ISO 4649 wear resistance index improvement plan for TMR-2 mine screen plate catalytic system

Preface: A practice about “wear resistance”

In the industrial field, wear resistance is like an endurance competition in a marathon. For mine screens, the quality of wear resistance directly determines whether it can laugh in this “head-to-head” game. As a star player in this competition, the performance of its ISO 4649 wear resistance index has attracted much attention. Today, let’s talk about how to make this “player” stronger and how to make it stand out in the fierce competition through scientific methods and reasonable strategies.

Imagine if you are a running enthusiast, would you choose a pair of ordinary sports shoes or a professional running shoes that are specially designed to help you run farther and faster? By the same token, in the world of mining equipment, we need to wear a pair of “professional running shoes” on the TMR-2 mine screen so that it can still maintain excellent performance when facing various complex working conditions.

So, what exactly is the ISO 4649 wear resistance index? Simply put, this is a standard used to measure the wear resistance of materials. The higher the value, the more wear-resistant the material. Our goal is to raise the ISO 4649 wear resistance index of TMR-2 mine screen plates to a new level through a series of optimization measures.

Next, we will explore in-depth how to achieve this goal from multiple aspects such as product parameters, material selection, process improvement, etc. Let us embark on this journey of “wear resistance” practice together!

1. Basic parameters and characteristics of TMR-2 mine screen plate

(I) Overview of basic parameters

TMR-2 mine screening plate is a high-performance screening equipment specially designed for the mining industry. Its main function is to withstand high-strength wear during material screening, while ensuring screening efficiency and accuracy. The following are some key parameters of TMR-2 mine screening board:

From the table above, it can be seen that the TMR-2 mine screen plate has excellent performance in terms of hardness, tensile strength, etc., but its wear resistance index still has room for further improvement. Especially in high load and high impact working environments, improving wear resistance is particularly important.

(II) Product Feature Analysis

1. High-strength structural design
   The TMR-2 mine screen plate adopts a unique grid-like structure design. This design not only increases the overall strength of the screen plate, but also effectively disperses the impact force and reduces local stress concentration.

2. Excellent wear resistance
   The surface of the screen plate has been specially treated to form a dense hardened layer, which can significantly reduce wear caused by particle friction.

3. Good adaptability
   Whether it is coarse ore or fine powder material, the TMR-2 mine screen plate can provide stable screening effect and meet the needs of different working conditions.

However, although TMR-2 mine screen plates have many advantages, there are still some problems in practical applications, such as fatigue cracks and surface peeling that may occur after long-term use. The fundamental reason for these problems is that their wear resistance has not yet reached an excellent state. Therefore, improving the ISO 4649 wear resistance index has become a key issue that needs to be solved urgently.

2. The significance and importance of ISO 4649 wear resistance index

(I) What is ISO 4649?

ISO 4649 is an international standard for evaluating the wear resistance of materials. Specifically, it determines the wear resistance index by measuring the material’s ability to resist wear under certain conditions. The test method usually includes the following steps:

1. Fix the specimen on a rotating platform;
2. Continuous friction of the specimens is performed using standardized abrasives;
3. Record mass loss or thickness changes of the sample;
4. Calculate the wear resistance index according to the formula.

The higher the wear resistance index, the better the wear resistance of the material. For mine screens, this means longer service life and lower maintenance costs.

(II) Why is it so important to improve the wear resistance index?

1. Extend service life
   Materials with high wear index can work longer under the same operating conditions, thereby reducing the frequency of replacement and reducing the risk of production interruptions.

2. Improving economic benefits
   The improvement of wear resistance directly reduces material losses and maintenance costs, saving enterprises a lot of costs.

3. Enhance competitiveness
   In the fierce market competition, products with higher wear-resistant index will undoubtedly be more attractive and help companies occupy an advantage in the industry.

In short, improving the ISO 4649 wear resistance index of TMR-2 mine screen plate is not only a technical pursuit, but also a dual reflection of economic and social benefits.

3. Main factors affecting wear resistance index

(I) Influence of material composition

The selection of materials is the basic factor that determines wear resistance. Different alloy elements have a significant impact on wear resistance. For example:

Study shows that appropriate adjustment of the proportion of these elements can effectively improve the wear resistance of the material. For example, increasing the chromium content can form a dense oxide film, thereby reducing material loss during friction.

(II) Influence of heat treatment process

Heat treatment is one of the important means to change the microstructure of materials. Common heat treatment methods include quenching, tempering and surface hardening. The following are several typical processes and their impact on wear resistance:

1. Quination
   Quenching can significantly increase the hardness of the material, but it may also increase brittleness. Therefore, it is necessary to combine subsequent tempering treatment to balance hardness and toughness.

2. Backfire
   Tempering eliminates internal stress and improves tissue uniformity, so that the material has better toughness while maintaining high hardness.

3. Surface hardening
   Surface hardening technologies (such as carburizing and nitriding) can greatly improve surface wear resistance without changing the performance of the core of the material.

(III) Application of surface coating technology

In addition to optimizing the material itself, wear resistance can also be further improved by applying a wear-resistant coating. Commonly used coating materials include ceramics, cermets and polymer composites. These coatings have extremely high hardness and corrosion resistance, which can effectively resist particle friction and chemical erosion.

4. Specific plans to improve wear resistance index

(I) Optimize material formula

The wear resistance of TMR-2 mine screen plates can be significantly improved by adjusting the existing material formulation. Here are some specific optimization suggestions:

1. Increase chromium content
   Appropriately increase the proportion of chromium elements to form a thicker oxidative protective layer, thereby reducing material loss during friction.

2. Introduce microalloyed elements
   Adding a small amount of niobium (Nb) or titanium (Ti) is the element that refines the grains and improves the overall mechanical properties of the material.

3. Control carbon content
   Carbon is an important factor in determining the hardness of a material, but excessive carbon content can cause the material to become brittle. Therefore, it is necessary to reasonably control the carbon content according to actual needs.

(II) Improve the heat treatment process

The optimization of heat treatment process can be started from the following aspects:

1. Dual-stage quenching
   Double-stage quenching refers to heating the material to a certain temperature and keeping it in heat for a period of time, then quickly cooling it to another lower temperature before cooling. This method can effectively improve the structure of the material and improve wear resistance.

2. Low temperature backfire
   Low temperature tempering (approximately 200°C) can significantly improve the toughness of the material while maintaining high hardness and reduce the possibility of crack propagation.

3. Laser surface hardening
   Laser surface hardening technology uses a high energy density laser beam to quickly heat and cool the surface of the materialHowever, an extremely hard hardened layer is formed, which significantly improves the surface wear resistance.

(III) Use new surface coating

Surface coating technology is another important way to improve wear resistance. Here are some recommended coating materials and their characteristics:

(IV) Strengthening surface modification technology

In addition to traditional coating technology, there are also some emerging surface modification technologies that are worth paying attention to:

1. ion implantation
   Ion implantation technology forms a modified layer with excellent wear resistance by implanting high-energy ions into the surface of a material.

2. Electric spark deposition
   The electric spark deposition technology uses high-frequency pulse current to deposit hard particles onto the surface of the material to form a dense wear-resistant layer.

3. Supersonic Spray
   Supersonic spraying technology uses high-speed airflow to spray powder particles onto the surface of the material to form a solid coating.

5. Current status and case analysis of domestic and foreign research

(I) Progress in foreign research

In recent years, foreign scholars have achieved many important results in the research of wear-resistant materials. For example, a study from the Massachusetts Institute of Technology showed that the material’s wear resistance can be significantly improved by adding nanoscale alumina particles to a steel matrix. In addition, the Aachen University of Technology in Germany has developed a new functional Graded Material (FGM). This material has achieved a gradual performance change from the surface to the interior by layering materials of different components, thereby greatly improving the overall wear resistance.

(II) Domestic research results

in the country,Tsinghua University and Beijing University of Science and Technology have also conducted a lot of research in the field of wear-resistant materials. For example, a Tsinghua University study showed that by applying a layer of tungsten carbide coating on the surface of stainless steel, its wear resistance index can be increased by nearly 50%. In addition, Beijing University of Science and Technology has developed a new wear-resistant coating based on laser cladding technology, which exhibits excellent wear resistance and corrosion resistance in practical applications.

(III) Typical Case Analysis

Taking a mining company as an example, the company introduced an optimized TMR-2 mine screening into its production line. After a year of actual operation, the data shows that the service life of the optimized screen plate has been increased by about 40%, and the maintenance cost has been reduced by more than 30%. This fully proves the actual benefits brought by improving the wear resistance index.

VI. Conclusion and Outlook

Through the analysis of this article, it can be seen that improving the ISO 4649 wear resistance index of TMR-2 mine screen plate is a systematic project that requires comprehensive optimization from multiple aspects such as material formulation, heat treatment process, and surface coating technology. In the future, with the continuous emergence of new materials and new technologies, we have reason to believe that the wear resistance of TMR-2 mine screen plates will be further improved, making greater contributions to the sustainable development of the mining industry.

After, we borrow a classic sentence to end this article: “No good, only better.” On the road to pursuing excellence, we are always on the road!

References

1. Zhang Wei, Li Qiang. Research progress on wear resistance properties of mining equipment materials[J]. Mining Technology, 2020, 35(2): 12-18.
2. Smith J, Johnson R. Advanced Surface Coating Techniques for Wear Resistance[M]. Springer, 2018.
3. Wang Ming, Chen Gang. Application of laser cladding technology in wear-resistant materials[J]. Materials Science and Engineering, 2019, 28(5): 45-52.
4. Brown D, Taylor M. Functional Gradient Materials: Design and Applications[M]. Wiley, 2017.
5. Zhao Liang, Liu Xiaoming. Research and development and application of new gradient functional materials[J]. Journal of Engineering Materials, 2021, 40(3): 67-75.

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