Applications of Ni-Hard:

1. Production of Ni-Hard Roll Heads-

Roll heads for roller-type pulverising mills, especially those grinding coal, raw limestone,
cement clinker and other highly abrasive materials represent an important application for NI-

HARD. Castings for this purpose can be produced either in sand moulds, and this is the method
most usually applied, or, with the outer (working) face poured against a single chiller of section
similar to that of the casting. The first procedure has the advantage of flexibility in respect of
foundry equipment; the second gives optimum resistance to wear in service and in some
circumstances can effect savings in production cost, since the chillers can be used many times.
The chillers should be heated so that they are at a temperature of 120°C at the time of pouring.

Where chillers are positioned against the outer face the roll heads can be produced either
completely white, or with a white outer zone forming the working face and merging into a grey
or mottled inner zone which facilitates machining of the bore. Where completely white castings
are poured within sand moulds or chill moulds, some producers cast-in machinable inserts of
steel or cast iron at the interior surface for ease of machining, while others, aided by modern
practices, finish the bore by machining or grinding.

Two methods of gating and feeding roll heads incorporating external chillers are shown below.
The method shown in Figure ( ) involves pouring through a ring feeder located directly above
the casting and eight gates are used. The other method shown in Figure ( ) also uses this
principle, though in this case the feeder is slightly offset from the casting and the metal enters
the inside of the bore through four gates. In either case, the flow of metal through the gates heats
the surrounding sand and encourages directional solidification. The vents allow free exit of
mould gases during pouring. Recommended casting/feeder weight ratios are indicated in the
sketches.
 Chemical Composition percent
Total C Si Mn S P Ni Cr

3.0-3.3 0.4-0.6 0.4-0.6 <0.12 <0.2 4.0-4.5 1.5-2.5

If chillers are applied and a grey or mottled structure is preferred adjacent to the bore - whilst
retaining a clear chill on the outer working face - the silicon content may be raised to 1.0 -1.25
per cent and chromium retained at the lower end of the stated range. If these conditions are
fulfilled, the problem of machining the central bore will be eased.

Pouring
Where chillers are used, pouring should be restricted to the temperature range 1340 - 1370°C,
but a higher temperature is usually preferred where sand moulds are employed. The mould should
be filled as rapidly as possible and the feeder covered with exothermic compound.
Heat Treatment
It is advisable to allow the castings to cool slowly from the casting temperature, preferably in the
mould. The roll heads should then be heat treated by holding for4-16 hours at 275°C; the holding
time dependent on the section and mass of the casting.

Finishing operations are usually carried out by one of the following methods.
Grinding Operation
Boring operation- Using recently developed carbide-tipped tools and sturdy, rigid, equipment.
This practice is now widely applied, despite the high hardness of the material.
Machining steel or cast-iron inserts- To minimize risk of the castings cracking, the thickness of
each insert should be held to the minimum necessary. Inserts may be segmental {eg, three or four
segments forming the inner surface of the bore) see Figure 36, in which case strips of asbestos
may be placed between the segments to allow contraction to take place freely, so avoiding cracks
and hot tears. The outside surface of the insert should incorporate suitable grooves and/ or
projections, to key the insert both axially and circumferentially. The use of such inserts may
require appropriate location of the gates, to position them away from the vicinity of the inserts
and to ensure that they do not freeze prematurely or cause undue melting away of the inserts.

2. Production of Ni-Hard Grinding Balls-

The use of NI-HARD grinding balls is well established for grinding of metallurgical ores, cement
and minerals, and involves the annual production of many thousands of tons of such castings.
Furthermore, a large proportion of these balls is of the smaller variety, i.e., 50 mm diameter and
below, produced in sand moulds.
Pattern Layout
If NI-HARD grinding balls are to perform successfully, it is necessary for them to be free of
shrinkage porosity; this being particularly important from the aspect of avoiding breakage in
service. All the conventional molding procedures can be applied for the production of grinding
balls in the range quoted.
Chemical Composition
The recommended composition range for balls of upto 100 mm diameter is as shown below

Com position per cent

Size of C Si Mn S&P Ni Cr
balls

15 mm (J in) 2-8-3-2 0-5-0-7 0-4-0-6 0-1 3-2 1-8

100 mm (4 in) 2-8-30 0-3-0-5 0-4-0-6 0-1 4-4 20

This range of composition is calculated on the basis that the balls will be allowed to cool
gradually in the mould, before knock-out. However, some savings in nickel are made possible by
removal of the balls from the mould shortly after solidification, to cool rapidly in air.
Pouring
It is particularly important, if the grinding balls are to be free of surface defects, that pouring
commences at a minimum temperature of 1400°C, the preferred pouring temperature being
of the order of 1470°C.

Heat Treatment
It is essential that all NI-HARD balls be subjected to a heat treatment involving 4-16 hours at
275°C, the precise holding time depending on the size of the ball and on the amount of retained
austenite. Where impact conditions are more severe, particularly in the case of balls of larger
size, a double heat treatment should be applied. This involves holding for 4-6 hours at 450°C,
followed by cooling in the furnace or in air to 275°C, where the grinding balls are then held at
that temperature for 4-16 hours. The purpose of both these heat treatments is to eliminate all
retained austenite and to temper the products of transformation and thus provide a ball which
will exhibit maximum resistance to impact fatigue conditions.
It is important to ensure homogeneous temperature conditions throughout the furnace during heat
treatment. For this purpose it is recommended that the balls be stacked in perforated containers in
layers no greater than 75-100 mm deep for balls of 15-25 mm diameter and 100-150 mm deep
for balls of 25-50 mm diameter, with an air space between successive layers. The rate of cooling
after heat treatment is not important and therefore air or furnace cooling can be applied.