Fibrous Monolith Wear Resistant Components for the Mining Industry

Abstract

The work performed on this program was to develop wear resistant, tough FM composite materials with efforts focused on WC-Co based FM systems. The materials were developed for use in mining industry wear applications. Components of interest were drill bit inserts for drilling blast holes. Other component applications investigated included wear plates for a variety of equipment such as pit shovels, wear surfaces for conveyors, milling media for ball milling operations, hydrocyclone cones, grader blades and dozer teeth. Cross-cutting technologies investigated included hot metal extrusion dies, drill bits for circuit board fabrication, cutting tools for cast iron and aluminum machining.An important part of the work was identification of the standard materials used in drilling applications. A materials trade study to determine those metals and ceramics used for mining applications provided guidance for the most important materials to be investigated. WC-Co and diamond combinations were shown to have the most desirable properties. Other considerations such as fabrication technique and the ability to consolidate shifted the focus away from diamond materials and toward WC-Co.Cooperating partners such as Kennametal and Kyocera assisted with supplies, evaluations of material systems, fabricated parts and suggestions for cross-cutting technology applications for FM architectures. Kennametal provided the raw materials (WC-Co and Al-TiCN powders) for the extent of the material evaluations. Kyocera shared their research into various FM systems and provided laboratory testing of fabricated materials. Kyocera also continued research of the FM systems with the intention of developing commercial markets for a variety of applications. The continued development of FM technology by Kyocera is seen as a direct result of the cooperation established under this funding. Kyocera has a specific interest in the commercial development of the FM technology and have licensed it and have paid for the right to develop FM materials for the commercial exploitation.Field testing provided by partners Superior Rock Bit and Brady Mining and Construction provided insight into the performance of the fabricated materials under actual operational conditions. Superior Rock Bit was permitted to evaluate tri-cone roller bits in drilling applications at a mine in the Iron Range of Minnesota. Brady performed evaluation of the roof bit inserts at coal mines in medium hardness strata. The coal mine used for testing was not revealed. Additional field testing of cross-cutting technology, the extrusion of hot metals, at Extruded Metals showed the potential for additional market development.While ACR was able to perform field testing in a number of mines, tunnel boring locations and at a hot metal extrusion house under this effort, limitations of material suppliers reduced our ability to take advantage of the offered facilities at mines in the southern Arizona region. Phelps Dodge mine at Green Valley Arizona provided equipment inserts to modify for evalua...