XTC Crushing Tools Launches a New Generation of Composite-Reinforced Tungsten Carbide Plate
— Cast Substrate + Hardfacing Wear Layer + Carbide Studs, Solving the “Impact Resistance + Wear Resistance” Challenge
Recently, our company Products for Crushing &Mixing has made significant progress in its R&D project on wear pats for crushing equipment. The new generation of composite-reinforced crusher tooth plates has been successfully trial-produced and has entered the batch verification stage under real-world operating conditions. Specifically developed for high-impact, high-wear environments such as mining, metallurgy, building materials, and solid waste processing, this product utilizes a composite manufacturing technology combining a “high-toughness cast substrate + surface hardfacing wear layer + carbide stud reinforcement.” This achieves comprehensive improvements in impact resistance, wear resistance, and service life.
Substrate Material
The new product uses a high-strength, high-toughness alloy cast steel, achieving a tensile strength of ≥850 MPa, yield strength of ≥650 MPa, and impact toughness (AKV, room temperature) of ≥35 J/cm², with hardness is HB280–320. By optimizing the casting process and heat treatment, the internal density and overall load-bearing capacity have been significantly improved. This allows the tooth plate to maintain excellent stability under continuous impact from large ores, effectively reducing the risk of fracture, chipping, and spalling.
Wear Reinforcement
Using advanced automated hardfacing technology, a high-hardness wear-resistant layer is applied to the main wear areas of the tooth plate. The hardfacing layer achieves a hardness of HRC 58–63, a single-layer thickness of 4–8 mm, and a bond strength of ≥350 MPa, offering excellent resistance to abrasive wear and scouring. Laboratory abrasion tests show that the wear life of the hardfaced area is 2–3 times longer than that of conventional high-manganese steel tooth plates. Moreover, through post-weld stress relief and gradient transition design, the hardfacing layer remains resistant to spalling and cracking under high-impact loads.
Carbide Stud Reinforcement
At the critical crushing Tools areas, the company has innovatively applied brazed carbide stud reinforcement technology to upgrade the tooth tips. The studs are made of high-performance tungsten-cobalt cemented carbide, with a hardness of HRA 88–90, bending strength of ≥2200 MPa, and compressive strength of ≥4000 MPa. Using a high-strength brazing process, the studs are firmly bonded to the tooth plate body, significantly improving the cutting and crushing efficiency of the tooth tips and reducing rounding and dulling. In practical applications, the service life of the tooth tip area is expected to increase by more than three times.
Validation Results
Based on simulated operating conditions and preliminary field verification, the comprehensive service life of the new generation composite-reinforced tooth plate is 80%–200% longer than that of conventional cast steel tooth plates. The replacement interval for a single set of tooth plates is significantly extended, and equipment downtime for maintenance is reduced by over 30%. This effectively helps customers lower consumable costs per ton of ore and improve continuous equipment operation efficiency.
Commitment to Innovation
Going forward, we will continue to respond to customer needs in real-world operating conditions, advancing upgrades to our series of products including crusher tooth plates, toothed rollers, and wear-resistant liners. With higher product performance standards, more advanced manufacturing processes, and a better service system, we aim to help industry customers achieve efficient, safe, and stable production.