Hammers Martillos

Jorge Garduo
Jorge.garduno@ssab.com
Wood = HARDOX ++
Wood? Yes, if cold application.
No, if heat create more than 200 degrees celcius.

Metal = HARDOX - +
Metal? Yes, if refridgerator, cars etc (Soft) No, if solid shafts.

Stone = HARDOX + (Limestone ++)

Hardox is most suitable for mid size and smaller stones

Waste = HARDOX +
Waste? Yes, PH value between 5-9.
No, if more acid or more basic. (Stress corosion)

Competing material:
Manganeese steel =Cheap and hard after impact
Ni-hard =Expensive and hard (650 HB)
Cast iron =Cheap
Hardness reduction due to tempering
Surface Hardness vs. Tempering temperature

650
Above 200C to HARDOX
600
250C HARDOX 600
HARDOX
starts losing 500
550
hardness! Surface Hardness (HBW)

500

450

400

350

300

250
100 150 200 250 300 350 400 450
Tempering temperature (C)
Metal scrap processing
Sucessful trial:

-The sandwich hammer made by Hardox 500 tested in scrap processing

-There is 16 hammers (120x515x569), netto weight 167 kg as one set.

Previos life time for hammers measured in

scrap volumes:
S690Ql 1600 tons
Hardox 400 2500 tons
Original 12%Mn steel 7000 tons
New adwance 12%Mn steel 9700 tons
Hardox 500 (sandwich) 14500 tons

4
5
 Lime stone hammers
Steelgrade
Hardox 500
Thickness range
30 to 60 mm
Industry segment
Cement
Type of application
Chrusher
Description of the application
Hammers for hammer crusher in
cement mill.
Previous material
12% Mn steel
Service life
Ca 3 months
Competitive advantage
Availability of plate
Volume
82 pcs, 60x220x320 mm, for one set
Manufacturing steps
Cutting method - Gas cutting;
Machining -
Status
Success
Reason for failure or success
Roughly the same lifetime as 12%
Mn steel, better availibility.
Comments
Cutting and machining represents
ca 30 % of total price

6
Hardox 600 hammer
Thickness range 30 to 60 mm

Industry segment Ceramic

Description of the application

Hammer made in Hardox 600
40mm replacing cast iron

Previous material
cast iron

Service life
two times longer than before

Competitive advantage
Service life

Manufacturing steps
Cutting method - Waterjet cutting

Status Success

Reason for failure or success

Hardness-Longer live. Uniform
wear to predict service live

7
 Shredders

Different types
Low speed high torque
High speed
Crushing by hammers
Shredding by flails
Shredding by teeth

Recommended material:
HARDOX 500 and above
 Wear - Hammer

Hammers in shredders in general require hardness

close to the edge. Thus choosing the right cutting
method is of importance.

Both gliding and impact wear

Impact direction
 Wear contra Cutting

Real example:
Replacement are needed after 15 mm of wear

Pay attention to the axel connection

450 mm
15 mm

150 mm
Scredders for wood and plastic recycling
Hardox 600 6-10mm
Segment: recycling
Status: Sucess
Manufacturing: water jet gives a longer service lift
Prevoiusly mild steel
 New hammer concepts!

- Rotatable hammer head

- Rotate hammerhead 4 times

before replacement.

- Material option in the shank

- Easy to assembly

- Better yield for cutted plates

 New hammer concepts

-Concepts with good functionality for sandwich design or thick plates

Approx 240 mm
Ni-hard concept today
-Used in a stone crusher
Original solid rotor hammer 16% Mn casting
Used in an open pit mine crushing stone to gravel
- Total weight 380 kg
-Weight exposed to wear is 80 kg
Original life time is100-120h

Original hammer made by 12%

Carbon-Mn steel
Weight: 90kg
Abrasive: Limestone in a cement plant
Real life-time: 2 months
500
450
400
350
300
HV2
250
200
150
Upgrade step 1. Solid rotor hammer made by Hardox 400
New life time is 400h with some hard facing maintanance. Avstnd [mm]
-Sucess story from Turkey
The SSAB hardness measurement shows that the hammer effect
is reaching a hardness of maximum 500 HB

14
Hammer in 150 mm HARDOX 600 recycling of railway sleepers
Field study 1hammers in HARDOX 550

Field study at an incinerator

plant processing 200 000
ton waste per year.

In their crusher they

previously used 75 tonnes
of cast manganese steel
hammers per year.
Conclusions Field study

ADVANTAGES : HARDOX 550 vs. Manganese steels

HARDOX 550 hammers were harder and had longer service life than Mn hammers.
HARDOX 550 hammers were hard from the beginning.
The wear on HARDOX 550 was much less severe on the sides of the hammer,
important for the cutting function.
Less storage costs and less lead time due to local manufacturing.
Less problems with health risks during cutting or repairing.
All hammers had the same weight, no balancing of the machine was needed.
Homogenous material, no material separations due to casting defects.
Possibility to use twin hammers.
The twin hammers could be shifted in order to increase the service life.
The maintenance organisation appreciate one type of wear material in different
applications.
The design of the hammers could be modified depending on the processed material.
The design of the hammers could be modified to give longer service life.
Field study Economical result

Costs:
Material
Cutting
Grinding
+ Welding
Totally <200 each.
..which is less then the cast
alternative.

The maintenance cost was reduced by 100 000 per year.

The availability of each crusher increased by 6.5 %.
The crushing process was improved.
Hammers made out of plates

The design is easily

modified
Homogeneous
mechanical properties
Constant weight
Always available
Lamellar hammer design

Tougher material
Fracture arrest
Assembling

Weld configuration
Austenitic electrodes
limits preheating
Optimal performance

Be observant on the hammer shaft.

Grind notches and scale off the
shaft opening of the hammer.

To reach optimal hardness;

Use cutting under water or
abrasive water jet.
Always use cutting speed and
sequences according to the
HARDOX cutting
recommendations.
Field study 2- waste incinerator plant
Original Casting hammer:
Size of the hammers: 417 x 330 x 100 mm (casting)
Number of hammers: 14
Weight: 64 Kg /hammer.

Hardox 550 in 50 mm:

Size: the same as casting hammers
Number of hammers: 28. The double pair hammers are not joined together
Production: oxy cutting under water and mechanizing 15 mm the side of the hammer

Comparing casting hammers with Hardox 550 twin hammers, the cost is a 12,6 % more/set
but the service life is 40 % higher. The customer save a lot of money.