Physical metallurgy for toughness of 1% Cr abrasion resistant steel for grinding ball stock

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The processing of mineral ores such as coal, coke, cement, and ironstone, involves crushing big rocks in order to reduce them to fine sizes for the extraction of any desired minerals. In crushing and grinding minerals, grinding media (balls and rods) play a critical role. The scientific objective of this CRD project is to develop the physical metallurgy for impact-abrasion resistant steels. The technical objectives of the project are: 1) To design new impact-abrasive steels by investigating the effect of alloying elements; 2) To enhance the steel toughness by investigating the segregation and brittle phases; and 3) To minimize residual stresses in the ball stock by investigating phase changes and thermal strains. This proposed research and training project will apply a systematic metallurgical approach to the critical industrial issue of spalling embrittlement in grinding ball stock. Based upon the successful outcome of a current Engage project, this proposed study integrates within the broader scope of the PI's Discovery research program on energy materials. The outcome of this project will directly benefit the industrial partners through the establishment of chemical composition, process windows, and providing the currently unavailable "know how" related to its business. Canadian mining and manufacturing industries will benefit from better economics and capabilities of advanced grinding material for wear mitigation. The field of materials engineering will be strengthened by the new findings, direct observations, interpretations, and models to come from this work. Over the course of this research, two PhD students and four undergraduates will be trained in the use of latest generation scientific tools and research methodologies. The practical application of the theoretical and experimental findings will be implemented at AltaSteel, Edmonton, Alberta facility and Moly-Cop Canada, British Columbia facility.