This document provides a history of manganese steel and discusses new developments in reinforced manganese steel. It summarizes that manganese steel was first developed in the 1880s and improves hardness, toughness, and wear resistance. Recent innovations include reinforcing manganese steel with a hard inlay or ceramic inserts to increase lifetime by 30-60% in heavy impact applications like mining and aggregate processing equipment.

1. 1
The History of Manganese Steel
February 24, 2016

2. 2
Mangalloy

3. 3

4. 4
MANGALLOY STEEL
11-14
%
manganese steel that
performs best in
extreme impact
applications
3x
Initial surface rigidity
increases up to 3x &
retains interior
durability
Ideal
Material
for heavy impact and
abrasive service
Non-
Magnetic
for electrical transformer
assemblies & industrial
lifting magnets.
As the surface work-hardens, takes a mirror-like finish, and retains its original underneath toughness. An example is wear strips under conveyor chains.
The compressive abrasion of metal-to-metal contact deforms the surface structure of Manganal and therefore, work-hardens it rapidly. The polish that it
develops and its low coefficient of friction not only reduces the wear on the conveyor chain, but usually results in reduced power requirements for
operating the equipment, because of reduced friction.
The high impact and grinding abrasion destroys most other steels rapidly. Mangalloy Steel withstands the punishing abuse, without breaking or quickly
eroding. Other typical uses are shovel buckets, teeth and loaders working in earth and stone where there is a general mixture of impact/compressive
abrasion. Depending on deformation of the surface crystalline structure, it can work-harden up to more than 500 Brinell. When originally put into service
it is about 200 Brinell.

5. 5
HISTORY
In 1816, a German researcher Carl J. B. Karsten noted that adding fairly
large amounts of manganese to iron would increase its hardness without
affecting its malleability and toughness, but the mix was not homogeneous
and the results of the experiment were not considered to be reliable. "and
no one understood that the real reason why the iron mined in Noricum
produced such superb steel lay in the fact that it contained a small amount
of manganese uncontaminated by phosphorus, arsenic, or sulfur, and so was
the raw material of manganese steel.”
In 1860, Sir Henry Bessemer, trying to perfect the Bessemer process of
steel making, found that adding manganese and carbon to the steel after it
was blown helped to remove excess sulfur and oxygen. Sulfur combines with
iron to form a sulfide that has a lower melting point than steel, causing weak
spots, which prevented hot rolling. Manganese is usually alloyed with most
modern steels because of its powerful ability to remove sulfur, phosphorus
and oxygen, which are all common impurities in steel.
Mangalloy was the first alloy created from carbon steel, also called
Hadfield steel after its British inventor, Sir Robert Hadfield, in 1882, and was
first produced in the US.
1816
1860
1882

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REINFORCED
MANGANESE STEEL
NEW PRODUCTS PORTFOLIO
PRESENTATION

7. 7
REINFORCED MANGANESE STEEL
MANGANESE STEEL:
NEW GENERATION

8. 8
REINFORCED
MANGANESE STEEL SB® & GPF ®
Bowl Lines
Jaw Liners
New Products
Patented technology
SUPER BITE &
GRIP PLUS
GP®
SB®

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REINFORCED
MANGANESE STEEL SB® & GPF ®
Bowl Lines
Jaw Liners
New Products
Patented technology
SUPER BITE &
GRIP PLUS
GP®
SB®

10. 10
NEW
PRODUCTS
SUPER BITE SB® & GRIP PLUS GP®
FEATURES
The same toughness
We tailor the hard inlay to match the customer
needs, according to our know-how to reach the
best result. Customer shows us only where he
notes maximum wear on the casting.
BENEFITS
Increase the hardness of manganese steel 18%
where impact is not enough to work-hardening the
surface and reducing wear due to abrasion
Increase the life time in very abrasive application

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SB® FOR JAW
Examples of Inlay for Different
Thoot Shapes

12. 12
SB® CASE
HISTORY Application: fixed and mobile jaw with SB
Feed: Granite
PRODUCT INFORMATION
This trial exemplifies the benefit of
tailored inlay over std manganese steel.
The inlays increase life time about 30%
more.
BENEFITS
Minimize shutdowns
Save maintenance hours
Increase equipment up time
Increase life time on
field application
+30%

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GP® FOR
CONE/MANTLE
Example

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GP® CASE
HISTORY
Swedish site
+66%
increase
GP® technology
lifetime
STD lifetime

15. 15
GP®
Increases the life-time of parts almost 100%
on site application

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HSI Castings
• Blow Bars
• Apron Liners
• Monoblocks
• Side Liners
Alloys
• Martensitic:F60, F60
45/47 HRC
• White Iron: FX15,
FX25
• WRI technology
• MNX Manganese
• MNGP Inserts
Jaws / Cones
• Fixed & Swing Dies
• Cheek Plates
• Wedges
Conveyor Belting
• Wear resistant rubber top coats
• Standard options available as well
(2-220/ 3-330/ 4-440 etc)
Wear Parts Overview
HSI/ VSI, Jaw, Cone, Gyratory
Bear Claw
Bohringer
Brown Lenox
CEC
Cedar Rapids
Crush Tek
Eagle
Excel
Extec
Finley
Gator
Hartl
Hazemag
Humbolt
Wedag
Inertia
Irock/ Indy
KeesTrack
McCloskey
Metso
Nordberg
Parker
Pegson
Pioneer
Powerscreen
Rubble Master
Sandvick
Stedman
Svedala
Telsmith
Terex
Tesab
Trio
Universal

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Technical
Details

18. 18
TECHNICAL
BULLETIN
We have developed new innovative Manganese steel – called
MNX. Manganese steel combines excellent wear-resistant
characteristics with high durability.
MNX can be utilized as an alternative to all Manganese steels.
AmCast uses it mostly to produce jaws and cones. However, the
best application for this kind of product is one in which the
Manganese Steel with high percentage of Chrome represents a
challenge in casting because of the particular shape and
thickness or where the resistance to breakage and longer wear
ratio needs to be improved.
Our steel grade has performed well in very wet conditions,
where normally the wear ratio increases dramatically.

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COMPARISON
Bending test with samples that
have the same shape &
dimensions
See how MnX bends at a greater
angle than Manganese steel
because of the high percentage
of Chrome.
Manganese steel
with a high Chromium content
MnX

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WEAR PATTERN
Evidence of the MnX steel durability
can be seen in these photos of the
wear pattern after the campaign.
Manganese steel high Chromium
MnX

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WEAR PATTERN Wear pattern of cone (red line)
compared with the original pattern.
MNX Microstructure: finely dispersed
HARD PHASES,consisting of Titanium
Cabonitrides
Manganese Steel High Chromium
Hardness 2500-3000 HV

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The winning characteristic of this material is
joining the typical MnCr18.2 toughness to a
homogeneous and very fine dispersion of Hard
Phases, with HV hardness values that are
generally twice in comparison with typical
Chromium carbides.
CONCLUSION
After several laboratory and field test our
technology department is confident in stating
that overall the performance of the MNX is clearly
superior than the range of manganese steel used
in the production of cones, jaws and blow-bars.
MNX

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REINFORCED SPECIAL
MANGANESE STEEL
For heavy applications
A patented technology for
manganese casting

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This trial exemplifies the benefits of tailored inlay over standard manganese steel.
The inlay increases the life time about 30% more.
“The manganese
steel reinforced
with SB®/ GPF®
tech increases the
lifetime of the
blow bar by
30-60% in field
applications.“
STD
SB®
136.000 ton
177.000 ton

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The hard inlay is embedded into
the casting and during the
entire life of the liner protects
the surface from sliding wear.
We tailor the hard inlay to match
the customer needs, according to
our research results. Customers
show us the location of maximum
wear on the casting.
The manganese steel has
durability similar to Mn12
REINFORCED MANGANESE STEEL
INCREASED
THICKNESS
NEW INLAY
DESIGN
HARD PINS
INSIDE
1
2
3

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Ceramic
Inserts

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Our ceramic insert
was developed to
increase the lifetime
of martensitic White
Chromium blow bars
CERAMIC
INSERT
For standard working conditions
Blow Bars

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CERAMIC INSERT
For standard working conditions
The ceramic particles have a high
hardness to prevent the wear
abrasion due to feed material.
The ceramic pad is tailored to
guarantee maximum absorption
of the molten steel.
Innovative, exclusive chemical
composition and heat
treatment guarantee an
increased durability of our steel
grades with respect to our
competitor’s alloys.
Honeycomb
Structure
Steel
Grades
Ceramic
Particles

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“The ceramic insert is
the key to my success.
I reduced downtime,
increasing the lifetime
of the blow bars, and
consequently, the
productivity.”
Feedback from our customer

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Our RD department
developed a new ceramic pad
with the aim to increase the
lifetime of blow bars in
applications where reducing
production costs is necessary.
MASTER CERAMIC
For heavy duty business
AmCast research is focused
on global challenges. Our
research and development
investment was focused on
increasing wear life of
spare parts.
AmCast research helps
drive solutions to these
challenges through
inclusive innovation.
Our team is working with
customers to create
solutions that meet the
unique needs of people
working in quarry, mining
and recycling.

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MASTER CERAMIC
For heavy duty business
The ceramic particles
have a modified shape to
permit an increased
wettability.
The new design guarantees
keep an optimum wear
profile until the complete
end of life.
The thickness of the pad
was increased up to 60%.
Increased
Thickness
New Inlay
Design
New Ceramic
Particles

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• Honeycomb structure
• 30mm deep
MASTER CERAMIC PAD
• Innovative shape
• +60% of ceramic
• Tailored design
SDT
or
STD?
Standard?
STANDARD vs
MASTER
STANDARD CERAMIC PAD
MASTER CERAMIC PAD

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Increased life time
Full protection of the
rotor during the entire
life of the bar
Decreased maintenance
time
MASTER CERAMIC
Key Benefits
Front View
Side View

34. 34
NEW SHAPE
FOR MASTER
CERAMIC
We modified also the shape of
ceramic pad. Our RD department
developed this pattern to increase
the surface covered by the ceramic
pad. This texture permits to obtain
by many of our customer a
significant decreased wear rate

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MASTER
POWER
A new ceramic material developed
with the University of Udine

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DEVELOPMENT
TESTING
We have completed tests in field with very
satisfactory results. Now we are working on
improvements to extend this technology for blow
bars of different shapes.
MasterPOWER is a new ceramic pad
and it was developed to increase life
time of blow bar used in very
abrasive application as:
• Asphalt
• Slag
• High Abrasive Natural Rock
• Iron Ore
• Quartzite
• Basalt

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Let the future tell the truth, evaluate each
one according to his work accomplishments.
The present is theirs; the future, for which I
have really worked, is mine.”
“
A
Visit
to
Nikola
Tesla,
by
Dragislav
L.
Petkoviæ
in
Poli=ka
(April
1927)

38. COMPANY INTRODUCTION
• Overview of the International Group and Am Cast’s
position
• International group of foundries and
machine manufacturers
• Our company philosophy
• Performance Wear Parts and Innovation in
Crushing Systems
38
Am Cast, Inc. Specializes in the manufacturing of
abrasion resistant castings, WRI technology,
sustainable, sand-crushing equipment.
About Us
AmCast, Inc.

39. 39
34 Aero Road, Bohemia New York 11716
Toll Free: 888-993-2772
Local: 631-750-1644
Fax: 631-750-1646
Am Cast West
2303 West Oxford Ave, Sheridan, Colorado 80110
Telephone: 303-761-6333
Fax: 303-762-6151
Innovation In
Aggregate
Systems
Contact Us

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