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High Wear Ball Mill Shell Liners
,Alloy Steel Mining Mill Liner
,Tough Discharge End Liner
High wear resistance and toughness alloy steel wave type mill liners
Product Description:
Wave Type Mill Liners are high-wear resistance liners designed for the mineral processing and cement industries. Featuring a wave-shaped cross-section, they provide higher lift efficiency and more uniform grinding in equipment such as ball mills and rod mills. Compared with traditional flat liners, Wave Type Mill Liners significantly improve grinding efficiency, reduce wear, and extend replacement intervals, helping mining operations achieve lower operating costs and a steadier production pace.
Material Introduction:
| Material Type | Hardness Range | Key Advantages | Typical Applications / Working Conditions |
|---|---|---|---|
| High Manganese Steel | 240–500+ BHN (work hardening) | Excellent work-hardening capacity and good toughness | Strong impact, coarse grinding in large‑diameter mills |
| Ultra‑High Manganese Steel | Higher (10%+ increase over standard high manganese steel) | Good toughness + significantly improved wear resistance | Mining grinding, large‑diameter ball mills |
| Chromium‑Molybdenum Alloy Steel | HRC 48–60 | Excellent balance of hardness and toughness | Power plants, mining ball mills, and crusher jaw plates |
| High‑Carbon Multi‑Alloy Steel | Uniform hardness across section | Good heat resistance and cost‑effectiveness | Severe abrasive wear, boltless liners |
| Medium‑Carbon Multi‑Alloy Steel | HRC 50–57 | Wear resistance comparable to high‑chromium cast iron, toughness far superior | Liners and diaphragm plates for medium/large ball mills |
| Low‑Carbon Multi‑Alloy Steel | HRC 45–50 | Excellent wear resistance in wet conditions, low cost | Mining wet ball mills |
Ball Mill Liner Casting Methods: Sand Casting vs. Lost Foam Casting
1. Sand Casting for Ball Mill Liners – The Industry Standard
Sand casting is the most widely used method for manufacturing heavy-duty mill liners, especially for large mills in mining and cement plants. It offers unmatched flexibility for producing liners weighing from a few hundred kilograms up to 20+ tons.
How It Works
- A pattern (wood or metal) is used to create a cavity in resin-bonded or sodium silicate-bonded sand.
- Molten alloy (e.g., high manganese steel, Cr-Mo alloy steel) is poured into the mould.
- After solidification, the sand mould is broken, and the casting is cleaned and heat-treated.
Key Advantages for Liners
- High integrity: Resin sand casting achieves a density of ≥98%, minimizing internal porosity.
- Cost-effective for large sizes: Tooling costs are low, making it ideal for one-off or small-batch production of oversized liners.
- Versatile alloy compatibility: Works with all liner materials – from Mn13 to ultra-high manganese and multi-alloy steels.
- Proven reliability: Decades of use in the mining industry guarantee consistent results.
Typical Applications
- Large-diameter ball mills (SAG/AG mills)
- Coarse grinding chamber liners
- Heavy-section lifter bars and shell plates
2. Lost Foam Casting – Precision for Complex Shapes
Lost foam casting (also known as evaporative pattern casting) is a modern precision method that excels in producing intricate liner designs with superior surface finish and dimensional accuracy.
How It Works
- A polystyrene (EPS) foam pattern, identical to the final liner shape, is coated with refractory paint and buried in dry sand.
- Molten metal is poured directly onto the foam; the heat vaporizes the foam and the metal fills the cavity.
- The process is carried out under vacuum to improve metal flow and eliminate gas defects.
Key Advantages for Liners
- Excellent surface finish (Ra 6.3–12.5 µm) – reduces or eliminates machining.
- Tighter dimensional tolerances (CT8–CT10) – ensures consistent fit and bolt-hole alignment.
- No flash or parting lines – minimizes stress risers that could lead to cracking.
- Ideal for bimetal composite liners – allows sequential pouring of wear layer and tough core in one mould.
- Reduced weight and material usage – precise cores and thin sections are achievable.
Typical Applications
- Wave-shaped or stepped liners with complex profiles
- Liners for medium-sized ball mills (3–15 tons per piece)
- High-alloy liners requiring minimal post-casting processing
Comparison Table: Sand Casting vs. Lost Foam Casting
| Feature | Sand Casting | Lost Foam Casting |
|---|---|---|
| Typical liner weight | 0.5 – 20+ tons | 1 – 15 tons |
| Dimensional accuracy | CT10–C T12 | CT8–CT10 |
| Surface roughness | Ra 25–50 µm | Ra 6.3–12.5 µm |
| Tooling cost | Low | Moderate to high |
| Production speed | Faster for large runs | Faster for complex shapes (no core assembly) |
| Alloy suitability | All types | All types, especially high-Cr and Mn steels |
| Defect risk | Porosity, sand inclusion (if not controlled) | Gas defects (well-controlled under vacuum) |
| Best for | Heavy, simple, or low-volume liners | Complex, high-precision, or medium-volume liners |
Product Package
Steel Pallet, Wooden Pallet
Product Inspection
We follow strict inspection and test plan for mining casting wear parts to guarantee product performance and traceability.
Our inspection covers chemical composition analysis heat treatment monitoring dimensional check and 3D scanning visual inspection and liquid penetrant testing PT.
Destructive tests including tensile charpy impact and metallography are carried out from test coupons.
All products comply with ISO and ASTM standards. Inspection reports and quality certificates can be provided upon request.
Dimensional inspection
MT Magnetic Particle Testing
UT Ultrasonic Testing
Heat Treatment
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