Development and characterization of composite materials for high-impact high-wear applications.

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The goal of the proposed partnership is to enable a new collaboration between Syncrude Canada Ltd., Unicast Inc. and the University of British Columbia on the development of a novel bi-metallic composite materials for high-impact high-abrasion applications. Canada is among the world leaders in the extraction of materials and commodities that are critical for global manufacturing and technology sectors. The first step in the extraction of valuable materials (e.g., graphite, nickel, copper, titanium, uranium) is a mining operation, where mineral-rich ores are extracted and subsequently crushed. The crushing operations can be achieved using several methods, with the most common being an impact crusher (horizontal or vertical). Fracturing of rocks or ores in such crushers occurs as a result of impact of hammers on the rocks during feeding through the crusher. The crushing environment represents some of the harshest conditions a material can be exposed to: 1) extremely high impact loads, 2) high operating temperatures, 3) high mechanical dynamic loads, and 4) high abrasion wear. As a result, development of materials capable of surviving such conditions is critical to ensure adequate performance and economy of operation for the rock crushing operation. This Alliance project focuses on the development of bimetallic hammers made of abrasion resistant high chromium white irons (HCWI) mated to tough high manganese steel (HMS) shanks. Additional breakthrough is expected when tungsten carbide (WC) reinforcements will be metallurgically bonded to the HCWI material, thereby further enhancing its lifespan, performance and abrasion resistance. Industry and academic HQP will engage in material development, casting, characterization and in-service evaluation of the novel hammers. The expected outcomes of the project have a direct and immediate implication for both Syncrude Canada Ltd and Unicast Inc., leading to improved performance of the crushers, enhanced economy of operation, as well as making a fundamental scientific contribution to the development of advanced bi-metallic materials.