Especificaciones clave
- TiC Hardness
- 2,800–3,200 HV
- Rod Diameters
- 10–20 mm
- Carbide Volume Fraction
- 15–50% (application-tuned)
- Matrix Compatibility
- Mn14Cr2 – Mn22Cr2, alloy steels
- Bonding Type
- Metallurgical cast-in (true fusion bond)
- Wear Life Extension
- 2–4x vs. non-reinforced castings
- Applications
- Jaw plates, cone liners, gyratory concaves, HPGR studs
- Standards
- ASTM A128 (Mn matrix), ISO 513 (carbide classification)
TiC Insert Technology for Crusher Wear Parts
Titanium carbide (TiC) inserts are cylindrical rods of sintered TiC composite—typically 10 to 20 mm in diameter—that are metallurgically bonded into a manganese steel or alloy steel casting during the pouring process, forming a true fusion bond at the carbide-metal interface. The TiC phase, with a hardness of approximately 2,800–3,200 HV (significantly harder than the 1,200–1,600 HV range of alumina and ZTA ceramic inserts), creates localised zones of extreme abrasion resistance within a tough, impact-absorbing austenitic manganese matrix (Mn14Cr2 through Mn22Cr2 per ASTM A128). This dual-material structure allows TiC-reinforced wear parts to operate in conditions where conventional single-alloy castings—whether manganese steel at 200–550 BHN work-hardened or high-chrome white iron at 600–700 BHN—fail prematurely due to severe abrasive wear from hard, angular siliceous rock particles.
The technology works by distributing TiC rods in calculated patterns across the high-wear zones of a casting, with rod spacing and density engineered from field wear-profile data. As the surrounding manganese matrix material wears preferentially (being softer), the protruding TiC rods shield the adjacent matrix from direct abrasive contact, creating a self-protecting wear surface that progressively slows the overall wear rate as the rods become more exposed. The carbide volume fraction (CVF)—calculated as the proportion of TiC rod cross-sectional area to total wear-surface area—can be tuned from 15% to 50% depending on the balance of abrasion and impact in each application: higher CVF maximises abrasion resistance for grinding and fine-crushing duties, while lower CVF preserves matrix toughness for primary and secondary crushing applications where impact energy from large feed material must be absorbed without insert fracture. When correctly specified and matched to the application, TiC insert technology delivers 2–4 times the service life of equivalent non-reinforced castings in abrasion-dominated duties.
Key Features of TiC Insert Wear Parts
Metallurgical Bonding to Matrix
TiC rods are cast-in during the pouring stage, forming a true metallurgical bond with the manganese or alloy steel matrix. This eliminates the de-bonding and insert pull-out failures common with mechanically retained inserts.
Application-Specific Rod Placement
Insert patterns are designed using wear-profile mapping from field data. Rods are concentrated in high-abrasion zones and reduced or eliminated in areas subject to high-energy direct impact where the matrix must absorb shock.
Adjustable Carbide Volume Fraction
CVF is tuned from 15% to 50% depending on the balance of abrasion and impact in each application. Higher CVF maximises abrasion resistance; lower CVF preserves matrix toughness for impact tolerance.
Self-Protecting Wear Surface
As the softer matrix wears preferentially, TiC rods protrude slightly above the surface. The protruding rods deflect abrasive particles and shield the surrounding matrix, progressively slowing the overall wear rate.
Compatible with Mn14-Mn22 Matrix
TiC rods are compatible with standard austenitic manganese grades (Mn14Cr2 through Mn22Cr2) as well as alloy steel matrices. Matrix grade is selected to match the impact energy of the application.
Field-Proven Wear Life Gains
Documented performance data shows 2-4x wear life extension in appropriate applications. Gains are highest in medium-to-high abrasion duties with moderate impact, such as secondary and tertiary crushing of hard siliceous rock.
TiC Insert Configurations
TiC insert specification involves selecting the rod diameter, carbide volume fraction (CVF), and placement pattern to match the wear mechanism and impact energy of the target application. Larger rods with higher CVF suit pure abrasion duties; smaller rods at lower CVF are used where impact resistance must be preserved.
| Material | Dureza | Aplicación | Notas |
|---|---|---|---|
| TiC Rods 12mm / 25% CVF | 2800-3200 HV (TiC phase) | Jaw crusher fixed and swing jaw plates in hard abrasive rock (granite, basalt) | Balanced impact tolerance and abrasion resistance for primary crushing |
| TiC Rods 16mm / 35% CVF | 2800-3200 HV (TiC phase) | Cone crusher mantles and concaves in secondary and tertiary crushing | Medium-high CVF for abrasion-dominant wear with moderate impact |
| TiC Rods 20mm / 45% CVF | 2800-3200 HV (TiC phase) | Gyratory crusher concave segments and mantle lower sections in highly abrasive ore | High CVF for maximum abrasion resistance; lower impact tolerance |
| TiC Rods 10mm / 20% CVF | 2800-3200 HV (TiC phase) | HSI blow bars and impact plates in recycling and mixed-feed applications | Lower CVF preserves matrix toughness for high-impact duties |
| TiC Rods 16mm / 40% CVF (Zoned) | 2800-3200 HV (TiC phase) | HPGR stud linings and roller surfaces processing hard iron ore or clinker | Zoned placement: high CVF on wear face, no inserts at mounting interfaces |
TiC Rods 12mm / 25% CVF
TiC Rods 16mm / 35% CVF
TiC Rods 20mm / 45% CVF
TiC Rods 10mm / 20% CVF
TiC Rods 16mm / 40% CVF (Zoned)
Note: CVF percentages are calculated as the proportion of TiC rod cross-sectional area to the total wear-surface area. Actual configurations are finalised after review of site-specific wear data and impact conditions.
Evaluate TiC Inserts for Your Wear Application
Share your current wear part consumption, material type, and operating conditions. ATF engineering will assess whether TiC insert technology is suitable and provide a cost-per-tonne comparison.
Applications by Equipment Type
TiC insert technology is applicable across a wide range of comminution equipment. The primary requirement is that the wear mechanism is abrasion-dominant with moderate or controlled impact energy. The following equipment types and applications have demonstrated consistent performance gains with TiC-reinforced wear parts.
Jaw Crushers
- Fixed jaw plates for hard siliceous feeds (quartzite, granite, basalt)
- Swing jaw plates in secondary jaw crushing of pre-screened material
- Cheek plates in abrasive applications where side-wall wear limits plate life
Cone Crushers
- Mantles and concaves in secondary and tertiary crushing of hard abrasive rock
- Feed cone liners exposed to direct impingement abrasion
- Bowl liners in fine crushing applications with high circulating loads
Gyratory Crushers
- Concave ring segments in the lower parallel zone where abrasion dominates
- Mantle lower sections subject to grinding abrasion from compacted material
- Spider cap and arm liners in dusty, abrasive ore environments
HSI Impact Crushers
- Secondary and tertiary impact plates in clean aggregate operations
- Blow bars for abrasive natural stone (limited to moderate feed size)
- Side liners and housing protection in high-throughput secondary applications
HPGR / Roller Mills
- Roller stud linings for hard iron ore and clinker grinding
- Edge wear segments subject to combined abrasion and material slip
- Cheek plate inserts for reducing flanking wear on roller ends
Hammer Crushers / Mills
- Hammer faces in cement raw material crushing (limestone with silica inclusions)
- Grate bars subject to sliding abrasion from material passing through apertures
- Breaker plates in single-rotor hammer mills processing moderately abrasive feed
TiC Inserts Preguntas frecuentes
Encuentre respuestas a preguntas comunes sobre tic inserts materiales, selección, mantenimiento y pedidos. ¿No encuentra lo que busca?
Contactar a nuestro equipoHow does TiC insert technology differ from ceramic (alumina) inserts?
Can TiC inserts be used in all crusher wear parts?
What happens if a TiC rod fractures during operation?
How is carbide volume fraction (CVF) selected for a specific application?
Do TiC insert parts require different installation procedures?
What is the typical cost increase for TiC insert wear parts?
Related Innovation Pages
Ceramic Insert Technology
Alumina and zirconia-toughened ceramic inserts for crusher wear parts. Lower cost alternative to TiC in moderate abrasion applications.
Más informaciónManganese Steel Alloys
Austenitic manganese steel grades from Mn14 to Mn22. Matrix material selection for TiC-reinforced and standard crusher castings.
Más informaciónHigh-Chrome White Iron
High-chromium white iron alloys for maximum abrasion resistance in non-impact crushing and grinding applications.
Más informaciónContenido técnico revisado por el equipo de ingeniería de ATF | Especificaciones metalúrgicas verificadas según normas ASTM/ISO
Extend Wear Life with TiC Insert Technology
Provide your current wear part details and operating conditions. ATF engineering will assess TiC suitability and deliver a cost-per-tonne comparison against your current solution.
Contact ATF Engineering