Crusher Carbide Hammer VS High Chrome Hammer For Abrasion Resistance, Which One Better

When comparing carbide crusher hammers (e.g., tungsten carbide, WC-based) and high chrome hammers (e.g., high chromium cast iron, 15-30% Cr) specifically for abrasion resistance, carbide hammers are generally superior. Here’s a focused analysis:

1. Material Properties Related to Abrasion Resistance

Carbide Hammers (WC-Based):
- Hardness: Tungsten carbide has an exceptional hardness of 1200-1400 HV (Vickers), far exceeding most materials. This is due to WC’s near-diamond-like structure.
- Abrasion Mechanism: WC resists wear from hard, abrasive particles (e.g., silica, quartz) because its hardness surpasses that of most abrasives encountered in crushing (e.g., silica’s hardness is ~1000 HV).
- Structure: Typically applied as hard-facing or inserts on a steel base, with a high volume fraction of WC particles (70-90%) in a cobalt binder.
High Chrome Hammers:
- Hardness: High chromium cast iron achieves 600-700 HV, thanks to hard chromium carbides (Cr₇C₃, ~1200 HV) embedded in a martensitic or austenitic matrix.
- Abrasion Mechanism: The Cr₇C₃ carbides provide good resistance to abrasion, but the softer matrix (300-500 HV) wears faster, reducing overall performance against highly abrasive materials.
- Structure: A homogeneous alloy with carbide particles distributed throughout, typically 20-35% carbide by volume.

2. Abrasion Resistance Comparison

Carbide (WC):
- Performance: WC’s extreme hardness ensures minimal material loss against abrasive particles. It excels in conditions with fine, hard abrasives like silica, sand, or coal ash.
- Lab Evidence: In ASTM G65 dry sand abrasion tests, WC-Co hard-facing typically shows mass loss of ~0.1 g, reflecting its superior resistance.
- Field Example: In coal crushing with 15% silica, WC hammers might last 9-12 months due to their ability to withstand continuous scratching and grinding.
High Chrome:
- Performance: The chromium carbides resist abrasion well, but the softer matrix erodes faster, exposing carbides that can then break away. It’s effective but less durable against extreme abrasives.
- Lab Evidence: In the same ASTM G65 test, high chrome might lose ~0.3-0.4 g of mass, 3-4 times more than WC.
- Field Example: In the same coal crushing scenario, high chrome hammers might last 4-6 months, wearing out quicker as the matrix degrades.

Crusher Carbide hammer- — **Crusher tungsten carbide hammer**

3. Key Factors in Abrasion Resistance

Hardness Differential: WC’s 1200-1400 HV outclasses high chrome’s 600-700 HV overall, and even Cr₇C₃ carbides (~1200 HV) are less effective due to lower volume fraction and matrix vulnerability.
Carbide Volume: WC hammers have a higher concentration of hard phases (70-90% vs. 20-35% in high chrome), providing a denser barrier against abrasive wear.
Binder/Matrix Effect: Cobalt in WC-Co (6-12%) is tougher than high chrome’s matrix, maintaining structural integrity longer under abrasive attack.

4. Practical Outcome

Carbide Wins: For pure abrasion resistance, carbide hammers outperform high chrome hammers significantly. They’re the better choice in highly abrasive environments, such as crushing coal with high silica content, quartz-rich ores, or sandstone, where scratching and grinding dominate wear.
High Chrome Limitation: While high chrome is abrasion-resistant, it’s less effective against extreme abrasives due to matrix wear, making it a secondary option in such conditions.

For abrasion resistance alone, carbide crusher hammers (WC-based) are better than high chrome hammers. Their superior hardness and higher carbide content make them more durable against abrasive materials, often achieving 2-3 times the lifespan in abrasive-heavy applications.

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