency: Doubling the lifespan means 50% fewer impact plate replacements, reducing downtime for disassembly and assembly (each replacement requires 4-8 hours), and improving equipment efficiency.
Reduced spare parts consumption: No need to frequently purchase and stockpile spare parts, reducing inventory and procurement costs.
Suitable for high-load crushing: Maintains stable performance even when crushing high-hardness basalt and granite (Mohs hardness > 7), avoiding problems such as substandard crushed product particle size and production interruptions caused by component failure.
IV. Usage Precautions: Ensure full performance
Must match "impact load conditions"
Work hardening of ZGMn13 requires sufficient impact energy (generally requiring an impact stress ≥ 200 MPa). If used for crushing soft rock (such as limestone) or low-impact conditions, the hardening effect is insufficient and wear resistance is significantly reduced. In these cases, high-chromium cast iron is more economical. Avoid use in low-temperature environments.
Water-toughened ZGMn13 steel is susceptible to "austenite low-temperature embrittlement" below -40°C, resulting in a sharp drop in impact toughness. Therefore, it is unsuitable for outdoor crushing equipment in cold regions. (High-manganese steel with improved low-temperature toughness, such as ZGMn13Cr2, should be used.)
Control the particle size of the crushed material.
Although it has strong impact resistance, it should be avoided from direct impact with oversized hard rock (such as boulders larger than the feed opening) to prevent localized excessive deformation or matrix damage, which would affect the overall lifespan.
In summary, the ZGMn13 water-toughened high-manganese steel impact plate, through the combination of "water-toughening to activate toughness + work-hardening to enhance wear resistance," precisely addresses the dual requirements of "impact resistance" and "wear resistance" in hard rock crushing, ultimately doubling its lifespan. It is a core and preferred component for hard rock crushing in industries such as mining, building materials, and metallurgy.
High-manganese steel impact plates (represented by ZGMn13), thanks to the unique properties imparted by the hydro-toughening process, have become core wear-resistant components in equipment used to crush hard rock (such as granite, basalt, and iron ore). Their impact and wear resistance directly doubles their service life. The following provides a detailed analysis of the material properties, process principles, performance advantages, and application value:
I. Core Foundation: The "Performance Binding" of ZGMn13 High-Manganese Steel and Hydro-Toughening
ZGMn13 is a typical austenitic high-manganese steel with a carbon content of 1.0%-1.4% and a manganese content of 11%-14%. This high carbon and manganese ratio is a prerequisite for its impact and wear resistance, but hydro-toughening (solution treatment followed by water quenching) is required to activate these properties.
Hydraulic Toughening Process Principle:
ZGMn13 castings are heated to 1050-1100°C and held for a sufficient period (usually 2-4 hours) to allow the carbides (such as The Fe₃C and Mn₃C) are completely dissolved into the austenite matrix, forming a uniform single-phase austenite structure. The steel is then rapidly cooled in water (water quenching) to inhibit carbide precipitation during the cooling process.
Performance changes after treatment:
Untreated ZGMn13: Carbides are distributed in a network or blocky pattern at the grain boundaries, making the material brittle (hardness approximately 200 HB), easily fractured by impact, and exhibiting poor wear resistance.
After water quenching: A pure austenite structure is obtained, with hardness reduced to 180-220 HB and toughness significantly improved (impact toughness αk ≥ 150 J/cm²). It also exhibits "work hardening" properties—the core mechanism of its impact and wear resistance.
II. Key Performance Advantages: Dual-Core "Impact Resistance + Wear Resistance" for Hard Rock Crushing
During the hard rock crushing process, impact plates must withstand high-frequency, high-energy rock impacts (impact forces reaching thousands of Newtons), as well as sliding friction and compressive wear from the rock. The water-toughened ZGMn13's performance precisely matches this operating condition:
Impact Resistance: "Toughness for Impact Resistance, Preventing Fracture"
The water-toughened single-phase austenite structure is extremely tough, absorbing the energy generated by hard rock impacts without cracking or breaking. Compared to ordinary wear-resistant steels (such as NM450), ZGMn13's impact toughness is 3-5 times greater, enabling it to withstand the "instantaneous impact loads" of hard rock crushing, preventing premature failure of the impact plate, such as edge collapse and cracking. Wear Resistance: "Work Hardening + Dynamic Wear Resistance"
ZGMn13's wear resistance doesn't rely on its initial high hardness, but rather on the "work hardening effect under impact load."
When hard rock impacts or squeezes the impact plate surface, the austenite matrix undergoes plastic deformation, and carbon atoms aggregate at dislocations to form martensite and carbides. The surface hardness rapidly increases from 200HB to 500-800HB, creating a tough, wear-resistant surface layer.
After the surface layer wears away, the unhardened austenite matrix beneath remains exposed, hardening again during subsequent impacts, achieving "dynamic wear resistance." This "hardening with use" property perfectly adapts to the "impact-wear cycle" of hard rock crushing, avoiding the shortcomings of ordinary steels: fixed hardness and irreversible wear. Synergistic Impact and Wear Resistance: Avoiding "Single Performance Weakness"
In hard rock crushing, "purely hard and brittle materials" (such as high-chromium cast iron) have high initial hardness but poor impact resistance and are prone to cracking. "Purely tough materials" (such as ordinary carbon steel) resist impact but have low hardness and are prone to wear and failure. ZGMn13, through water-toughening treatment, achieves a combination of "tough matrix + dynamically hardened surface layer," achieving both impact and wear resistance, resolving the contradiction between "hard but brittle, tough but soft."
III. Application Value: The Core Logic of "Double the Lifespan" in Hard Rock Crushing
In hard rock crushing equipment (such as impact crushers and hammer crushers), the "doubling of the lifespan" of the ZGMn13 water-toughened impact plate is not an exaggeration; it demonstrates performance advantages based on actual operating conditions:
Reducing premature failure and extending effective service life
Ordinary wear-resistant steel (such as Q355 with a welded wear layer) is prone to fracture due to insufficient impact resistance under hard rock impact (typically a failure period of 1-2 months). The ZGMn13 impact plate, with its high toughness, avoids this premature failure. Furthermore, the work-hardening effect slows wear, resulting in an effective service life of 3-6 months, effectively doubling its lifespan.
Reduced O&M costs and improved equipment efficiency.
Reduced replacement frequency: Doubling the lifespan means 50% fewer impact plate replacements, reducing downtime for disassembly and assembly (each replacement requires 4-8 hours), and improving equipment efficiency.
Reduced spare parts consumption: No need to frequently purchase and stockpile spare parts, reducing inventory and procurement costs.
Suitable for high-load crushing: Maintains stable performance even when crushing high-hardness basalt and granite (Mohs hardness > 7), avoiding problems such as substandard crushed product particle size and production interruptions caused by component failure.
IV. Usage Precautions: Ensure full performance
Must match "impact load conditions"
Work hardening of ZGMn13 requires sufficient impact energy (generally requiring an impact stress ≥ 200 MPa). If used for crushing soft rock (such as limestone) or low-impact conditions, the hardening effect is insufficient and wear resistance is significantly reduced. In these cases, high-chromium cast iron is more economical. Avoid use in low-temperature environments.
Water-toughened ZGMn13 steel is susceptible to "austenite low-temperature embrittlement" below -40°C, resulting in a sharp drop in impact toughness. Therefore, it is unsuitable for outdoor crushing equipment in cold regions. (High-manganese steel with improved low-temperature toughness, such as ZGMn13Cr2, should be used.)
Control the particle size of the crushed material.
Although it has strong impact resistance, it should be avoided from direct impact with oversized hard rock (such as boulders larger than the feed opening) to prevent localized excessive deformation or matrix damage, which would affect the overall lifespan.
In summary, the ZGMn13 water-toughened high-manganese steel impact plate, through the combination of "water-toughening to activate toughness + work-hardening to enhance wear resistance," precisely addresses the dual requirements of "impact resistance" and "wear resistance" in hard rock crushing, ultimately doubling its lifespan. It is a core and preferred component for hard rock crushing in industries such as mining, building materials, and metallurgy.
