Mill Liners

Cast White Iron Mill Liners by WALKSON: Unmatched Durability for Grinding Excellence

Function and Specific Design

Cast white iron mill liners serve as protective barriers within grinding mills, shielding the mill shell from abrasive wear caused by grinding media and processed materials. These liners are critical for extending mill lifespan, reducing maintenance costs, and optimizing grinding efficiency. WALKSON’s liners are meticulously designed to fit various mill types, including ball mills, SAG mills, and AG mills, with customized profiles to enhance material flow and grinding performance.

· Key Design Features:

· Precision-engineered shapes for seamless integration with specific mill configurations.

· Optimized lifter bar profiles to improve grinding media trajectory and efficiency.

· High wear resistance to withstand abrasive conditions in mining and cement applications.

· Customizable thicknesses and configurations to meet unique operational needs.

Our liners are tailored to maximize uptime and minimize downtime, ensuring your mills operate at peak performance.

Material Grades (EN and ASTM Standards)

WALKSON’s cast white iron mill liners are crafted from high-chromium white cast iron, renowned for its exceptional hardness and abrasion resistance. We adhere to the following international material standards:

· ASTM A532 Class III Type A (25% Cr): This grade offers a minimum hardness of 621 HBW (Brinell Hardness), providing superior wear resistance for high-abrasion, low-impact environments. The high chromium content ensures a robust carbide microstructure, ideal for grinding applications.

· EN 12513 (EN-GJN-HV600): Compliant with European standards, this grade specifies abrasion-resistant white cast irons with a focus on chemical composition and hardness, ensuring global compatibility.

These standards guarantee that our liners deliver consistent performance and durability, meeting the stringent requirements of international markets.

Modern and Standardized Manufacturing Process

WALKSON employs a state-of-the-art manufacturing process that blends advanced technology with rigorous quality control to produce cast white iron mill liners of unmatched quality. Each step adheres to international standards, ensuring precision and reliability.

· Material Selection and Preparation:

· High-purity iron, chromium, and alloying elements are sourced to meet ASTM A532 and EN 12513 specifications.

· Chemical composition is precisely controlled to optimize carbide formation and wear resistance.

· Sand Casting:

· Utilizes advanced sand casting techniques to create complex liner shapes with high dimensional accuracy.

· Molds are designed using CAD software to ensure consistency and fitment, compliant with ISO 9001 quality management standards.

· Heat Treatment:

· Liners undergo controlled quenching and tempering processes in high-capacity furnaces to achieve the required hardness (≥621 HBW).

· Heat treatment follows ASTM A532 guidelines, ensuring a uniform microstructure for maximum durability.

· Precision Machining:

· CNC milling, turning, and grinding machines refine liners to exact specifications, ensuring a perfect fit for customer mills.

· Machining adheres to ISO 2768 tolerances for dimensional accuracy.

· Quality Inspection:

· Each liner is subjected to rigorous inspections using advanced equipment to verify compliance with ASTM A532 and EN 12513 standards.

This standardized process ensures repeatability, quality, and compliance with global industry requirements.

International Standards Guiding Production

WALKSON’s production process is guided by the following international standards to ensure quality and reliability at every stage:

· ASTM A532: Specifies the chemical composition, hardness, and performance requirements for abrasion-resistant cast irons, ensuring liners meet global benchmarks for wear resistance.

· EN 12513: Defines grades of abrasion-resistant white cast irons, providing a framework for material properties and quality in European markets.

· ISO 9001: Ensures a robust quality management system, covering material sourcing, production, and inspection processes.

· ISO 2768: Governs machining tolerances, ensuring dimensional accuracy and fitment.

· ISO 8062: Guides casting tolerances, ensuring consistent quality in sand-cast components.

These standards underpin our commitment to delivering liners that meet the highest global quality and performance expectations.

Manufacturing and Inspection Equipment

WALKSON’s advanced manufacturing facility is equipped with cutting-edge technology to produce and inspect cast white iron mill liners:

· Casting Equipment:

· High-capacity electric arc furnaces for melting high-chromium alloys.

· Automated sand molding systems for precision mold creation, supporting large-scale production.

· Heat Treatment Furnaces:

· Controlled-atmosphere quenching and tempering furnaces to achieve uniform hardness and microstructure.

· Temperature monitoring systems compliant with ASTM A532 requirements.

· Machining Centers:

· CNC milling and turning machines for precision finishing, ensuring exact fitment.

· High-precision grinding machines for surface quality and dimensional accuracy.

· Inspection Equipment:

· Brinell Hardness Tester: Measures hardness to ensure ≥621 HBW, as required by ASTM A532.

· Impact Testing Machine: Assesses toughness under impact loads, critical for mill applications.

· Ultrasonic Testing (UT) Machine: Detects internal defects, ensuring structural integrity.

· Coordinate Measuring Machine (CMM): Verifies dimensional accuracy against customer specifications.

· Wear Resistance Testing Rig: Simulates abrasive conditions to validate liner longevity.

This equipment ensures that every liner meets stringent quality standards, delivering reliability and performance.

Testing Procedures and Protocols

WALKSON implements comprehensive testing protocols to validate the quality and performance of cast white iron mill liners, adhering to ASTM A532 and EN 12513 standards:

· Hardness Testing:

· Conducted using a Brinell hardness tester to confirm a minimum hardness of 621 HBW.

· Multiple points are tested across the liner surface to ensure uniformity, as required by ASTM A532.

· Impact Testing:

· Performed using an impact testing machine to evaluate toughness, ensuring liners can withstand operational stresses.

· Results are measured in Joules, following ASTM E23 standards for impact testing.

· Wear Resistance Testing:

· Simulates abrasive conditions using a wear testing rig to assess liner longevity.

· Tests are designed to replicate real-world mill environments, ensuring performance under high-abrasion conditions.

· Ultrasonic Testing (UT):

· Uses high-frequency sound waves to detect internal defects or discontinuities, ensuring structural integrity.

· Conducted per ASTM A609 standards for castings.

· Dimensional Inspection:

· Performed using a CMM to verify that liners meet customer specifications and ISO 2768 tolerances.

· Ensures precise fitment and compatibility with mill designs.

Clients are invited to witness these tests during the Factory Acceptance Test (FAT), ensuring transparency and confidence in product quality. We also welcome third-party inspectors designated by clients to oversee testing and production, demonstrating our commitment to accountability.

Industry Applications and Relevance

WALKSON’s cast white iron mill liners are designed for high-abrasion environments across multiple industries:

· Mining: Protects ball and SAG mills in mineral processing, ensuring efficient ore grinding and reduced downtime.

· Cement: Enhances cement mill durability, handling abrasive clinker and raw materials with ease.

· Power Generation: Used in coal pulverizers for reliable performance in power plants.

· Metal Recycling: Provides wear protection in shredders and crushers for scrap metal processing.

Our liners are compatible with equipment from leading brands such as Metso, FLSmidth, and Bradken, ensuring seamless integration and optimal performance in existing mill setups.

Quality Assurance Processes

To ensure customer satisfaction and product reliability, WALKSON implements advanced quality assurance processes before batch production:

· PPAP (Production Part Approval Process): Provides detailed documentation and samples to confirm that the production process meets customer requirements.

· FAT (Factory Acceptance Test): Allows clients to observe testing and inspection at our facility, ensuring transparency.

· PFMEA (Process Failure Mode and Effects Analysis): Identifies and mitigates potential risks in manufacturing, enhancing reliability.

· APQP (Advanced Product Quality Planning): Ensures a structured approach to product development, aligning with customer and industry standards.

These processes guarantee that our liners meet the highest quality standards, delivering value and performance.

Advantages of Choosing WALKSON

When you choose WALKSON for your cast white iron mill liners, you benefit from:

· Unmatched Expertise: Over 20 years of experience in wear-resistant castings, making us a trusted partner in the industry.

· Superior Quality: Liners crafted to exceed ASTM A532 and EN 12513 standards, ensuring durability and performance.

· Customization: Tailored solutions to match your mill’s specific requirements, optimizing efficiency and longevity.

· Global Support: Comprehensive technical assistance and after-sales service, with fast deliveries worldwide.

· Transparency: Openness to third-party inspections and client-witnessed testing, building trust and accountability.

Consult with WALKSON to discover how our mill liners can enhance your operations. Contact us today to discuss your needs and receive a customized solution.

Contact WALKSON

For inquiries, customization requests, or to place an order, reach out to our team:

· Email: info@walkson.com

· WhatsApp/WeChat: : +86 188 6716 5932

Let WALKSON be your trusted partner for high-performance cast white iron mill liners. Visit walkson.com to learn more and elevate your grinding operations.