Open Source Wear Resistant quit a new generation of high chrome cast ball, wear resistance increased by 30%.
“July 15, 2024, Jinan Haoyang Casting & Forging Co., Ltd, China” - Jinan Open Source Wear Resistant Materials Co., Ltd, a leading global manufacturer of abrasive media, announced today that its self-developed ”Multi-Gradient Quenching System IV (MGQS-IV) “ was officially put into mass production. This technological breakthrough elevates the wear resistance of high-chromium alloy cast balls to a whole new level, providing a more cost-effective solution for heavy wear industries such as mining and cement.
Core highlights of the technology upgrade
1. AI dynamic temperature-controlled quenching process
- Adopting machine learning algorithm to adjust the flow rate and temperature of quenching medium in real time, so that the difference in hardness of Ø20-150mm cast ball cores is narrowed from ≥8HRC in the traditional process to ≤3HRC.
- The surface hardness is stabilized to HRC 63-65, and the impact toughness is increased to 15J/cm² (according to ASTM E23 standard).
2. Nano tungsten carbide coating technology
- Forms a dense carbonized layer within 0.2mm depth of the cast ball surface, reducing the wear rate by 37% compared with the conventional process (based on BMW method lab test)
3. Whole process quality traceability system
- Each batch of steel balls is implanted with a laser QR code, which can be scanned by customers to obtain melting composition analysis reports, heat treatment curves and quality inspection videos.
Empirical data and customer feedback
CODELCO's 12-week test run at the El Teniente copper mine showed that:
- Ball consumption per ton of ore: reduced from 0.68kg to 0.45kg.
- Crushing rate: <0.15% (60% lower than original supplier)
- Overall cost: annual savings of over $1.2M in grinding media expenditure
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Market strategy and production capacity layout
1. Flexible production line: support customized production of Cr content 10%-30%, diameter Ø15-180mm, minimum order quantity down to 5 tons
2. Green Manufacturing: Waste heat recovery system reduces energy consumption by 22%, TÜV Rheinland Carbon Neutral Factory (Pilot) Certification
3. Global Service: Overseas warehouses in Johannesburg, South Africa and Lima, Peru are officially opened, and urgent orders are delivered within 72 hours.
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